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Ceramic Capacitors
| Product Code |
: |
94389 |
| Quality and Standards
|
: |
IS 5786 (Part I):1978
|
| Uploaded on |
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May 2007 |
Introduction
Ceramic cores for resistors are specialized
ceramic material made out of steatite porcelain. These cores
are in the form of rods and tubes of various diameters and
length. It is manufactured by using highly pure raw materials
like calcined alumina with addition of small quantity of pure
clay. These are used in consumer electronic products such
as radios, televisions and sophisticated electronic instruments.
Market Potential
The demand of the product is increasing
day-by-day as development of electronic industry is showing
upward trend. Our country has a very big concentration of
electronic industries. In view of the fast development in
the industrial activity in the field of electronics, the demand
for the technical ceramics is ever increasing and creating
wide scope for setting up new units.
Basis and Presumptions
i. It has been taken into consideration
that the unit will work on single shift basis for 300 days
in a year. The firing operations are, however, to be carried
out continuously on three shifts basis till particular firing
cycle is completed in all respects.
ii. To achieve full production 1 to 2 months trial production
is required.
iii. Labor and wages are mentioned as per the prescribed Minimum
Wages Act.
iv. Interest rate 13% on total capital investment.
v. The cost of land, construction charges, cost of machinery
and equipment, raw materials, and consumables, other expenditure
etc. indicated in the profile are based on the prices prevailing
at the time of preparation and are subject to necessary changes
from time to time based on local conditions.
Implementation Schedule
| Sl.No. |
Activity |
Period
(in months) |
| 1. |
Registration as SSI,
site selection, processing for financial assistance. |
6 |
| 2. |
Procurement of machinery,
their installation and trial run. |
6 |
| 3. |
Time required for commercial
operation of the plant |
6 |
|
Total
|
18 |
Technical Aspects
Process of Manufacture
China clay, talc and barium carbonate
are the main raw materials required for the manufacture. All
the raw materials in powdered form (150 to 200 mesh) are taken
in proportion and charged into the ball mill. Wet grinding
is carried out by adding sufficient quantity of water. The
main objective of ball mill is to get a homogeneous mixture.
The ground material is discharged into an agitator through
an electromagnet and sieve. The slurry is then sent to the
filter press where filter cakes with 18-20% water content
are obtained. Filter cakes are charged into de-airing pugmill
and cores are extruded by fixing the desired die. The shaped
cores are dried and fired in an electric or muffle furnace
at a temperature of 1300ºC after which the cores are
trimmed and packed for dispatch.
Quality Control
and Standards
IS 5798 (Part I) General requirements and methods of test.
Production Capacity
This scheme envisages manufacture of 600
MT of ceramic cores per annum of various diameters.
Pollution Control
The project does not create any noise
or water pollution. The latest shuttle is more fuel efficient.
The smoke emission will have to be continuously monitored
as per rule.
Financial Aspects
A Fixed Capital
| (i) Land and Building
|
(Rs.) |
| a) Land 1000 sq. meter
@Rs 4000 sq. meter |
4000000
|
| b) Building : Built-up
area workshed 400 sq. meters. @ Rs. 6000 sq. mtrs. |
2400000
|
| Storage shed 100 sq.
mtrs. @ Rs. 7000 sq. mtrs. |
700000
|
| Office, Laboratory and
chowkidar's cabin 200 sq. mtrs. @ Rs. 7000 sq. mtrs. |
1400000
|
|
Total
|
8500000
|
(ii) Machinery and Equipments
| Description |
Rate (Rs.) |
Nos. |
Total price (Rs.)
