LT Cable, MV Cable, DC Solar Cable, Covered Cable and H.V. Cable Manufacturing Plant (Production Capacity: 150 MT/Day)
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LT CABLE, MV CABLE, DC SOLAR CABLE, COVERED CABLE AND H.V. CABLE MANUFACTURING PLANT (PRODUCTION CAPACITY: 150 MT/DAY)
[EIRI/EDPR/4770] J.C.: 2990INR, 2990US$
INTRODUCTION
Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.
There are two main types of wires: solid or stranded.
A solid wire is a single conductor that is either bare or insulated by a protective colored sheath. It offers low resistance and is perfect for use in higher frequencies. When inside a covering there are many thin strands of wires twisted together, it is called a stranded wire. Stranded wires are used where flexibility is important because which the wire can be used for a longer period. This type of wire have larger cross-sectional area than solid wires for the same current carrying capacity. Stranding is process of twisting together of small wires to form a single larger conductor. Used to provide flexibility, ease of handling and vibration resistance.
Copper Wire
Copper Wire is a single electrical conductor manufactured out of Copper Ore. This widely used conductor can either be insulated or uninsulated. Having a moderate conductivity, it’s used to transfer electricity with low voltage. Electrical wiring in buildings is the largest market for the copper industry worldwide. As per estimation, around half of the copper mines is consumed in manufacturing electrical wire and cable conductors.
COST ESTIMATION
Plant Capacity 150 MT/Day
Land & Building (21,600 sq.mt.) Rs. 6.02 Cr
Plant & Machinery Rs. 10.84 Cr
Working Capital for 2 Months Rs. 392.65 Cr
Total Capital Investment Rs. 410.56 Cr
Rate of Return 9%
Break Even Point 61%
CONTENTS
INTRODUCTION
TYPES OF ELECTRICAL WIRES
THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
COPPER WIRE
PROPERTIES
PROPERTIES OF COPPER WIRE:
ELECTRICAL CABLE
PVC COPPER CABLE
PROPERTY
APPLICATION
ADVANTAGES
ADVANTAGES OF PVC CABLES
SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
CONSTRUCTION
CONDUCTOR
1. SOLID/STRANDED
A. SOLID
B. STRANDING
2. CIRCULAR/ SHAPED
A. CIRCULAR
B. SHAPED
INSULATION
THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
LAYING UP
INNERSHEATH
A. EXTRUDED INNERSHEATH
B. TAPPED INNERSHEATH
ARMOURING
OUTERSHEATH
USES AND APPLICATION
B.I.S. SPECIFICATION
MANUFACTURING PROCESS
TECHNOLOGY
FEATURES
MANUFACTURING PROCESS
DRAWING
ANNEALING
STRANDING
TWISTING
INSULATING
LAY-UP
SHEATHING
ARMORING
PACKING
MANUFACTURING FLOW CHART
SINGLE WIRE
MULTIPLE WIRE
FLEXIBLE WIRE
FLAT TWIN-CORD WIRE
POWER CABLE WIRE
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
PRODUCTION PROCESS OF SOLAR CABLE
STEP 1: PURCHASE AND PREPARATION OF RAW MATERIALS
STEP 2: MANUFACTURE OF THE CONDUCTOR
STEP 3: MANUFACTURE OF THE INSULATING LAYER
STEP 4: SHEATH MANUFACTURING
STEP 5: CABLE ASSEMBLY
STEP 6: TESTING
MANUFACTURING PROCESS OF SOLAR CABLES
1. PREPARATION OF RAW MATERIALS:
2. CONDUCTOR CORE PREPARATION:
3. INSULATION LAYER PREPARATION:
4. SHEATHING LAYER PREPARATION:
5. TESTING AND PACKAGING:
CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
(A) TYPE TEST
1. THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
PHYSICAL TESTS FOR INSULATION AND SHEATH
(B) ACCEPTANCE TEST:
THE FOLLOWING SHALL CONSTITUTE ACCEPTANCE TEST:
(C) ROUTINE TEST:
THE FOLLOWING SHALL CONSTITUTE THE ROUTINE TEST.
CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
TEST FOR THICKNESS OF INSULATION OF POWER CABLE
APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION OF POWER CABLE
PROCEDURE FOR TESTING OF THICKNESS OF INSULATION OF POWER CABLE
HIGH VOLTAGE TEST (WATER IMMERSION TEST):
TEST ON COMPLETED CABLES (ACCEPTANCE AND ROUTINE TEST):
FLAMMABILITY TEST:
ANNEALING TEST FOR WIRES AND CONDUCTORS
PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
TENSILE TEST OF CONDUCTORS
APPARATUS REQUIRED FOR TENSILE TEST:
METHOD OF TENSILE TEST OF CONDUCTORS
PROCEDURE
PERSULPHATE TEST OF CONDUCTOR
WHY COPPER WIRES ARE TINNED?
