Chromum Plating on ABS Plastic

Product Code	339967005
Quality and Standards	IS : 1068-1993 for Copper, Nickel and Chromium Electrode deposited coating
Production Capacity: Qty.	Quantity : 25,000 Sq. mtrs. Per Annum
Value	Rs.75,00,000/-
Uploaded on	February 2020

Introduction

 

Plastic can be readily moulded into intricate shapes and the light weight and ease of fabrication in plastics may be combined with certain desirable characteristics of metal by plasting the tensile impact properties and abrasion resistance of plastics are improved by metal coating. The applications of metallized plastic include P.C.B.S. draw pulls doorknobs automobile and electric appliances hardwares, frontguards, push buttons and regulators knobs for fan cooler etc. Plastics that can be plated are phenol formaldehyde, melamin , acrylics epoxide and Acrylonitrile Butadiene Styrene (ABS).

 

Market:

 

ABS Moulded Components with chrome finish are being increasingly used for various engineering and other automobile accessories computer hardwares. There exist sufficient scopes for new job plating units for plating of ABS plastic moulded components.

 

This item can also be marketed as ancillary items to other industries like Radio, T.V. Industries, Electronic and Electrical Indus tries, Automobile Industries etc. from the production of 1500 M.T. in 1950. The production of ABS has since increased 200000 M.T. A considerable part of this production is expected to be plated which is a fair demand for this industry.

 

Basis & Presumptions :

 

(i) The efficiency of the unit is calculated at 70% of the total production capacity. The unit will work 25 days a month on single shift basis and 300 days in a year.

(ii) The time period for achieving the full envisaged capacity utilization is six months after starting of production.

(iii) The labour wages are as per the prevailing rates in the market.

(iv) The rate of interest for fixed and working capital is taken as 14%

(v) The margin money requirement for the project is 30 per cent.

(vi) The pay back period of this project is 3 years.

 

Implementation Schedule

 

The time requirement for preparation of Project Report	:	Two months
Time requirement for selection of site	:	One month
Time required for registration as small scale unit	:	One month
Time required for acquiring the loan	:	Two months
Construction of building	:	Three months
Machinery procurement, erection and commissioning	:	One month
Recruitment of labourer etc.	:	One month
Trial runs	:	One month

 

Technical Aspects:

Process Outline

 

The process of electroplating on plastics is similar to that on metals with the difference that the former are made conducting by some treatments before electroplating. The preparatory operations on plastic substrates include etching or conditioning, sensitizing, activation and electroless plating.

 

The degree of adhesion of plate to plastic depends on a number of factors. The most important of which are the particular ABS resin the conditions under which the plastic was moulded and the conditioning treatment special grade of ABS specifically formulated for plating generally plate with greater adhesion than non-plating grades.

 

Flow Process Chart

 

The following sequence of operation is usually followed for plating on ABS:

 

 

Quality & Standard

 

IS:1068-1993 for Copper, Nickel and Chromium electrodeposited coatings.

 

Production Capacity (Per Annum)

 

Quantity	: 25000 Sq. mtrs.
Value	: Rs. 75,00,000/-

 

Motive Power Requirement

 

The power requirement is 30 KWH, 3 Phase 440 Volts.

 

Pollution Control Measures

 

Since this unit has been classified as pollution making industry, the No Objection Certificate has to be taken from the State Pollution Control Board. However, a suitable arrangement has been made to control the pollution problem.

 

Energy Conservation:

 

Proper insulation of bath and other related pipes should be made so that the wasting of energy can be saved.

 

Financial Aspects:

 

(i) Fixed Capital
Land & Building

 

	Area Sq. Mtrs.	Rate Rs./Sq. Mtr.	Value (Rs.)
Land	200 Sq. Mtrs.	2000/-	4,00,000/-
Building	100 Sq. Mtrs.	5000/-	5,00,000/-
Total			9,00,000/-

 

Machinery & Equipment

 

Sr. No.	Description of Machines		Qty.(Nos.)	Value (Rs.)
(a)	Production Unit
1.	Oil Cooled Silicon Rectifier with stepless control, output current rating 1000 amps. Output voltage 12 V complete with Metal Panel etc.		1	2,00,000/-
2.	Filtration unit for Bright Nickel with 2 HP Motor and 16 plates		1	32,000/-
3.	Filter unit for Acid Copper with 2 HP Motor 16 plates 2800 RPM		1	32,000/-
4.	Bright Nickel Tank Capacity 1500 Ltr.		1	65,000/-
5.	Chrome tank cap. 300 litres		1	4,000/-
6.	Acid copper tank capacity 500 litres		1	15,000/-
7.	Drag out Tank		2	10,000/-
8.	Neutralization tank cap. 300 litres		1	5,000/-
9.	Sensitizing tank		1	5,000/-
10.	Etching tank 2'x2'x2' Ms/5mm L.L.		1	40,000/-
11.	Polishing machine motorized 2 HP		1	13,000/-
12.	Immersion Heaters 3 KW Lead banding M.S.		2	7,000/-
(b)	Testing Equipment like different Reagent, Glassware, P.H. Meter		L.S.	1,00,000/-
(c)	Pollution Control equipment unit			2,00,000/-
(d)	Electrification and Installation charges @ 10% of cost of machinery			70,000/-
	Total cost of machinery & equipment			7,98,000/-
	Cost of office equipment/working table/computer			1,50,000/-
			Total Rs.	9,48,000/-

 

(iii) Pre-operative Expenses (Project cost, non-refundable)	50,000/-
Total Fixed Capital = (i+ii+iii)
Fixed Capital	9,00,000
Machinery & Equipment	9,48,000
Pre-operative Expenses	50,000
	18,98,000/-

 

Working Capital (Per Month)

(A) Staff & Labour

 

Designation	Nos.	Salary (Rs.)	Total (Rs.)
Chief Chemist cum Manager	1	10,000/-	10,000/-
Skilled Worker	1	6,000/-	6,000/-
Workers	6	4,000/-	24,000/-
Accountant cum Store Keeper	1	5,000/-	5,000/-
Clerk cum Typist	1	4,500/-	4,500/-
Total salaries + perquisites @ 15%		Total : Or say :	49,500/-
			----------- 7,425/- -----------
			56,925/-
			57,000/-

 

(B) Raw Materials

 

Sr. No.	Particulars	Qty. (kgs.)	Rate (Rs./kg or litre)	Value (Rs.)
1	Bright Nickel Salt	80	430/kg.	34,400/-
2	Brightner (initial make up)	12	400/ltr.	4,800/-
3	Brightner Maintenance	22	400/ltr.	8,800/-
4	Decorative chrome salt	32	400/kg.	12,800/-
5	Nickel Anode (4”x4”)	40	2600/kg.	1,40,000/-
6	Copper Anode	17	480/kg.	8,160/-
7	Soak Cleaner	32	100/kg.	3,200/-
8	Neutralizer	32	50/ltr.	1,600/-
9	Sensitizer	32	1800/ltr.	57,600/-
10	Etchant	77	185/ltr.	14,245/-
11	Immersion Nickel Concentrate (A)	42	350/ltr.	14,700/-
12	Immersion Nickel (B)	42	330/ltr.	13,860/-
13.	Acid Copper Brightner (Additive)	17	350/ltr.	5,950/-
14	Misc. chemicals viz. caustic soda, sulphuric acid, copper wire, PH Paper, Hydrogen Peroxide activated Carbon	L.S.		20,000/-
			Total Or say	3,40,115/- 3,40,000/-

 

(C) Utilities (Per Month)

 

		(Rs.)
Power : 30 KWH @ 5.50 per unit (30 KWH X 8 Hrs. x 25 days x 5.50)		33,000/-
Water : L.S.		5,000/-
Total		38,000/-

 

(D) Other Contingent expenses (Per Month)

 

	Rs
Postage & Stationery	2,000/-
Telephone	2,000/-
Consumable Stores	1,500/-
Repairs & Maintenance	3,500/-
Transportation charges	2,000/-
Advertisement & Publicity	2,000/-
Insurance	3,000/-
Miscellaneous Expenditure	2,000/-
Total	18,000/-

 

Total Working Capital (Per Month)

 

	Rs
(A+B+C+D) Working Capital (Per Month):	57000/-
Raw Materials:	340000/-
Utilities (Per Month):	38000/-
Other Contingent expenses (Per Month):	18,000/-
Total	4,53,000/-

 

