Graphite Crucibles
| Product Code | 29127 and 29128 |
| Quality and Standards | IS 1748:1981 |
| Production Capacity: Qty. | Quantity: 420 MTs. Value : Rs. 25200000 |
| Value | Rs.1,45,03, 000 |
| 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
- The envisaged production capacity is based on single shift basis on 300 working days in a year.
- The unit will purchase the technology from National Metallurgical Laboratory, Jamshedpur which have developed improved technologies for Graphite Crucibles.
- The costs given are based on the current market rates and may vary from time to time.
- The wages are as per the prevailing norms.
Implementation Schedule
Activity |
Period |
| Preparation of Project Report and preliminary work with institutions, site selection | 2 |
| Follow-up action for Term Loan sanction | 1 |
| Acquisition of land and construction of buildings, selection of machinery, placing orders | 3 |
| Supply of machineries and erection | 2 |
| Getting power connection, completion of other formalities with various agencies, working capital, loan sanction etc., trial run and production | 1 |
| 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 |
Motive Power 60 HP.
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 / (Rs.) |
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)
Particular |
Qty. (MT) |
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) |
Rate (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 |
Total Capital Investment
| i) Fixed capital | 7316000 |
| Working capita l (2 month) | 2765264 |
| Total | 10081264 |
Financial Analysis
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 |
Total Sales Turnover (per annum) |
Rs |
| By sale of 420MT of Graphite Crucibles (After allowing nearly 7% rejections) @ of 60000 per MT | 25200000 |
Profit (per annum)
Sales – Cost of production Rs. 25200000– 18471748.32 6728251.68 |
Net Profit Ratio
Net profit per year x 100 Turnover per year 6728251.68x 100 25200000 26.7 |
Rate of Return (per annum)
Net profit per year x 100 Total investment 6728251.68 x 100 10081264 66.74 |
Break-even Point
Fixed Cost (per annum) |
(Rs.) |
| Depreciation on building @5% | 217000 |
| Depreciation on Plant and Machinery @10% | 177600 |
| 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
- M/s. Keshab Engn. Co. Ltd.
Bose Park, P.O. Sikchar,
24, Paraganas (North),
(West Bangal) - M/s. Amic Industries (P) Ltd.
10, B.T. Road,
Kolkata - 700 056 - M/s. Pappu Veeranna and Sons
Dhowleswaram Rajahmundry,
East Godavari District - M/s. Hari Machines Ltd.
Rajgangapur - 770 017 - 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
- M/s. Patna State Graphite Minerals Co.
Titagarh (PO), (Orissa) - M/s. Laxmi Narayan Agarwal Co.
Sambhalpur, (Orissa) - M/s. Hindustan Graphite Refining and Products Co.
Opp. Petrol Pump, G.T. Road Kovvur,
West Godavari Dist., (A.P) - M/s. Hari Machines Ltd.
Rajgangapur - 770 017 M/s. Grindwel Narton (P) Ltd.
4th Floor, 114 MG Road,
Bangalore - M/s. Indian Metal and Ferro Alloys
Terubali, Rayagada Dist.,
(Orissa) - M/s. Elector Thermics
C-5, SBH Colony,
Hyderabad - 500 034 - M/s. East India Minerals
Fireylal Chowk, Ranchi,
(Jharkhand)
Shuttle Kiln Fabricators
- M/s. Unifire
Shakespere, 16-12, Sarani,
4th Floor, Kolkata
- M/s. Bengallium Industrial Funales
24-B, Carmae Street,
Kolkata - 700 016 - M/s. Techno Thermo Projects Pvt. Ltd.
225/2, C.I.T. Road, Scheme VII-M,
Kolkata - 700 054 - M/s. N.M. Kiln Pvt. Ltd.
A-706, Rail Vihar, Seetu
15-11, Jharza Road,
Gurgaon - 122 001 - M/s. Sharma Kiln Technology
206, Hare Krishna Complex,
Opp. Kottawala Flats,
Ashram Road,
Ahmedabad - 380 007 - M/s. Associated Industrial Furnaces
2/5, Sarai Julane, 1st Floor,
Okhla Road,
New Delhi - 110 025
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