METHODS
METHOD A:
METHOD B:
TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)
WRAPPING TEST FOR CONDUCTORS
(6) COILING AND PACKING
INDUSTRY /MARKET OVERVIEW
ECONOMIC OUTLOOK
GLOBAL ECONOMY
INDIAN ECONOMY
IMF KEPT THE GROWTH FORECAST FOR 2024 AT 6.3%, THE GROWTH RATE IT HAD PREDICTED IN APRIL, 2023.
INDEX OF INDUSTRIAL PRODUCTION
TABLE: INDEX OF INDUSTRIAL PRODUCTION YOY
SECTORAL PERFORMANCE
CONSUMPTION AND INVESTMENT
CAPITAL MARKET PERFORMANCE
INDEX MOVEMEN
MARKET CAPITALISATION OF INDIA AND ITS HISTORIC TREND
IMPACT OF THE RUSSIA INVASION ON ECONOMY
OUTLOOK
OVERVIEW OF WIRE AND CABLE INDUSTRY
GLOBAL WIRE AND CABLE MARKET HISTORIC TRENDS
THE CHART BELOW SHOWS THE GROWTH OF THE GLOBAL WIRE AND CABLES MARKET FROM 2020 – 2029 IN USD
GLOBAL WIRE AND CABLE MARKET FORECAST GROWTH
THE CHART AND TABLE BELOW SHOW THE YEAR-ON-YEAR GROWTH OF THE GLOBAL WIRE AND CABLES MARKET FROM 2023 – 2032.
INDIAN WIRE AND CABLE INDUSTRY MARKET
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:
NHB INDIA HOUSING PRICE INDEX*
HOUSING DEMAND-SUPPLY UNITS IN TOP 8 CITIES 2016-2020
INFRASTRUCTURE:
PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES
2. POWER
INDUSTRIAL EXPANSION AND STRONG GDP GROWTH DRIVING POWER DEMAND
1. RAILWAYS:
1. GROWING DEMAND
2. POLICY SUPPORT
3. INFRASTRUCTURE DEVELOPMENT
4. TELECOMMUNICATION
STRONG GROWTH IN BROADBAND DRIVES INTERNET ACCESS REVENUES
KEY COMPANIES IN THE MARKET
CHALLENGES FACED BY THE INDUSTRY
CYCLICAL MARKET
CONVERSION INDUSTRY AND WORKING CAPITAL
DE-REGULATION LOWERS BARRIERS OF ENTRY
INCREASED RAW MATERIAL PRICES
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
1. MAKE IN INDIA
2. 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
• COMPETITION AMONG THE EXISTING COMPETITORS
IMPLICATIONS OF PORTER FIVE FORCES ON WIRE & CABLE COMPANY
1. MANUFACTURING PROCESS
1. CONDUCTOR
3. CABLES & WIRES PLAYERS IN THE INDUSTRY
MOST OF THE ELECTRICAL PLAYERS HAVE DIVERSIFIED OVER THE LAST FIVE YEARS
1. FINOLEX CABLES LIMITED
2. KEI INDUSTRIES LIMITED
3. POLYCAB INDIA LIMITED
4. HAVELLS INDIA LIMITED
1. RR KABEL LIMITED
2. V-GUARD INDUSTRIES LIMITED
7. PLAZA WIRES LIMITED
PRODUCT PROFILE OF PLAZA CABLES:
TOTAL REVENUE CONTRIBUTION
KEY INDUSTRIAL REGULATIONS AND POLICIES
GENERAL CORPORATE COMPLIANCE
THE COMPANIES ACT, 2013
SEBI REGULATIONS
THE ARBITRATION AND CONCILIATION ACT, 1996
TAX RELATED REGULATIONS
INCOME TAX ACT, 1961
GOODS AND SERVICE TAX ACT, 2017
CUSTOMS ACT, 1962
THE GUJARAT STATE TAX ON PROFESSIONS, TRADERS, CALLINGS AND EMPLOYMENTS RULES, 1976
BUSINESS / TRADE RELATED LAWS / REGULATIONS
THE ELECTRICAL WIRES, CABLES, APPLIANCES AND PROTECTION DEVICES AND ACCESSORIES (QUALITY CONTROL) ORDER, 2003
THE INDIAN ELECTRICITY RULES, 1956
THE BUREAU OF INDIAN STANDARDS ACT, 2016 (“BIS ACT”)
LEGAL METROLOGY ACT, 2009 (THE “LM ACT”) AND THE LEGAL METROLOGY (PACKAGED COMMODITIES) RULES, 2011 (THE “LMRULES”)
E-WASTE (MANAGEMENT AND HANDLING) RULES, 2022 (“E-WASTE RULES”)
PLASTIC WASTE MANAGEMENT (PWM) RULES, 2016 AND AMENDMENTS THERETO
ENVIRONMENT LAWS
NATIONAL ENVIRONMENTAL POLICY, 2006
