Detailed Project Report on backward integration for aluminium rolling mill for pressure cooker and utensils

BACKWARD INTEGRATION FOR ALUMINIUM ROLLING MILL FOR PRESSURE COOKER AND UTENSILS

[CODE NO.4257]  

Aluminium is the world’s most abundant metal and is the third most common element, comprising 8% of the earth’s crust. The versatility of aluminium makes it the most widely used metal after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. In the 100 years since the first industrial quantities of aluminium were produced, worldwide demand for aluminium has grown to around 29 million tons per year. About 22 million tons is new aluminium and 7 million tons is recycled aluminium scrap. The use of recycled aluminium is economically and environmentally compelling. It takes 14,000 kWh to produce 1 tonne of new aluminium. Conversely it takes only 5% of this to remelt and recycle one tonne of aluminium. There is no difference in quality between virgin and recycled aluminium alloys. Pure aluminium is soft, ductile, and corrosion resistant and has a high electrical conductivity. It is widely used for foil and conductor cables, but alloying with other elements is necessary to provide the higher strengths needed for other applications. Aluminium is one of the lightest engineering metals, having strength to weight ratio superior to steel. By utilising various combinations of its advantageous properties such as strength, lightness, corrosion resistance, recyclability and formability, aluminium is being employed in an ever-increasing number of applications. This array of products ranges from structural materials through to thin packaging foils.

COST ESTIMATION

Plant Capacity                                            100 MT/Day

Land & Building (18,000 sq.mt.)               Rs. 15.74 Cr

Plant & Machinery                                       Rs. 117.29 Cr

Working Capital for 2 Months             Rs. 93.82 Cr

Total Capital Investment                            Rs. 228.36 Cr

Rate of Return                                               42%

Break Even Point                                          41%

• 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
• ALUMINIUM SHEETS
• PROPERTIES OF ALUMINIUM SHEET METAL
• ITS MOST VALUABLE PROPERTIES INCLUDE:
• SPECIFICATIONS
• USES
• ALUMINUM SHEET ADVANTAGES
• CONTINUOUSLY RECYCLABLE SHEET METAL
• HIGH-PERFORMANCE ARMOR
• ALUMINUM SHEET GAUGE
• THE COLDER THE TEMPERATURE, THE STRONGER THE ALUMINUM
• SPECIFICATION OF COIL
• USES AND APPLICATION
• ROOFING –
• ARTISTIC CEILINGS –
• BALCONIES –
• DRINKS CANS, BEER BARRELS & OTHER FOOD INDUSTRY CONTAINERS
• CABLE SHEATHINGS –
• CLADDING AND FASCIA PANELS –
• CRANES, TRUSSES, SUPPORTS AND LIFTING GEAR –
• HIGH STRESS APPLICATIONS –
• LAMP REFLECTORS –
• SHELTERS –
• CARAVANS –
• FLOORING AND WALLS –
• APPLICATIONS
• PACKAGING INDUSTRY -
• HOME APPLIANCES -
• BUILDING & CONSTRUCTION INDUSTRY -
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• ROLLING PROCESS
• MEANING OF ROLLING:
• HOT ROLLING
• COLD ROLLING MILLS
• FOIL MILLS
• DEFECTS IN ROLLED PRODUCTS:
• (I) EDGE CRACKING:
• (II) FOLDS:
• (III) ALLIGATORING:
• (IV) SCALE FORMATION:
• ROLLING 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
• MARKET OVERVIEW
• TOP ALUMINIUM PLATE AND SHEET MANUFACTURERS
• ARCONIC
• ALERIS
• CONSTELLIUM
• HULAMIN
• CHALCO
• MARKET TREND
• APPLICATION OUTLOOK:
• REGIONAL OUTLOOK:
• MARKET-O-NOMICS:
• ADVANTAGES OF ALUMINUM FLAT PRODUCTS IN AUTOMOTIVE 
• BODY PANEL TO SPUR MARKET SIZE
• PLANT LAYOUT
• SUPPLIERS OF ALUMINIUM SHEET AND COIL
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF ALUMINIUM SLAB
• SUPPLIERS OF PICKLING CHEMICALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF ALUMINIUM ROLLING MILL
• EUROPEAN SUPPLIERS OF ALUMINIUM FOIL MILL
• INDIAN SUPPLIERS FOR ALUMINIUM SHEET AND COIL MILL
• EUROPEAN 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 EFFLUENT 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 – 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)