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    Vehicle Scrap Yard (PV Scrap Vehicle 600 Nos. Per Month and CV Scrap Vehicle 66 Nos. Per Month)

    Vehicle Scrap Yard (PV Scrap Vehicle 600 Nos. Per Month and CV Scrap Vehicle 66 Nos. Per Month)
    Vehicle Scrap Yard (PV Scrap Vehicle 600 Nos. Per Month and CV Scrap Vehicle 66 Nos. Per Month)
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      VEHICLE SCRAP YARD (PV SCRAP VEHICLE 600 NOS. PER MONTH AND CV SCRAP VEHICLE 66 NOS. PER MONTH)

      [EIRI/EDPR/4677] J.C.: 2894XL


      Vehicle recycling is the dismantling of vehicles for spare parts. At the end of their useful life, vehicles have value as a source of spare parts and this has created a vehicle dismantling industry. The industry has various names for its business outlets including wrecking yard, auto dismantling yard, car spare parts supplier, and recently, auto or vehicle recycling. Vehicle recycling has always occurred to some degree but in recent years manufacturers have become involved in the process. A car crusher is often used to reduce the size of the scrapped vehicle for transportation to a steel mill.

      The process of recycling a vehicle is extremely complicated as there are many parts to be recycled and many hazardous materials to remove. Briefly, the process begins with incoming vehicles being inventoried for parts. The wheels and tires, battery and catalytic converter are removed. Fluids, such as engine coolant, oil, transmission fluid, air conditioning refrigerant, and gasoline, are drained and removed. Certain high value parts such as electronic modules, alternators, starter motors, infotainment systems - even complete engines or transmissions - may be removed if they are still serviceable and can be profitably sold on; either in "as-is" used condition or to a remanufacturer for restoration. This process of removing higher value parts from the lower value vehicle body shell has traditionally been done by hand. As the process is labour intensive, it is often uneconomical to remove many of the parts.

      A technique that is on the rise is the mechanical removal of these higher value parts via machine based vehicle recycling systems (VRS). An excavator or materials handler equipped with a special attachment allows these materials to be removed quickly and efficiently. Increasing the amount of material that is recycled and increasing the value the vehicle dismantler receives from an end-of-life vehicle (ELV). 

      After all of the parts and products inside are removed, the remaining shell of the vehicle is sometimes subject to further processing, which includes removal of the air conditioner evaporator and heater core, and wiring harnesses. The remaining shell is then crushed flat, or cubed, to facilitate economical transportation in bulk to an industrial shredder or hammer mill, where the vehicles are further reduced to fist-sized chunks of metal. Glass, plastic and rubber are removed from the mix, and the metal is sold by multiple tons to steel mills for recycling.

      Recycling steel saves energy and natural resources. The steel industry saves enough energy to power about 18 million households for a year, on a yearly basis. Recycling metal also uses about 74 percent less energy than making metal. Thus, recyclers of end-of-life vehicles save an estimated 85 million barrels of oil annually that would have been used in the manufacturing of other parts. Likewise, car recycling keeps 11 million tons of steel and 800,000 non-ferrous metals out of landfills and back in consumer use. 


      COST ESTIMATION

      Plant Capacity            9252 Nos./Day  

      Land & Building (2 Acres)    Rs. 4.92 Cr    

      Plant & Machinery                    Rs. 2.00 Cr 

      Working Capital for 1 Month    Rs. 2.93 Cr 

      Total Capital Investment          Rs. 10.14 Cr 

      Rate of Return                          29%

      Break Even Point                      55%


      CONTENTS

      INTRODUCTION

      VEHICLE SCRAPPAGE POLICY

      SOME INCENTIVES FOR SCRAPPING OLD VEHICLES AND BUYING NEW ONES ARE AS FOLLOWS:

      CHALLENGES

      RTO RULES FOR SELLING OF CARS AS SCRAP IN INDIA

      SOME POINTS TO NOTE ABOUT THE SCRAPPING PROCESS ARE AS FOLLOWS:

      VALUATION OF OLD CARS:

      CHALLENGES FOR INDIAN ECONOMY

      IMPORTANT DEFINITION REGARDING SCRAPING OF VEHICLE

      POWERS AND OBLIGATIONS OF RVSF

      CONDITIONS OF ELIGIBILITY OF RVSF

      ELIGIBILITY CONDITIONS

      REGISTRATION OF RVSF

      CRITERIA FOR SCRAPPING OF VEHICLE

      VALIDITY AND RENEWAL OF AUTHORIZATION:

      CERTIFICATE OF VEHICLE SCRAPPING

      APPLICABLE RULES/ACTS

      BENEFITS OF SCRAPING POLICY

      DISINCENTIVES FOR KEEPING OLD VEHICLES:

      USES AND APPLICATION

      ENVIRONMENTAL BENEFITS

      WILDLIFE PROTECTION

      CONSERVATION OF ENERGY AND RESOURCES

      MAKE SPACE

      BIS SPECIFICATION

      OPERATION OF VEHICLE SCRAP YARD

      HANDLING:

      STORAGE:

      PRE-CONDITIONS FOR STORING ELVS

      TRANSPORTATION

      DE-POLLUTION PROCESS

      DE-POLLUTION SEQUENCE

      A. BEFORE LIFTING VEHICLE

      B. LIFT THE VEHICLE ON DE-POLLUTION FRAME OR LIFTING DEVICE

      DRAIN FUEL TANK

      C. REMOVE VEHICLE FROM DE-POLLUTION FRAME OR LIFTING DEVICE

      FOR LIQUID HAZARDOUS SUBSTANCES

      A. WASTE OILS

      B. TRANSMISSION OIL

      C. BRAKE FLUIDS & CLEANERS

      D. FUEL AND FUEL FILTERS

      E. COOLANT (ANTIFREEZE)

      FOR SOLID HAZARDOUS SUBSTANCES

      A. LEAD ACID BATTERIES

      B. AIR FILTER

      G. RUBBER PARTS

      H. GLASS PARTS

      I. ELECTRONIC PARTS

      J. REFRIGERANT GASES

      K. AIRBAGS

      L. CATALYST

      DISMANTLING & SEGREGATION

      IN THE CASE OF M1 CATEGORY VEHICLES:

      IN THE CASE OF LL AND L2 CATEGORY VEHICLES:

      SHREDDING AND SEPARATION AND PROCESSING OF RESIDUES

      TECHNOLOGIES FOR THE ELV RECYCLING PROCESS

      TECHNOLOGIES FOR PROCESSING RESIDUES - SEGREGATION OF NON-FERROUS METAL FRACTIONS:

      OTHER TECHNOLOGIES

      TECHNOLOGIES FOR TREATMENT OF SEGREGATED MATERIALS

      INPUT/OUTPUT DATA

      PROCESS FLOW CHART

      RECOMMENDED TOOLS & EQUIPMENT FOR PRE-TREATMENTS:

      UTILITIES PER MONTH (ESTIMATED)

      SUPPLIERS OF PLANT AND MACHINERY

      SUPPLIERS FOR VEHICLE RECYCLING PLANT

      SUPPLIERS OF DG SETS

      SUPPLIERS OF EOT CRANE

      SUPPLIERS OF POWER TRANSFORMERS

      SUPPLIERS OF ELECTRICAL PANEL

      SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

      SUPPLIERS OF AIR COMPRESSORS

      SUPPLIERS OF PLATFORM WEIGHING MACHINE

      SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

      SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

      PROJECT CYCLE

      PRINCIPLES OF PLANT LAYOUT

      MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

      PLANT LOCATION FACTORS

      PRIMARY FACTORS

      RAW-MATERIAL SUPPLY:

      MARKETS:

      POWER AND FUEL SUPPLY:

      WATER SUPPLY:

      CLIMATE:

      TRANSPORTATION:

      WASTE DISPOSAL:

      LABOR:

      REGULATORY LAWS:

      TAXES:

      SITE CHARACTERISTICS:

      COMMUNITY FACTORS:

      FLOOD AND FIRE CONTROL:

      GENERATION & MANAGEMENT OF WASTES/GREEN BELT

      WASTE WATER (ESTIMATED)

      WASTE (ESTIMATED)

      HEALTH SAFETY AND ENVIRONMENT

      ANTICIPATED ENVIRONMENTAL IMPACTS

      CONSTRUCTION PHASE

      OPERATION PHASE

      MITIGATION MEASURES (PROPOSED)

      HSE REQUIREMENT

      PROPOSED IMPLEMENTATION SCHEDULE

      PROJECT FINANCIALS

      BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

      PRELIMINARY PLANT LAYOUT

      CAR SCRAP DEALERS


      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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