FOLLOWING ARE THE OBJECTIVES OF NATIONAL ENVIRONMENTAL POLICY:-
ENVIRONMENTAL LEGISLATIONS
THE NOISE POLLUTION (REGULATION AND CONTROL) RULES, 2000
HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRAN BOUNDARY MOVEMENT) RULES, 2016 (“HAZARDOUS WASTE RULES”) AND AMENDMENTS THERETO
ENVIRONMENT IMPACT ASSESSMENT NOTIFICATION OF 2006
PUBLIC LIABILITY INSURANCE ACT, 1991
REGULATIONS RELATED TO FOREIGN TRADE AND INVESTMENT
THE FOREIGN DIRECT INVESTMENT
FOREIGN EXCHANGE MANAGEMENT ACT, 1999 (“FEMA”) AND REGULATIONS FRAMED THEREUNDER
DUTY DRAWBACK SCHEME
OWNERSHIP RESTRICTIONS OF FIIS
FOREIGN TRADE POLICY 2023
LAWS RELATED TO EMPLOYMENT OF MANPOWER
THE INDUSTRIAL (DEVELOPMENT AND REGULATION) ACT, 1951
THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE, 2020
THE CODE ON SOCIAL SECURITY, 2020
EMPLOYEES PROVIDENT FUND AND MISCELLANEOUS PROVISIONS ACT, 1952
THE EMPLOYEES COMPENSATION ACT, 1923
THE EMPLOYEES’ STATE INSURANCE ACT, 1948 (THE “ESI ACT”)
THE FACTORIES ACT, 1948
THE MINIMUM WAGES ACT, 1948
PAYMENT OF GRATUITY ACT, 1972, AS AMENDED (THE “GRATUITY ACT”)
THE MATERNITY BENEFIT ACT, 1961
THE PAYMENT OF BONUS ACT, 1965
THE EQUAL REMUNERATION ACT, 1979
THE CHILD LABOUR PROHIBITION AND REGULATION ACT, 1986
THE TRADE UNION ACT, 1926 AND TRADE UNION (AMENDMENT) ACT, 2001
THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION, PROHIBITION AND REDRESSAL) ACT, 2013
THE INDUSTRIAL DISPUTES ACT, 1947 (“ID ACT”) AND INDUSTRIAL DISPUTE (CENTRAL) RULES, 1957
LAWS RELATING TO INTELLECTUAL PROPERTY
TRADEMARKS ACT, 1999
THE PATENTS ACT, 1970
THE DESIGNS ACT, 2000 (DESIGNS ACT)
THE COPYRIGHT ACT, 1957
OTHER GENERAL RULES AND REGULATIONS
THE MICRO, SMALL AND MEDIUM ENTERPRISES DEVELOPMENT ACT, 2006 (“MSME ACT”)
STATE LAWS
MUNICIPALITY LAWS
OTHER REGULATIONS
PROPERTY RELATED LAW
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COOPER WIRE ROD
SUPPLIERS OF PVC COMPOUND CABLE GRADE
SUPPLIERS OF PACKAGING MATERIALSSUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF WIRE DRAWING MACHINE
SUPPLIERS OF PVC EXTRUSION PLANT
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
BUNCHING MACHINE MANUFACTURERS
STRANDING MACHINE MANUFACTURERS
MATERIAL HANDLING EQUIPMENTS
LABORATORY TESTING EQUIPMENTS
STEEL WIRES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
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
SOLAR CABLE MANUFACTURERS
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:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
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
LIST OF DOCUMENTS REQUIRED FOR LICENSES
SWOT ANALYSIS
1. STRENGTH
2. WEAKNESS
3. OPPORTUNITY
4. THREATS
ORGANIZATION CHART
ORGANIZATIONAL STRUCTURE
1. MANAGER
DUTIES AND RESPONSIBILITIES
2. THE MANUFACTURING DEPARTMENT DUTIES AND RESPONSIBILITIES: -
3. ADMINISTRATION AND FINANCE DEPARTMENT
DUTIES AND RESPONSIBILITIES:-
FINANCE SECTION
DUTIES AND RESPONSIBILITIES:-
4. MARKETING AND SALES DEPARTMENT
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)
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