|
Graphite Crucibles
| Product Code |
: |
29127 and 29128 |
| Quality and Standards
|
: |
IS 1748:1981 |
| Production Capacity
|
: |
Quantity: 420 MTs.
Value : Rs. 25200000 |
| Uploaded on |
: |
June 2007 |
Introduction
Graphite Crucibles are refractory containers
specially shaped for metallurgical operations. These are
made of a mixture of Graphite, Refractory Clay, Grog and
other additives. These crucibles are termed as clay bonded
Graphite crucibles according to the raw materials used.
The crucibles are available with or without spout. These
crucibles are used for melting ferrous, non-ferrous metals
alloys and noble metals.
Market Potential
The main market for the product is foundry
industry. With the growing industrial sector the need for
specialized metal and alloy castings is increasing day-by-day.
With the advent of many multinational automobile industrial
units, many auto spare are manufactured in large numbers
in Haryana, Delhi, Punjab and Maharashtra States. There
is a good demand in these States for graphite crucibles.
As per an assessment 8.5% growth in foundry and Casting
Industry is estimated in the country. The use of Graphite
Crucibles shall accordingly increase. There is a good scope
of development of modern smallscale industries with the
growing prospects of special casting metallurgical industry
both for domestic and export market.
Basis and Presumptions
i. The envisaged production capacity
is based on single shift basis on 300 working days in a
year.
ii. The unit will purchase the technology from National
Metallurgical Laboratory, Jamshedpur which have developed
improved technologies for Graphite Crucibles.
iii. The costs given are based on the
current market rates and may vary from time to time.
iv. The wages are as per the prevailing
norms.
Implementation Schedule
| Sl. No. |
Activity |
Period (in months)
|
| 1. |
Preparation of Project
Report and preliminary work with institutions, site
selection |
2 |
| 2. |
Follow-up action for
Term Loan sanction |
1 |
| 3. |
Acquisition of land
and construction of buildings, selection of machinery,
placing orders |
3 |
| 4. |
Supply of machineries
and erection |
2 |
| 5. |
Getting power connection,
completion of other formalities with various agencies,
working capital, loan sanction etc., trial run and production
|
1 |
| 6. |
Total implementation
of the project including commencement of production
|
12 |
Technical Aspects
Process of Manufacture
The manufacturing process of the products
is based on the improved technology developed by National
Metallurgical Laboratory, Jamshedpur. The raw materials
such as graphite, Refractory/plastic clay, grog and other
additives are mixed in a pan mixer after taking proper batch
proportions. The wet mass is then kept for ageing. The aged
mix is then extruded in a de-airing pugmill and blanks are
made. The crucibles are prepared from the blanks either
by pressing in a hydraulic press or by jiggering. The shaped
crucibles are then dried, glazed and fired in a kiln to
develop strength and glaze.
Quality Control and Standards
The following BIS specifications may
be referred for day-to-day quality control:
| IS 1748:1981 |
Sizes of Graphite Crucibles
|
| IS 8977:1978 |
Clay bonded Graphite
Crucibles |
| IS 9927:1981 |
Methods for determination
of life of Graphite Crucibles |
| IS 11321:1985 |
Graphite for Graphite
Crucibles |
Production Capacity
Clay-Graphite Crucibles of different
sizes upto No. 500
| Quantity |
: 450MT (per annum)
|
| Value |
: Rs. 19530000 |
Pollution Control
The unit should be equipped with proper
flue-gas exhaust system and dust collectors to control environment
pollution. It has to follow the guidelines prescribed by
State Pollution Control Board.
Energy Conservation
It is suggested to construct a low thermal
mass kiln for firing of the product to save energy.
Financial Aspects
A Fixed Capital
| ( i ) Land and Building
|
(Rs.) |
| Land 1 Acre |
1200000 |
| Office: 50sqm. @5000
sq. m . Manufacturing sheds: |
250000 |
| 400sqm @ 4000 sq. m.
|
1600000 |
| Stores: 50sqm @5000 sq.
