Manufacturing of House Wire & Cables (Copper) & Aerial Bunched Cable (Cap: 75 Tons/Day)

MANUFACTURING OF HOUSE WIRE & CABLES (COPPER) & AERIAL BUNCHED CABLE (CAP: 75 TON/DAY) [EIRI/EDPR/4722] J.C.: 2942US$

The market for wire and cables is divided into different segments in terms of product variation. The basic division is between cables and conductors. Cables are either power cables or control cables. Power cables supply energy at voltages up to 230 KV. Control cables are low voltage cables (up to 0.6 KV) used to transmit control signals in switch boards. The conducting material can be copper or aluminum with insulating material, PVC, XLPE, elastomers or paper. The cable market is segmented by the combination of material used to form the conductor, the insulator, sheathing and armoring.

An ABC Cable, also known as Aerial Bundled Cable, is an overhead power line. This cable consists of numerous insulated conductors, bundled and wrappedtogether tightly. It also comes along with a bare neutral conductor. The use of insulation is the ABC cable is in contrast with the traditional transmission cables that were uninsulated. Additionally, these cables can transmit power in low voltages.

COST ESTIMATION

Plant Capacity            75 TON/Day

Land & Building (10,000 sq.mt.)    US$ 6.79 Lac

Plant & Machinery                    US$ 4.04 Lac

Working Capital for 2 Months    US$ 1.36 Cr

Total Capital Investment          US$ 1.48 Cr

Rate of Return                          20%

Break Even Point                      48%

CONTENTS

INTRODUCTION

OBJECTIVE OF THE PROJECT

THE SOCIO-ECONOMIC SIGNIFICANCE OF THE PROJECT

EMPLOYMENT OPPORTUNITY

SAVE THE COUNTRY FOREIGN EXCHANGE

BENEFIT FOR THE LOCAL COMMUNITY

STIMULATE THE LOCAL ECONOMY

TECHNOLOGY TRANSFER

PRODUCT DESCRIPTION

TYPES OF ABC CABLES:

LOW VOLTAGE AERIAL BUNDLE CABLES:

MEDIUM VOLTAGE AERIAL BUNDLE CABLES:

DUPLEX/TRIPLEX SERVICE DROP WIRE:

AERIAL BUNCHED CABLES

CONSTRUCTION OF ABC

MATERIALS

APPLICATION

AERIAL BUNCHED CABLES CAN BE CONVENIENTLY USED:

ADVANTAGES/APPLICATIONS

ADVANTAGES OF USING ABC CABLES:

• INCREASED SAFETY:

• LOW MAINTENANCE COSTS:

• WIDE AREA COVERAGE:

• SECURE FROM SHORT CIRCUITS:

• AFFORDABLE PRICES:

EASY DETECTION OF FAULTS:

• EASY INSTALLATION:

B.I.S. SPECIFICATIONOF PRODUCTS

INDUSTRY/MARKET OVERVIEW

ECONOMIC OUTLOOK

GLOBAL ECONOMY

TABLE 1: GLOBAL GROWTH OUTLOOK PROJECTIONS (IN%)

1.1 INDIAN ECONOMY

1.1.1 INDEX OF INDUSTRIAL PRODUCTION

1.1.2 SECTORAL PERFORMANCE

1.1.3 CONSUMPTION AND INVESTMENT

1.1.1 CAPITAL MARKET PERFORMANCE

1.1.2 IMPACT OF THE RUSSIA INVASION ON ECONOMY

1.1.3 OUTLOOK

OVERVIEW OF WIRE AND CABLE INDUSTRY

GLOBAL WIRE AND CABLE MARKET HISTORIC TRENDS

GLOBAL WIRE AND CABLE MARKET FORECAST GROWTH

INDIAN WIRE AND CABLE INDUSTRY MARKET

C & W MARKET IN REVENUE TERMS

GROWING SHARE OF ORGANIZED PLAYERS

COVID IMPACT ON WIRE AND CABLE INDUSTRY

GROWTH & DEMAND DRIVERS OF WIRE AND CABLE INDUSTRY

CABLES AND WIRES DEMAND DRIVERS

SUPERIOR QUALITY PRODUCT IN HOUSING WIRES LED TO HIGHER MARGINS FOR ORGANIZED PLAYERS

HOUSING SECTOR:

TIER II AND III CITIES TO DRIVE HOUSING CONSTRUCTION GROWTH

NHB INDIA HOUSING PRICE INDEX*

HOUSING DEMAND-SUPPLY UNITS IN TOP 8 CITIES 2016-2020

INFRASTRUCTURE:

PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES

POWER

INDUSTRIAL EXPANSION AND STRONG GDP GROWTH DRIVING POWER DEMAND

RAILWAYS:

1. GROWING DEMAND

2. POLICY SUPPORT

 RISING INCOME AND URBANISATION DRIVING PASSENGER TRAFFIC GROWTH

 INFRASTRUCTURE DEVELOPMENT

1. TELECOMMUNICATION

 SECOND-LARGEST SUBSCRIBER BASE

STRONG GROWTH IN BROADBAND DRIVES INTERNET ACCESS REVENUES

CHALLENGES FACED BY THE INDUSTRY

CYCLICAL MARKET

POWER SHIFTS IN THE SUPPLY CHAIN

CONVERSION INDUSTRY AND WORKING CAPITAL

DE-REGULATION LOWERS BARRIERS OF ENTRY

GOVERNMENT INITIATIVES UNDERTAKEN FOR INDUSTRY

1. HOUSING FOR ALL

PROGRESS OF PMAY:

PRADHAN MANTRI AWAS YOJANA-URBAN (PMAY-U)

PRADHAN MANTRI AWAS YOJANA GRAMIN (PRADHAN MANTRI AWAS YOJANA RURAL)

