Detailed Project Report on Assembly of Air-Conditioner/Chest Freezer/Refrigerator under One Production Line

ASSEMBLY OF AIR-CONDITIONER/CHEST FREEZER/REFRIGERATOR UNDER ONE PRODUCTION LINE

[EIRI/EDPR/1085] J.C.: 9729US$

INTRODUCTION

The early attempts at air conditioning were aimed solely at providing human comfort. Coider fields were sought to be covered in the nineteenth century and it was during this period that the foundation of modern air conditioning was laid with the controlling of humidity conditions in cotton textiles mills. In the initial stages, the air in the textile mills was humidified by evaporating water from steam ports in order to reduce breakages and static electricity of cotton yarns. The principles of air conditioning were then gradually extended to industries like printing. Candy making, wood production, tobacco manufacturing and to the storage of food and other perishable products. By 1897 the first form of humidification, namely an air washer, was patented and used on a wider scale. It cooled and humidified in addition to its primary function of cleaning the air.

The term air-conditioning was first suggested and used in 1906 by an American Stuart W. Cramer, who developed an air conditioning system which could control both humidity and temperature. At about the same time, another American, Willis H. Carrier, devised a control air conditioner unit of the air washer type which automatically controlled the humidity and saturation temperature of the air. With the development of new machines the applications of air conditioning were extended to the fields of commerce and transport. Commercial air-conditioning was started with the more heatness. In 1930, a small unitary air-conditioner was first installed in a railway coach operating in the Baltimore and Ohio railroad of the USA. In 1931 entire train running between New York and Washington was air-conditioned.

The definition of air conditioning as approved by the American Society of Heating and Ventilating Engineers is as follows - "the simultaneous control of all or at least the first three of those factors affecting both the physical and chemical conditions of the atmosphere with in any structure. These factors include temperature, humidity, motion, distribution, dust, bacteria, odors, toxic gases and ionization, most of which affect in greater or less degree human health or comfort."

Accepted trade definitions consider air conditioning to be the control of temperature, humidity, motion and cleanliness of the air within any structure, adding the qualifying prefix "Summer" to those systems designed only to maintain temperature and humidity at a point below the normal outside summer condition and "Winter" to those systems designed only to maintain elevated temperatures and humidities during cold weather. Systems designed to afford the stipulated control during all seasons of the year and usually designated as "Year-Round" air conditioning systems.

AIR CONDITIONING SYSTEMS

A basic air conditioning system involves the treatment of air in buildings. Such treatment essentially includes the proper adjustment and control of the air with regard to its cooling or heating, humidification or dehumidification, ventilation and cleaning.

Cooling: Cooling of air for hot weather comfort is carried out by transfer of heat from the air to a surface or medium at a lower temperature, which may be cool fluid, spray of water, a low pressure, evaporating, liquid-vapour mixture, or water ice. Air-cooling is also achieved by using refrigeration systems.

Heating: In climates where the temperature drops below 18o for any considerable period during the year, artificial heating becomes necessary. The heating systems are based on (i) warm air (ii) hot water (iii) radiation heating and (iv) heat pump.

Humidity Control: In addition to temperature relatively humidity is a very important factor in determining is a very important factor in determining human comfort is that the nearer to a completely saturated state the air in a room becomes, the less tendency there is for evaporation to take place from the body. Evaporation is a factor in the surface cooling of the skin and contributes greatly to hot weather comfort. On the other hand, the atmosphere in a room which is artificially heated during cold weather is very likely to prove deficient in moisture unless some means of humidification is provided.