m. |
250000 |
| Workers quarters 200
sq. m. @ 4200 sq. m. |
840000 |
| Water well, pump, pipelines
and compound wall etc. |
200000 |
|
Total
|
4340000 |
(ii) Machinery and Equipments
| Description |
Qty. |
Value (Rs.) |
| Roller Crusher, Single
roller size 350 x 300mm with a 7.5HP motor and accessories
|
1 |
120000
|
| Disintegrator 14” size
with 5HP Motor |
1 |
50000
|
Pan Mixer, 0.5MT capacity
with a 3 HP motor and other
accessories |
1 |
140000
|
Deairing pugmill, capacity
250 kg/hr. with a 5HP motor
vacuum pump and other accessories |
1 |
300000
|
| Hydraulic press with
all accessories cap: 1MT/day |
1 |
345000
|
Jigger and Jolly with
individual 1HP/2HP motor and
accessories for making large size crucibles |
4 |
60000
|
| Electro Magnet |
1 |
65000
|
| Saggar Press, Hand
operated with ram |
1 |
90000
|
| Glazing equipment comprising
of a glaze tank, compressor, booth, spray gums and other
fittings |
1 |
85000
|
| Wheel barrows for internal
transportation of large crucibles |
4 |
16000
|
Rotary screen for grading
of grog with a 3Hp motor and
other accessories erected on a platform |
1 |
40000
|
| Weighing scales 250kg.
and 25kg. |
1 |
15000 |
| Test Eqpt. Misc. Eqpt.
and tools |
1 |
50000 |
| 5 Tonne capacity oil
fired down draft kiln with good thermal insulation (back-up)
and with a 25 metres high chimney, thermocouples and
other draft measuring equipment |
1 |
1000000
|
| Installation and wiring
|
LS |
150000
|
| Office furniture and
equipments |
50000 |
| Pollution Control equipments
and dust collator |
200000 |
|
Total
|
2776000
|
| (iii) Preliminary and
Pre-operative expenses like deposits, project cost (non-refundable)
and other unforeseen expenditure) |
50000 |
|
Total
|
2826000
|
| (iii) Pre-operative
Expenses |
150000 |
|
Total
|
2976000
|
B. Working Capital (Per Month)
(i) Staff and Labour (per month)
| Designation |
Nos. |
Salary |
Total (Rs.) |
| Works Manager |
1 |
12000 |
12000 |
| Technical supervisor
|
2 |
8000 |
16000 |
| Accountant |
1 |
7000 |
7000 |
| Clerk |
2 |
4000 |
8000 |
| Mechanic (Maintenance)
|
1 |
4000 |
4000 |
| Skilled operators |
4 |
5000 |
20000 |
| Semi-skilled workers
|
4 |
4500 |
18000 |
| Firemen |
2 |
4800 |
9600 |
| Unskilled labour |
10 |
3000 |
300000 |
| Watchmen |
2 |
3000 |
6000 |
|
Total
|
400600 |
|
Perks @ 22%
|
88132 |
|
Total
|
488732 |
(ii) Raw Materials (per month)
| Description |
Qty. |
Rate/ MT |
Total |
| Graphite Powder (Flaky
and Lump IS 11321 grade) |
14MT |
20000 |
280000 |
| Crucible Grog |
2MT |
5000 |
10000
|
| Silicon Carbide granules
|
2MT |
60000 |
120000
|
| Fireclay and Plastic
Clay |
40MT |
1800 |
72000
|
| Fireclay Grog |
3MT |
1800 |
5400
|
| Coke Dust/Granules
|
10MT |
3500 |
35000
|
| Glaze and Chemicals
|
LS |
|
35000 |
| Consumables |
LS |
|
10000 |
| Packing Materials |
LS |
|
15000 |
|
Total
|
582400
|
| (iii) Utilities
(per month) |
(Rs.) |
| Power and Water |
50 kWH |
30000 |
| Furnace oil |
8 kL @ 30000 per kL
|
240000
|
|
Total
|
270000
|
| (iv) Other Contingent
Expenses (per month) |
(Rs.) |
| Postage and stationery
|
2000 |
| Transport and Conveyance
|
10000 |
| Advertisement and Publicity
|
10000 |
| Telephone |
4000 |
| Maintenance |
8000 |
| Insurance |
2500 |
| Other Contingent Expenses
|
5000 |
|
Total
|
41500 |
| Total recurring
expenditure (per month) (i+ii+iii+iv) |
1382632 |