1. GOVERNMENT’S FOCUS ON IMPROVING ELECTRIFICATION

2. MAKE IN INDIA

3. SMART CITIES MISSION

COMPETITIVE ANALYSIS & KEY INDUSTRY PLAYERS

1. PORTER FIVE FORCES ANALYSIS

• THREATS OF NEW ENTRANTS

• BARGAINING POWER OF SUPPLIERS

• BARGAINING POWER OF BUYERS

• THREATS OF SUBSTITUTE PRODUCTS OR SERVICES

• RIVALRY AMONG THE EXISTING COMPETITORS

IMPLICATIONS OF PORTER FIVE FORCES ON WIRE & CABLE COMPANY

1. FINOLEX CABLES LIMITED

3. POLYCAB INDIA LIMITED

4. HAVELLS INDIA LIMITED

5. RR KABEL LIMITED

6. V-GUARD INDUSTRIES LIMITED

7. PLAZA WIRES LIMITED

OUTLOOK/CONCLUSION

MANUFACTURING PROCESS

TECHNOLOGY

COPPER BONDING WIRE OF 99.999% PURITY

FEATURES

MANUFACTURING PROCESS

ANNEALING

STRANDING

INSULATING

LAY-UP

SHEATHING

ARMORING

PACKING

MANUFACTURING FLOW CHART

1. SINGLE WIRE

2. MULTIPLE WIRE

3. FLEXIBLE WIRE

4. FLAT TWIN-CORD WIRE

5. POWER CABLE WIRE

6. ARMOUR CABLE

DRAWING

BUNCHING

STRANDING

EXTRUSION

COILING AND PACKING

MANUFACTURING PROCESS

(I) METHOD OF MAKING STRIP

(II) PROCESS OF COVERING

(III) METHOD OF MATERIAL ANNEALING

MACHINERY & EQUIPMENTS REQUIRMENT

A. MACHINERIES

A. ACCESSORY EQUIPMENT’S

B. INSPECTION AND TESTING EQUIPMENT

PROCESS FLOW DIAGRAM

QUALITY CONTROL

KEY REGULATIONS AND POLICIES 

A. INDUSTRYRELATED LEGISLATION

1. THE FACTORIES ACT, 1948

1. THE ELECTRICAL WIRES, CABLES, APPLIANCES AND PROTECTION DEVICES AND ACCESSORIES (QUALITY CONTROL) ORDER, 2003

2. ELECTRICITY ACT, 2003

B. EMPLOYEE AND LABOUR RELATED LEGISLATIONS:

THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION, PROHIBITION AND REDRESSAL) ACT, 2013

A. SHOPS AND COMMERCIAL ESTABLISHMENTS LEGISLATION:

B. TAX RELATED LAWS:

1. INCOME-TAX ACT, 1961

2. CENTRAL GOODS AND SERVICES TAX ACT, 2017

1. INTEGRATED GOODS AND SERVICES TAX ACT, 2017

2. THE CUSTOMS ACT, 1962 AND THE CUSTOMS TARIFF ACT, 1975

5. PROFESSIONAL TAX

A. INTELLECTUAL PROPERTY LAWS

1. THE TRADEMARKS ACT, 1999

2. THE COPYRIGHT ACT, 1957

B. OTHER APPLICABLE LAWS:

THE COMPANIES ACT, 2013

1. THE CONSUMER PROTECTION ACT, 1986

1. THE TRANSFER OF PROPERTY ACT, 1882

2. THE SALE OF GOODS ACT, 1930

3. THE REGISTRATION ACT, 1908

4. THE INDIAN CONTRACT ACT, 1872

5. THE SPECIFIC RELIEF ACT, 1963

1. COMPETITION ACT, 2002

2. LEGISLATIONS PERTAINING TO STAMP DUTY

3. LEGAL METROLOGY ACT, 2009

A. ENVIRONMENTAL LAWS

1. THE ENVIRONMENT PROTECTION ACT, 1986 AND ENVIRONMENT (PROTECTION) RULES, 1986

1. THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (“THE WATER ACT”)

2. THE AIR (PREVENTION AND CONTROL OF POLLUTION)ACT,1981 (THE AIR ACT)

B. REGULATIONS REGARDING FOREIGN INVESTMENT

FOREIGN EXCHANGE MANAGEMENT ACT, 1999

SUPPLIERS OF MAJOR PLANT & MACHINERY

MACHINERY

MATERIAL HANDLING EQUIPMENTS

LABORATORY TESTING EQUIPMENTS

MIXING PLANT

STEEL WIRES

MIXTURE

SUPPLIERS OF SIEVING MACHINE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF JIGS AND FIXTURE

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

GENERATION AND MANAGEMENT OF WASTES

SOLID WASTES

LIQUID WASTES

GASEOUS EMISSION

OTHERS

INDUSTRIAL WASTE MANAGEMENT

SEWERAGE SYSTEM 

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

SAFETY DATA SHEETS

ENVIRONMENTAL/SAFETY LIABILITY 

PRE-PROJECT ACTIVITIES

PROPOSED IMPLEMENTATION SCHEDULE

PLANT LAYOUT

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSES 

LIST OF DOCUMENTS:

SWOT ANALYSIS

SWOT ANALYSIS

1. STRENGTH

2. WEAKNESS

3. OPPORTUNITY

4. THREATS

ORGANIZATION CHART

ORGANIZATIONAL STRUCTURE

1. MANAGER

2. THE MANUFACTURING DEPARTMENT DUTIES AND RESPONSIBILITIES: -

3. ADMINISTRATION AND FINANCE DEPARTMENT

FINANCE SECTION

DUTIES AND RESPONSIBILITIES: -

4. MARKETING AND SALES DEPARTMENT

IMPLEMENTATION SCHEDULE

FUTURE DEVELOPMENT

ENVIRONMENTAL IMPACT OF THE PROJECT

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)