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    LT Cable, MV Cable, DC Solar Cable, Covered Cable and H.V. Cable Manufacturing Plant (Production Capacity: 150 MT/Day)

    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)
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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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