|
| Ball mill size 1350 x1200
mm with porcelain lining, pabbles 10 HP motor, starter
and accessories |
130000 |
3 |
390000
|
| Vibrating screen 10"×18"with
0.5 |
25000 |
2 |
50000
|
| HP motor, starter and
accessories Electromagnet/ permanent magnetic separator
|
10000 |
3 |
30000
|
Agitator capacity 1000
ltrs. with 3 HP electric motor
and accessories |
60000 |
2 |
120000
|
| Diaphram pump with 5
HP motor and accessories |
90000 |
1 |
90000
|
| Filter press, Plates
500 |
95000 |
2 |
190000
|
| De-airing extruder, suitable
for drawing rods/tubes of sizes 1mm to 25mm dia cap.50
kgs./hr. |
160000 |
2 |
320000
|
| Drying oven size 1800x1200x900mm
with exhaust fan temp, controlling etc. |
200000 |
1 |
200000
|
| Centreless grinder, capable
of trimming rods of 1 mm to 25mm with motor, starter and
accessories |
100000 |
3 |
300000
|
| Weighing scale, platform
type cap. 500 kgs. |
22000 |
2 |
44000
|
| Laboratory equipment
for testing of water absorption, shrinkage and other tests
|
|
L.S. |
120000
|
|
Total
|
1854000
|
| Dies for various rods,
tubes hand tools and other misc. equipments |
|
L.S. |
70000 |
| Office equipment and
furniture |
|
L.S. |
100000 |
| Electrification and Installation
|
|
L.S. |
150000 |
| Shuttle kiln with L.D.O.
as fuel blower, burner and other accessories etc. |
|
L.S. |
1300000 |
|
Total
|
1620000
|
| (iii) Pre-operative
expenses |
130000 |
|
Total
|
3604000
|
B. Working Capital (per month)
(i) Staff and Labour
| Designation |
Nos. |
Salary / month |
Total (Rs.) |
| Works Manager |
1 |
17000 |
17000 |
| Technical supervisor
|
2 |
9000 |
18000 |
| Accountant/cashier |
1 |
7000 |
14000 |
| Operator |
6 |
5000 |
30000 |
| Semi-skilled workers
|
8 |
5000 |
40000 |
| Un-skilled workers |
5 |
3000 |
15000 |
| Watchman/Peon |
2 |
3000 |
6000 |
|
Total
|
140000
|
|
Perquisites@ 22%
|
30800 |
|
Total
|
170800
|
(ii) Raw Material (per month)
| Description |
Qty. |
Rate (Rs.) |
Total (In Rs.) |
| High Alumina calcined
|
10MT |
6000 |
60000
|
| China clay |
29MT |
3000 |
87000
|
| Ball clay |
3MT |
1800 |
5400
|
| Calcite |
3MT |
2000 |
6000
|
| Steatite |
9MT |
2000 |
18000
|
| Binders, packing materials
|
L.S. |
|
4000
|
|
Total
|
180400
|
| (iii) Utilities (per
month) |
(Rs.) |
| Average consumption of
10,000 units/months @Rs. 5 / units |
50000 |
| L.D.O. 10,000 ltrs. @Rs.
35 ltrs |
350000 |
|
Total
|
400000
|
| (iv) Other Contingent
Expenses |
(Rs.) |
| Postage and Stationery
|
2000 |
| Telephone |
4000 |
| Consumables stores |
10000 |
| Repair and Maintenance
|
10000 |
| Transportation charges
|
5000 |
| Advertisement and Publicity
|
10000 |
| Sales expenses |
10000 |
| Insurance |
2500 |
|
Total
|
53500
|
| (v) Total Recurring
Expenditure (per month) |
(Rs.) |
| Salaries |
170800
|
| Raw materials |
180400
|
| Utilities |
400000
|
| Other contingent expenses
|
53500 |
|
Total
|
804700
|
| Total Working Capital
(on 2 months basis) |
1609400
|
Machinery Utilization
The firing is the bottleneck in this industry.
The capacity utilization is considered to be 75% of the total
installed capacity.