C. Total Capital Investment
| i) Fixed capital |
7316000 |
| Working capita l (2
month) |
2765264 |
|
Total
|
10081264 |
Financial Analysis
| (1) Cost of Production
(per annum) |
(Rs.) |
| Total recurring cost
|
16591584 |
| Depreciation on building
@5% |
217000 |
| Depreciation on plant
and Machinery @10% |
192600 |
| Depreciation on kiln
@15% |
150000 |
| Depreciation on office
furniture @20% |
10000 |
| Interest on total capital
investment @13% |
1310564.32 |
|
Total
|
18471748.32 |
| (2) Total Sales
Turnover (per annum) |
Rs |
| By sale of 420MT of
Graphite Crucibles (After allowing nearly 7% rejections)
@ of 60000 per MT |
25200000
|
| (3) Profit (per annum)
|
= |
Sales – Cost of production
|
| |
= |
Rs. 25200000– 18471748.32
|
| |
= |
6728251.68 |
| |
|
|
| (4) Net Profit Ratio
|
= |
Net profit per year
x 100
-------------------- |
| |
|
Turnover per year |
| |
|
|
| |
= |
6728251.68x 100
--------------- |
| |
|
25200000 |
| |
|
|
| |
= |
26.7 |
| |
|
|
| (5) Rate of Return
|
= |
Net profit per year
x 100
--------------------------- |
| |
|
Total investment |
| |
|
|
| |
= |
6728251.68 x 100
---------------------- |
| |
|
10081264 |
| |
|
|
| |
= |
66.74 |
(6) Break-even Point
| Fixed Cost |
(Rs.) |
| Depreciation on building
@5% |
217000 |
| Depreciation on Plant
and Machinery @10% |
177600 |
| Depreciation on Kiln
and Chimney @15% |
150000 |
| Interest on capital
investment @13% |
1310564.32 |
| 40% of salaries |
2345913.6 |
| 40% of other Contingent
expenses |
187200 |
| Insurance |
30000 |
|
Total
|
4418277.92 |
| B.E.P |
= |
Fixed Cost ×
100
----------------------- |
| |
|
Fixed cost + Net Profit
|
| |
|
|
| |
= |
4418277.92 x 100
----------------------- |
| |
|
4418277.92 + 6728251.68
|
| |
|
|
| |
= |
39.64 |
Addresses of Plant and Machinery Suppliers
1. M/s. Keshab Engn. Co. Ltd.
Bose Park, P.O. Sikchar,
24, Paraganas (North),
(West Bangal)
2. M/s. Amic Industries (P) Ltd.
10, B.T. Road,
Kolkata - 700 056
3. M/s. Pappu Veeranna and Sons
Dhowleswaram Rajahmundry,
East Godavari District
4. M/s. Hari Machines Ltd.
Rajgangapur - 770 017
5. M/s. Gloheat Instruments (P) Ltd.
No. 73, 6th Main, 3rd Phase 4,
P. O. Box No. 5042, Peanya
Industrial Area, Bangalore.
Raw Material Suppliers
1. M/s. Patna State Graphite Minerals Co.
Titagarh (PO), (Orissa)
2. M/s. Laxmi Narayan Agarwal Co.
Sambhalpur, (Orissa)
3. M/s. Hindustan Graphite Refining and Products Co.
Opp. Petrol Pump, G.T. Road Kovvur,
West Godavari Dist., (A.P)
4. M/s. Grindwel Narton (P) Ltd.
4th Floor, 114 MG Road,
Bangalore
5. M/s. Indian Metal and Ferro Alloys
Terubali, Rayagada Dist.,
(Orissa)
6. M/s. Elector Thermics
C-5, SBH Colony,
Hyderabad - 500 034
7. M/s. East India Minerals
Fireylal Chowk, Ranchi,
(Jharkhand)
Shuttle Kiln Fabricators
1. M/s. Unifire
Shakespere, 16-12, Sarani,
4th Floor, Kolkata
2. M/s. Bengallium Industrial Funales
24-B, Carmae Street,
Kolkata - 700 016
3. M/s. Techno Thermo Projects Pvt. Ltd.
225/2, C.I.T. Road, Scheme VII-M,
Kolkata - 700 054
4. M/s. N.M. Kiln Pvt. Ltd.
A-706, Rail Vihar, Seetu
15-11, Jharza Road,
Gurgaon - 122 001
5. M/s. Sharma Kiln Technology
206, Hare Krishna Complex,
Opp. Kottawala Flats,
Ashram Road,
Ahmedabad - 380 007
6. M/s. Associated Industrial Furnaces
2/5, Sarai Julane, 1st Floor,
Okhla Road,
New Delhi - 110 025
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
|