COST ESTIMATION

Plant Capacity            100 Units/Day

Land & Building (2000 sq.mt.)    US$ 3.72 Lac

Plant & Machinery                    US$ 4.66 Lac

Working Capital for 3 Months    US$ 20.82 Lac

Total Capital Investment          US$ 29.58 Lac

Rate of Return                          73%

Break Even Point                      30%

CONTENTS

INTRODUCTION

AIR CONDITIONING SYSTEMS

HEATING OF UNITS

1. COOLING UNIT

2. AIR CONDITIONING UNIT

3. COOLING AIR CONDITIONING UNIT

4. SELF-CONTAINED COOLING UNIT

5. FREE DELIVERY TYPE

6. PRESSURE TYPE UNIT

7. FORCED CIRCULATION AIR COOLER

CONSTRUCTION OF VARIOUS UNITS

FREEZE AND REFRIGERATORS

SUBSTITUTES

TYPES OF FREEZERS

CHEST FREEZERS

UPRIGHT FREEZER

TYPES OF REFRIGERATORS

TYPES OF REFRIGERATORS

UNDER COUNTER MICROWAVE OVENS

APPLICATION OF REFRIGERATERS AND CHEAST FREEZERS

WIDESPREAD COMMERCIAL USE

HOME AND CONSUMER USE

CURRENT APPLICATIONS OF REFRIGERATION

APPLICATION OF AIRCONDITIONERS

BIS SPECIFICATION

INDIAN MARKET OF AIR CONDITIONERS

COMMERCIAL DEMAND AREA

GROWTH AVENUES

MAINTENANCE ASPECT

GLOBAL MARKET OF AIR CONDITIONERS

GLOBAL SALES OF AIR CONDITIONING SYSTEMS TO REACH 85 MILLION UNITS IN 2012, ACCORDING TO NEW REPORT BY GLOBAL INDUSTRY ANALYSTS

AIR CONDITIONERS

GLOBAL SCENARIO

REFRIGERANTS

GO GREEN

LATEST DEVELOPMENTS

REFRIGERATOR AND FREEZER

BASE CASE SCENARIO FOR THE RESIDENTIAL SECTOR

BASELINE UEC

BASELINE UEC FOR ALL END USES IN 2000 AND 2030

BASE CASE CONSUMPTION SCENARIO

HOUSEHOLD ELECTRICITY CONSUMPTION IN 2000 AND 2030 (URBAN AND RURAL)

ENERGY EFFICIENCY SCENARIOS

TARGETS ACHIEVABLE THROUGH EFFICIENCY PROGRAMS

EFFICIENCY SCENARIOS

REFRIGERATORS

AIR CONDITIONERS

THE RANGE AND RELATIVE IMPORTANCE OF THE ATTRIBUTES OF REFRIGERATORS

THE DIFFERENCE ANALYSIS OF THE UTILITY COEFFICIENT ON INDIVIDUAL LEVEL

THE RANDOM EFFECT COEFFICIENT VARIANCE AND MODEL RESIDUAL

VARIANCES OF REFRIGERATOR

PURCHASING POWER

PRICE ANTICIPATION

CONSUMPTION HABIT

CUSTOMERS’ SUPPORT

CONSUMER DURABLE MARKET ANALYSES

REFRIGERATORS

MARKET SIZE AND FORECAST DEMAND

REFRIGERATOR MARKET IS COMPOSED OF TWO SEGMENTS OF URBAN AND RURAL AREAS

RURAL HOUSEHOLD NET INCOME AND POSSESSION OF ELECTRICAL HOME APPLIANCES

MAJOR PLAYERS

FOREIGN FIRMS PRODUCING REFRIGERATORS IN CHINA

MARKET SHARE

TABLE 5 BEIJING’S MARKET SHARE OF REFRIGERATOR

GRAPH 1 BEIJING’S MARKET SHARE OF REFRIGERATOR

PLANT LAYOUT

MANUFACTURING PROCESS OF REFRIGERATORS AND CHEST FREEZERS

THE MANUFACTURING PROCESS

OUTER CABINET AND DOOR

INNER CABINET

COOLING SYSTEM

TESTING AND ADDING ACCESSORIES

QUALITY CONTROL

BY PRODUCTS/WASTE

ASSEMBLING PROCESS OF AIR CONDITIONER

AN ASSEMBLED UNIT AIR CONDITIONER CONSISTS OF FOLLOWING PARTS:-

1. COOLING COILS

2. FANS AND BLOWERS

3. HEAT PUMP

4. FILTERS

(A) DRY FILTER

(B) VISCOUS FILTERS

CONTROLS

CHOICE OF REFRIGERANT

INSTALLATION

SHEET METAL PARTS

TESTING OF REFRIGERATERS

DESCRIPTION OF TEST SPECIMENS

TEST PROCEDURE

INSTRUMENTATION

GENERAL TEST CONDITIONS

TEST RESULTS

REFRIGERATOR TESTS

FREEZER TESTS

DISCUSSION OF TEST RESULTS

CONCLUSIONS

THE OBSERVED EFFECTS OF THE VARIABLES STUDIED WERE AS FOLLOWS

SUPPLIERS OF PLANT & MACHINERY AND RAW MATERIALS

REFRIGERATORS

CHEST FREEZERS

AIR CONDITIONERS

COLOUR MASTERBATCHES

REFRIGENT GASES

NUT, BOLTS & SCREWS

GI SHEETS

COPPER TUBES

CAPILLARY TUBES

PLASTICS

AIR FANS

AIR FILTERS

ROTARY SWITCHES

THERMOSTATE SWITCH

RELAYS

CAPACITORS

BLOWERS

CONDENSING COIL

EVAPORATOR COILS

REFRIGERANT COMPRESSORS

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)