Industry Overview
Aluminium is the most abundant metal and the third most common element in the Earth's crust, comprising about 8% of the Earth's solid surface. Its combination of low weight, strength, corrosion resistance, conductivity, formability, reflectivity, and recyclability has made it one of the most widely used engineering metals after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. Since industrial-scale production began, worldwide demand has expanded substantially, supported by applications ranging from structural materials to packaging foils.
Aluminium has a density of around one third that of steel, providing an advantageous strength-to-weight ratio for transportation and other weight-sensitive applications. Its naturally formed oxide layer provides corrosion resistance, while its electrical and thermal conductivity supports applications in power transmission and heat transfer. Aluminium is also non-toxic and suitable for sensitive packaging applications, including food and pharmaceutical products.
Recycling is a major advantage of aluminium because recycled metal retains properties comparable to virgin aluminium while requiring only around 5% of the energy needed to produce virgin material. The report covers aluminium ingot, plate, sheet and foil manufacturing, including scrap preparation, melting, refining, rolling, annealing, slitting, cutting, lamination and coating processes, together with associated equipment, market information, suppliers and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 200 MT/Day |
| Land & Building (20,000 sq.mt.) | Rs. 14.14 Cr |
| Plant & Machinery | Rs. 122.23 Cr |
| Working Capital for 2 Months | Rs. 156.49 Cr |
| Total Capital Investment | Rs. 294.38 Cr |
| Rate of Return | 44% |
| Break Even Point | 43% |
Content Index
- INTRODUCTION
- PROPERTIES
- (1) STRENGTH TO WEIGHT RATIO
- (2) CORROSION RESISTANCE
- (3) ELECTRICAL AND THERMAL CONDUCTIVITY
- (4) LIGHT AND HEAT REFLECTIVITY
- (5) TOXICITY
- (6) RECYCLING
- PHYSICAL PROPERTIES OF ALUMINIUM
- OTHER INFORMATION ABOUT ALUMINIUM
- USES OF ALUMINIUM
- (1) ALUMINIUM PLATE:
- (2) ALUMINIUM SHEET:
- SPECIFICATIONS
- USES
- ALUMINUM SHEET ADVANTAGES
- CONTINUOUSLY RECYCLABLE SHEET METAL
- HIGH-PERFORMANCE ARMOR
- ALUMINUM SHEET GAUGE
- THE COLDER THE TEMPERATURE, THE STRONGER THE ALUMINUM
- ALUMINUM SHEET APPLICATIONS
- PACKAGING INDUSTRY
- HOME APPLIANCES
- BUILDING & CONSTRUCTION INDUSTRY
- (3) ALUMINIUM FOIL:
- SPECIFICATIONS
- USES AND APPLICATION
- (A) FOR PLATE
- (B) FOR SHEET
- (C) FOR FOIL
- USES
- USE OF ALUMINIUM IN FOOD & BEVERAGE SECTOR
- 1. FOIL ROLLS OF DIFFERENT THICKNESS & WIDTH
- SPECIFICATIONS
- USES
- USE OF AN ALUMINIUM FOIL IN MAKING OF FOOD CONTAINERS
- 1. FOIL ROLLS – PRINTED FOR BLISTER PRODUCTS
- SPECIFICATIONS
- USES
- USE OF PRINTED FOIL ROLLS FOR PACKEGING & IN PHARMACEUTICALINDUSTRY
- 2. FOIL ROLLS – PLAIN FOR PHARMACEUTICAL INDUSTRY
- SPECIFICATIONS
- USES
- USES OF PLAIN ALUMINIUM FOIL
- B.I.S. SPECIFICATION
- PROCESS FLOW DIAGRAM
- (A) FOR INGOT
- (B) FOR PLATE
- (C) FOR SHEET
- (D) FOR FOIL
- FOR LAMINATION AND COATING
- MANUFACTURING PROCESS
- (A) MANUFACTURING PROCESS OF ALUMINIUM INGOT
- (1) SCRAP PRETREATMENT –
- (A) MECHANICAL CLEANING –
- (B) PYROMETALLURGICAL CLEANING -
- (C) HYDROMETALLURGICAL CLEANING -
- MELTING
- MOC-SKELNER FURNACE
- TEMPERATURE CONTROL
- DEGASSING
- POURING
- CLEANING
- (3) EMISSIONS AND CONTROLS
- (A) SCRAP PRETREATMENT EMISSIONS -
- (B) SMELTING/REFINING EMISSIONS -
- SHIPMENT PROCESS FOR INGOT:
- (A) MANUFACTURING PROCESS OF ALUMINIUM PLATE
- (C) MANUFACTURING PROCESS OF ALUMINIUM SHEET
- DISCRIPTION
- ROLLING PROCESS
- (D) MANUFACTURING PROCESS OF FOIL
- WORKING PROCESS FOR LAMINATION AND COATING
- 1. CHART
- DESCRIPTION
- MEANING OF ROLLING:
- HOT ROLLING
- COLD ROLLING MILLS
- FOIL MILLS
- DEFECTS IN ROLLED PRODUCTS:
- (I) EDGE CRACKING:
- (II) FOLDS:
- (III) ALLIGATORING:
- (IV) SCALE FORMATION:
- ROLING MILL AND EQUIPMENTS
- KEY EQUIPMENTS
- KEY EQUIPMENTS IN SHEET DIVISION
- 1. 4-HI REVERSING ROLLING MILL
- SPECIFICATIONS
- 2. SLITTER MACHINE
- SPECIFICATIONS
- 3. CUT TO LENGTH MACHINE
- SPECIFIVATIONS
- 4. ANNEALING FURNACE (ELECTRICIALLY HEATED)
- SPECIFICATIONS
- KEY EQUIPMENTS IN FOIL DIVISION
- 1. ROLLING MILL
- SPECIFICATIONS
- KEY EQUIPMENTS IN CONVERSION DIVISION
- 1. HEAT & PRESS LAMINATOR MACHINE
- SPECIFICATIONS
- 2. COATING MACHINE
- SPECIFICATIONS
- DISCRIPTION
- ROLLING PROCESS
- WORKING PROCESS IN FOIL DIVISION
- 1. CHART
- DISCRIPTION
- WORKING PROCESS IN CONVERSION DIVISION
- 2. CHART
- DESCRIPTION
- EQUIPMENTS
- KEY EQUIPMENTS IN SHEET DIVISION
- 1. 4-HI REVERSING ROLLING MILL
- SPECIFICATIONS
- 2. SLITTER MACHINE
- SPECIFICATIONS
- 3. CUT TO LENGTH MACHINE
- SPECIFIVATIONS
- 4. ANNEALING FURNACE (ELECTRICIALLY HEATED)
- SPECIFICATIONS
- KEY EQUIPMENTS IN FOIL DIVISION
- 1. ROLLING MILL
- SPECIFICATIONS
- KEY EQUIPMENTS IN CONVERSION DIVISION
- 1. HEAT & PRESS LAMINATOR MACHINE
- SPECIFICATIONS
- 2. COATING MACHINE
- SPECIFICATIONS
- MARKET OVERVIEW
- SWOT ANALYSIS OF THE INDIAN ALUMINUM INDUSTRY
- 1. STRENGHTS:
- 2. WEAKNESS:
- 3. OPPORTUNITY:
- 4. THREATS:
- MARKET GROWTH
- GLOBAL MARKET
- PLANT LAYOUT
- SUPPLIERS OF ALUMINIUM PLATE AND SHEET
- SUPPLIERS OF ALUMINIUM FOIL FOR FOOD AND PHAMEUTICAL INDUSTRY
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ALUMINIUM SCRAP
- SUPPLIERS OF PACKING MATERIALS
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF ALUMINIUM ROLLING MILL
- EUROPEIAN SUPPLIERS OF ALUMINIUM FOIL MILL
- INDIAN SUPPLIERS FOR ALUMINIUM FOIL MILL
- EUROPEIAN SUPPLIERS OF ANNEALING FURNACE
- SUPPLIERS OF ANNEALING FURNACES
- EUROPEAN SUPPLIERS OF AUTOMATIC FLATNESS CONTROL, AUTOMATIC GAUGE CONTROL AND SEPARATOR
- SUPPLIERS OF FOIL PRINTING MACHINE, LAMINATING MACHINE AND EMBOSSING MACHINE
- SUPPLIERS OF METAL TESTING MACHINE
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF NDT INSPECTION EQUIPMENT
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- SUPPLIERS OF MILLING MACHINE
- SUPPLIERS OF CNC LATHE MACHINE
- SUPPLIERS OF BOARING MACHINE
- SUPPLIERS OF POWER HACKSAW
- SUPPLIERS OF GRINDING MACHINE
- SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium offers a combination of low weight, strength, corrosion resistance, conductivity, reflectivity, formability, and recyclability.
Its density is around one third that of steel, making it useful where low weight and adequate strength are important. Aluminium also forms a protective oxide coating when exposed to air, providing corrosion resistance. Its electrical and thermal conductivity supports power transmission and heat-transfer applications, while its non-toxic characteristics make it suitable for food and pharmaceutical packaging. These properties enable aluminium to serve applications ranging from structural materials and transportation components to sheets, plates and thin packaging foils.
Aluminium is widely used in electrical applications because it provides good conductivity combined with substantially lower weight than copper.
The report notes that, by weight, aluminium has around twice the conductivity of copper, making it particularly advantageous for large power transmission lines where weight is an important consideration. Aluminium alloys, including alloys in the 1000 and 6000 series, can be used for electrical conduction applications. Because aluminium conductors can have relatively low strength, overhead high-voltage conductors may incorporate reinforcing high-tensile steel wire.
Aluminium recycling is important because recycled aluminium retains its useful properties while requiring substantially less energy than primary production.
The report states that remelting and recycling aluminium requires only around 5% of the energy required to produce virgin aluminium metal. Recycled aluminium therefore provides both economic and environmental advantages. The material can be repeatedly recycled without degradation in properties compared with virgin aluminium. These characteristics make scrap recovery, preparation, remelting and reuse important parts of an aluminium manufacturing and processing operation.
Aluminium sheet and foil manufacturing generally involves rolling, followed by operations such as slitting, cutting and annealing as required by the product.
The report covers hot rolling, cold rolling and foil milling, along with equipment such as 4-Hi reversing rolling mills, slitter machines, cut-to-length machines and electrically heated annealing furnaces. Foil production may also involve conversion operations, including heat and press lamination and coating. Process control and inspection are important for maintaining dimensional accuracy, surface quality and the required characteristics of the finished aluminium products.
The project report covers aluminium ingot, plate, sheet and foil products, including products intended for packaging and other industrial applications.
It discusses specifications, uses and applications for aluminium plate and sheet, as well as foil products used in food and beverage packaging and pharmaceutical applications. The report also addresses plain and printed foil rolls, different foil thicknesses and widths, food containers, blister products, lamination and coating. This range demonstrates the flexibility of aluminium products across packaging, construction, home appliances and other end-use sectors.
An aluminium sheet and foil processing plant requires rolling, finishing, thermal-treatment and conversion equipment suited to the products being manufactured.
The report identifies key equipment including 4-Hi reversing rolling mills, slitter machines, cut-to-length machines, electrically heated annealing furnaces and foil rolling mills. The conversion division includes heat and press laminator machines and coating machines. Supporting facilities and equipment covered by the report include material-handling systems, cranes, electrical equipment, testing and inspection equipment, cooling systems, air compressors, pollution-control equipment and other plant utilities.
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