Total Capital Investment:

 

(a) Fixed Capital	18,98,000/-
(b) Working Capital for 3 months	13,59,000/-
Total	32,57,000/-

 

Financial Analysis:

 

Cost of Production (Per Year)	(Rs.)
Total recurring cost per year	54,36,000/-
Depreciation on Building @ 5%	25,000/-
Depreciation on machinery @ 10%	79,800/-
Depreciation on Office Equipment @ 20%	30,000/-
Interest on total capital investment @ 14%	4,55,980/-
Total cost of production	60,26,780/-

 

2) Sales/Turnover (per year)

 

Item	Qty. (sq. mtrs.)	Rate/sq.mtr (Rs.)	Amount (Rs.)
Chromium Plating on ABS job work on various types	25000	300	75,00,000/-

 

3) Turnover (Rs.)	Cost of Production (Rs.)	Profit (Rs.)
75,00,000	60,26780	14,73,220

 

4) Net Profit Ratio	=	Net Profit x 100 -----------------------------
		Turnover Per Year
	=	14,73,220 x 100 --------------------------------
		75,00,000
	=	19.64%

 

5) Rate of Return	=	Net Profit x 100 -----------------------------
		Total Investment
	=	14,73,220 x 100 -----------------------------
		32,57,000
	=	45.23%

 

6) Break-even Point

 

	Fixed Cost	Rs.
a)	Depreciation on Building	25,000/-
b)	Interest on total investment	4,55,980/-
c)	Insurance	36,000/-
d)	40% of salary and wages	2,73,600/-
e)	40% of other contingent expenses	86,400/-
	Total :	87,6980/-
	say :	8,77,000/-

 

B.E.P. %	=	Fixed Cost x 100 Fixed ------------------------------- Cost + Net Profit
	=	8,77,000 x 100 -------------------------------- 8,77,000 + 14,73,220
	=	37.31%

 

Names & Addresses of Machinery Suppliers:

 

1. M/s. Grauer & Well (India) Ltd.,
Sukh Sagar, 6th Floor
N.S. Patkar Marg Coupatty
Mumbai-400 007.

2. M/s. Canning Mitra Phoenics Ltd.,
Eucharstic Congress Building III,
Mumbai-400 039.

3. M/s. Modern Engineering Co.,
Plot No. 1/33, Phase IV, GIDC,
Vithal Udyognagar – 388 121
Dist. Anand (Gujarat)

4. M/s. S.S. Engineering,
C-1-B, Hatkesh Udyognagar
Kashmira Byander Road
Mumbai-401 104.

5. M/s. Technocrat (India)
Plot No. 21, Gali No. 28 (Opp: Gali No. 4)
Railway Line Side
Anand Parbat Industrial Area
Near Rohtak Road
New Delhi-110 005.

6. M/s. Rectiers & Controls
17/3, Mathura Road
Faridabad-121 002.

7. M/s. Jindal Rectifiers
4/B, 4th Floor, DCM Building
16, Barakhamba Road
New Delhi-110 001.

7. M/s. Vijay Industries
B/10, Phase-II
Mayapuri Industrial Area
New Delhi-100 064.

Names & Addresses of Raw Material Suppliers:

1. M/s. Mahavir Chemical Industries
Mahavir Estate
B/h. Shah Chambers
Nr. C.T.M. Cross Lane\
Amraiwadi, Ahmedabad.

2. M/s. Delta Chemicals
6, Deta House
J-1, Cama Zone, Goregaon (E)
Mumbai-4000 099.

3. M/s. Komal Agency
4, Sivangi Colony
Near Darpan Cinema
Andheri (E), Mumbai-400 099.

4. M/s. Manish Sales Corporation
178, Chetan Cloth Market
Sarangpur Gate
Ahmedabad-380 001.

5. M/s. Techno Enterprises
R 15/59, New Rajnagar
Ghaziabad (U.P)

6. M/s. Shankar & Co.,
200, Chawan Bazar
Delhi-110 016.

7. M/s. Ranject Engineering Works
FA 310, Mansarovar Garden
New Delhi-110 015.

8. M/s. Shree Chamunda Enterprise
1163/3, Patel Vas
Nava Asazwa
Ahmedabad-380 016 (Gujarat).

 

For further information please contact

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com