Detailed Project Report on cable tray manufacturing

CABLE TRAY MANUFACTURING
[CODE NO.3363]

A cable tray is a metallic frame array which is used to support or lay cables onto it. The cables will be tied onto the tray and will not be hidden. A cable trunk is an enclosure where cables are placed in for purposes of distribution. The cables may be tied or not tied is use for arranging power supply cable with the use of cable tie to look neat and for easy tracing if there is fault on the cable.

Type of Cable Trays:

(1) Ladder Cable Tray

    Generally used in applications with intermediate to long support spans 12 to 30 feet.

    Ladder cable tray is used for about 75 percent of the cable tray wiring system installations. It is the predominate cable tray type due to its many desirable features:

    A ladder cable tray without covers permits the maximum free flow of air across the cables. This allows the heat produced in the cable’s conductors to effectively dissipate. Under such conditions, the conductor insulation in the cables of a properly designed cable tray wiring system will not exceed its maximum operating temperature. The cables will not prematurely age due to excessive operating temperatures.

    The rungs of the ladder cable trays provide convenient anchors for tying down the cables in the non-horizontal cable tray runs or where the positions of the cables must be maintained in the horizontal cable tray runs. This capability is a must for single conductor cable installations. Under fault conditions (short circuit), the magnetic forces produced by the fault current will force the single conductor cables from the cable tray if they are not securely anchored to the cable tray.

    Cables may exit or enter the ladder cable trays through the top or the bottom of the cable tray. Where the cables enter or exit conduit, the conduit to cable tray clamps may be installed upright or inverted to terminate conduits on the top or bottom of the cable tray side rail.

    Moisture can’t accumulate in ladder cable trays.

    If cable trays are being installed where working space is a problem, hand access through the cable tray bottom may help to facilitate the installation of small diameter cables: control instrumentation, signal, etc.

    The most common rung spacing for ladder cable tray is 9 inches. This spacing may be used to support all sizes of cables. This spacing is desirable for the small diameter Type PLTC and TC cables as the support distance is such that there is no visible drooping of the small cables between rungs. 12 or 18 inch rung spacing provides adequate cable support but the slight amount of small diameter cable drooping between rungs may be aesthetically objectionable for some installations. The maximum allowable distance between supports for 1/0 through 4/0 AWG single conductor cables is 9 inches [1993 NEC Section 318-3(b) (1)].

COST ESTIMATION

Plant  Capacity                                           :    2500.00 Mtr./day                 
land & Building (4000 sq.mt)                  :    Rs. 4.22  Cr
Plant & Machinery                                     :    Rs. 98.90 Lacs
Working Capital for 2 Months                 :    Rs.  5.74 Cr
Total Capital Investment                          :    Rs. 11.18 Cr
Rate of Return                                           :    74%
Break Even Point                                      :    30%

INTRODUCTION    
TYPE OF CABLE TRAYS:    
(1) LADDER CABLE TRAY    
(2) PERFORATED TYPE CABLE    
(3) SOLID BOTTOM CABLE TRAY    
(4) TROUGH CABLE TRAY    
(5) CHANNEL CABLE TRAY    
(6) WIRE MESH CABLE TRAY    
(7) SINGLE RAIL CABLE TRAY    
USES AND APPLICATIONS    
WIDELY USED IN    
B.I.S. SPECIFICATION    
MARKET POSITION    
OVERVIEW OF THE GLOBAL CABLE TRAY MARKET    
COMPETITIVE LANDSCAPE AND KEY VENDORS    
LEADING VENDORS IN THE MARKET ARE -    
SEGMENTATION BY END-USER AND ANALYSIS OF THE CABLE TRAY MARKET    
GEOGRAPHICAL SEGMENTATION AND ANALYSIS OF THE CABLE TRAY MARKET    
CABLE MANAGEMENT MARKET OVERVIEW:    
TOP FACTORS IMPACTING THE WORLD CABLE MANAGEMENT MARKET    
TECHNOLOGICAL ADVANCEMENTS    
UNCERTAINTY OF RAW MATERIAL PRICES    
EMERGING MARKETS IN BRIC ECONOMIES    
MARKET SEGMENTS    
WORLD CABLE MANAGEMENT MARKET BY GEOGRAPHY    
CABLE MANAGEMENT MARKET KEY SEGMENTS    
BY TYPE    
BY END-USER INDUSTRY    
BY GEOGRAPHY    
EXPORT DATA OF CABLE TRAY    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF CABLE TRAY    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
MANUFACTURERS/SUPPLIERS OF CABLE TRAY    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
THERE ARE FOLLOWING STEPS ARE USED FOR MANUFACTURING PROCESS:    
HOT DIP GALVANISING -    
SURFACE PREPARATION -    
CLEANING –    
PICKLING –    
RINSING -    
FLUXING –    
GALVANIZING    
TESTING AND INSPECTION    
(7) QUALITY CONTROL    
QUALITY CONTROL SYSTEM    
(8) INSPECTION AND TESTING    
TESTS    
THE CABLE TRAYS, SHALL BE SUBJECTED TO THE FOLLOWING:    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
M.S. SHEET    
MIG ELECTRODE WIRE    
CAUSTIC SODA    
HYDROCLORIC ACID    
ZINC AMMONIUM CHLORIDE    
ZINC ANODE    
SUPPLIERS OF PLANT AND MACINERIES    
POWER PRESS    
SHEARING MACHINE    
FLYPRESS    
BENDING MACHINE
MECHANICAL PRESS    
CNC PLASMA CUTTING MACHINE    
BENCH GRINDER    
DRILLING MACHINE    
POWER HACSAW    
GRINDING MACHINE    
MIG WELDING MACHINE    
EOT CRANE    
DG SETS    
POWER TRANSFORMERS    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR COMPRESSORS    
PLATEFARM WEIGHING MACHINE    
POWDER COATING MACHINE    
ANODISING PLANT    
HOT DIP GALVANISING PLANT    
ELECTROPLATING PLANT    
MATERIAL HANDLING EQUIPMENTS    
PAINTING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
ELECTRICAL MEASURING INSTRUMENTS    

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