Detailed Project Report on aluminium extrusion plant capacity:10 ton/day

ALUMINIUM EXTRUSION PLANT CAPACITY: 10 TON/DAY
[CODE NO.3279]  

Extrusion is a plastic deformation process in which a block of metal (billet) is forced to flow by compression through the die opening of a smaller cross-sectional area than that of the original billet Extrusion is an indirect-compression process. Indirect-compressive forces are developed by the reaction of the workpiece (billet) with the container and die; these forces reach high values. The reaction of the billet with the container and die results in high compressive stresses that are effective in reducing the cracking of the billet material during primary breakdown from the billet . Extrusion is the best method for breaking down the cast structure of the billet because the billet is subjected to compressive forces only.

Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation

COST ESTIMATION

Plant  Capacity                                                :   12.00 MT./day       
land & Building (5000 Sq.mt)                      :    Rs. 4.70  Cr
Plant & Machinery                                          :    Rs. 4.88  Cr
Working Capital for 2 Months                      :    Rs. 10.96 Cr
Total Capital Investment                               :    Rs. 21.77 Cr
Rate of Return                                                :    76%
Break Even Point                                            :    28%

INTRODUCTION    
FACTORS AFFECTING EXTRUSION    
TYPES OF EXTRUDED PROFILES    
CLASSIFICATION OF ALUMINIUM EXTRUSION    
(A) DIRECT (FORWARD) EXTRUSION    
(B) INDIRECT (BACKWARD) EXTRUSION    
(C) HOT EXTRUSION    
(D) COLD EXTRUSION AND WARM EXTRUSION    
PROPERTIES    
PROPERTIES OF ALUMINIUM    
WEIGHT    
STRENGTH    
LINEAR EXPANSION    
MACHINING    
FORMABILITY    
CONDUCTIVITY    
JOINING    
REFLECTIVITY    
SCREENING EMC    
CORROSION RESISTANCE    
NON-MAGNETIC MATERIAL    
ZERO TOXICITY    
USES AND APPLICATION    
USES    
APPLICATION    
B.I.S. SPECIFICATION    
MARKET POSITION    
THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS    
ALUMINIUM EXTRUSIONS - THE PROS AND CONS    
THE PLAYERS    
THE FUTURE    
SPREADING AWARENESS    
FUTURE OUTLOOK    
THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY    
FUTURE OUTLOOK    
CHALLENGES IN THE INDIAN EXTRUSIONS MARKE    
RISKS AND AREAS OF CONCERN    
EXPORT DATA OF ALUMINIUM EXTRUSION    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF ALUMINIUM EXTRUSION    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
MANUFACTURERS/SUPPLIERS OF ALUMINIUM EXTRUSION SECTIONS    
MANUFACTURERS/SUPPLIERS OF ALUMINIUM PROFILE    
MANUFACTURING PROCESS    
THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:    
DESCRIPTION OF PROCESS    
(1) BILLET PREHEATING    
TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE ALUMINUM ALLOYS    
TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS    
(2) EXTRUSION    
(3) QUENCHING    
(4) STRETCHING    
(5) CUTOFF    
(6) ARTIFICIAL AGING    
TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS    
(7) INSPECTION AND TESTING    
EXTRUSION MATERIALS INSPECTION    
ALUMINUM ALLOY CHECK    
EXTRUSION DYE CHECK    
ADDITIVES CHECK    
EXTRUSION VISUAL INSPECTION    
VISUAL DEFECTS CHECK    
COLOR AND GLOSSINESS CHECK    
DIMENSIONAL INSPECTION    
COATING AND FINISHING CHECK    
WEIGHT AND DENSITY CHECK    
EXTRUSION PERFORMANCE INSPECTION    
TENSILE TEST    
WELDABILITY CHECK    
WORKABILITY CHECK    
CORROSION RESISTANCE    
FLAMMABILITY TESTING    
HARDNESS TEST    
WEATHERING RESISTANCE TESTING    
ABRASION RESISTANCE    
CHEMICAL RESISTANCE    
DESCRIPTION OF EXTRUSION PRESS    
PROCESS FLOW CHART    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY FOR ALUMINIUM EXTRUSION    
EOT CRANE    
POWER TRANSFORMER    
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING MACHINE    
SUPPLIERS OF RAW MATERIALS    
ALUMINIUM ALLOY BILLET    
DEGREASING CHEMICAL    
PICKLING CHEMICALS    
OIL AND GREASE    
   
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET