Detailed Project Report on Aluminium Extrusion (Cap: 9 MT/Day)

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ALUMINIUM EXTRUSION (CAP: 9 MT/DAY)

[EIRI/EDPR/1234] J.C. 9888

INTRODUCTION

Aluminium is a versatile metal with properties as under.

1. STRENGTH:- It is the major dominant requirement. Aluminium and its alloys meet the requirements fully and efficiently.

2. LIGHTNESS:- Aluminium is a light metal with weight 1/3rd of steel and copper. High strength to weight ratio of aluminium makes it more useful than steel even.

3. RESISTANCE TO CORROSION:- Atmospheric weathering in industrial rural and sea coast environments call for suitable material and finish. Aluminium prevents corrosion effectively.

4. ELECTRICAL CONDUCTIVITY:- It is conductor of heat and electricity. This makes aluminium one of the best bus bar materials.

These properties have made aluminium highly useful in manufacture of aircraft, passenger cars, railway rolling stock, ship building, electrical eng. manufacture of cine and photographic equipments, radio components, window frames and doors, railings, refinery equipments, foils, extruded sections and pipes for a wide range of uses. Aluminium powder is also used in paints and anodising industries. Extruded aluminium products are finding growing exports prospects. Aluminium extruded products are mainly tubes, pipes and blanks. These are manufactured in various forms and can be broadly classified in (a) rods & (b) sections. Sections include leath hollow and solid sections. In extrusion, the cylindrical rod called billet, is squeezed hydraulically into any shape by forcing the hot billet through the die orifice. Extrusion presses of various sizes are available ranging from 200 ton to 5000 tons capacity. These presses can be designed from simple to very complicated type with intricate and most sophisticated components equipments.

Aluminium extrusion products are widely used in transport industry, rail road’s, electronics and housing industry etc. The manufacturing of extruded products started long back. But, the industry expanded rapidly during last two decades. In 1967-68. There only 3 units engaged in manufacturing aluminium extruded products but till 1983-84 the number has reached 12 with total installed capacity 25,490 MT year @113% capacity utilisation. Imparts of aluminium extruded products in the seventies had been quite high but the stress is being made to reduce it in order to save foreign exchange and hence partially it is taking place of import substitute. This is clear from the import in 1979-80 as high as 3,36,659 M.T. valued at Rs. 1,05,35,820/- to just 33753 M.T. in 1980-81 and 56,222 in 1981-82.

On the other hand, the export of aluminium extruded products is gradually on rise (From 27,591 M.T. in 1973-74 to 55,395 M.T. in 1981-82). Afghanistan, Algeria, Bahrain, Bangladesh, Burma Hong Kong, Kenya, Kuwait, Oman, Srilanka, U.A.E. etc. are the main middle East countries to whom aluminium extruded products like tubes, pipes and blanks are being exports at present aluminium extrusion products have penetrated a large area of applications and are manufactured in India with or without foreign collaborations. It requires moderately high level of technology and investments but the industry is quite profitable and finds ready market within and outside the country.

COST ESTIMATION

Plant Capacity 9 MT/Day

Land & Building (5 Acres) Rs. 5.84 Cr

Plant & Machinery Rs. 7.74 Cr

Working Capital for 2 Months Rs. 7.47 Cr

Total Capital Investment Rs. 22.50 Cr

Rate of Return 24%

Break Even Point 62%

CONTENTS

INTRODUCTION

USES AND APPLICATIONS

RAW MATERIAL AVAILABILITY

PROPERTIES

PROPERTIES OF RAW MATERIAL

PHYSICAL PROPERTIES

MECHANICAL PROPERTIES

BIS PECIFICATIONS

MARKET FORCASTING

MARKET SIZE AND INDUSTRY OUTLOOK

PROCESS FLOW CHART

MANUFACTURING PROCESS

THE ALUMINIUM EXTRUSION PROCESS

DIRECT EXTRUSION

INDIRECT EXTRUSION

EXTRUSION PROCESS DESCRIPTION

MANUFACTURING PROCESS IN DETAIL

PLANT LAYOUT

SUPPLIERS OF ALUMINIUM EXTRUDED PRODUCTS

SUPPLIERS OF ALUMINIUM ALLOYS

SUPPLIERS OF ALUMINIUM MASTER ALLOYS

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF EXTRUSION PRESSES

COMPLETE PLANT AND MACHINERY ALUMINIUM EXTRUSION

SUPPLIERS OF INDUCTION FURNACE

SUPPLIERS OF LATHE MACHINES

SUPPLIERS OF SHAPING MACHINE

SUPPLIERS OF MILLING MACHINE

SUPPLIERS OF DRILLING MACHINE

SUPPLIERS OF GRINDING MACHINE

SUPPLIERS OF HEAT TREATING FURNACE

SUPPLIERS OF LABORATORY EQUIPMENTS

SUPPLIERS OF MEASURING TOOLS

SUPPLIERS OF CASTING MACHINE

SUPPLIERS OF EXTRUSION PRESS

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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