C. Total Capital Investment
| Total fixed capital |
12104000
|
| Total working capital
|
1609400
|
|
Total
|
13713400
|
Financial Analysis
| (1) Cost of Production
(per annum) |
(Rs.) |
| Total recurring cost
|
9656400
|
| Depreciation on building
@ 5% |
425000
|
| Depreciation on machinery
and equipment @ 10% |
185400
|
| Depreciation on furnace
@ 20% |
260000
|
| Depreciation on moulds
and fixtures @ 20% |
14000
|
| Depreciation on office
equipment@25% |
25000
|
| Total interest @ 13%
on Total capital Investment |
1782742
|
|
Total
|
12348542
|
(2) Turnover (per year)
| Item |
Qty. |
Rate |
Value (Rs.) |
| Technical ceramics (resistor
corer) |
600 MT |
24000/MT |
14400000
|
| (3) Net Profit (per
year) |
= |
Turnover – cost of production
|
| |
= |
Rs. 14400000– 12213682
|
| |
= |
2051458
|
| |
|
|
| (4) Net Profit Ratio
|
= |
Net profit per year x
100
-------------------- |
| |
|
Turnover per year |
| |
|
|
| |
= |
2051458 x 100
------------------- |
| |
|
14400000 |
| |
|
|
| |
= |
14.25
|
| |
|
|
| (5) Rate of Return |
= |
Net Profit per year x
100
--------------------------- |
| |
|
Total Investment |
| |
|
|
| |
= |
2051458 x 100
------------------- |
| |
|
13713400
|
| |
|
|
| |
= |
14.96
|
(6) Break-even Point
| Fixed Cost |
(Rs.) |
| Total Depreciation |
909400
|
| Total Interest |
1782742
|
| 40% of salary and wages
|
816000
|
| 40% of other Contingent
expenses (excluding insurance) |
244800
|
| Insurance |
30000
|
|
Total
|
3782942
|
| B.E.P |
= |
Fixed Cost × 100
----------------------- |
| |
|
Fixed Cost + Net Profit
|
| |
|
|
| |
= |
3782942 x 100
----------------------- |
| |
|
3782942 + 2051458 |
| |
|
|
| |
= |
64.84
|
Addresses of
Machinery Suppliers
1. M/s. Lokmanya Engg. Works
26, Bharatkhand Cotton Mill
Compound, Naroda Road,
Ahmedabad-380016.
2. M/s. Jivanlal Shiv Panchal
Opp. Old Civil Hospital,
Gheekanta Road,
Ahmedabad.
3. M/s. Modern Engg. and
Fabrication Works
Behind Kubeshwar Mahadev,
Saijpur (Ambravadi),
Ahmedabad
4. M/s. Bombay Furnace (P) Ltd.
5, Sodium House,
Veer Nariman Road,
Mumbai-400 020.
5. M/s. Associated Industrial
Furnace Pvt. Ltd.
F-19, Sector XI,
NOIDA, Ghaziabad (U.P.)
6. M/s. Electrotherma Furnace (P) Ltd.
32, B-II Phase,
Pooja Industrial Area,
Bangalore.
7. M/s. Sharma Kiln Technology
Kothmala Flat, Harekrishna
Complex, Near Paldi,
Ahmedabad-380 007.
Raw Material Suppliers
1. M/s. Colkem India Ltd.
Noble House, Swaroop Nagar,
Udaipur-313001
(Rajasthan)
2. M/s. Gujarat Minerals
Opp. S.T. Stand,
Vejalpur-363 721, Taluka Kalol,
Distt. Panchmahal, (Gujarat)
3. M/s. Ashok Minerals and Grinding Ind.
F-237-238, MIA, Modri,
Udaipur, (Rajasthan)
4. M/s. Sonpura Mines and Mineral Suppliers
Ravi Sarkar Pranshankar Road,
Thangadh-363 530
(Gujarat)
5. M/s. Tehla Ram and Sons
Rathkhana, Bikaner,
(Rajasthan)
Contact for more information:
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