Detailed Project Report on copper and aluminium wire and cable manufacturing unit

COPPER AND ALUMINIUM WIRE
AND CABLE MANUFACTURING UNIT
[CODE NO 3353]  


Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.

There are two main types of wires: solid or stranded.

A solid wire is a single conductor that is either bare or insulated by a protective colored sheath. It offers low resistance and is perfect for use in higher frequencies. When inside a covering there are many thin strands of wires twisted together, it is called a stranded wire. Stranded wires are used where flexibility is important because which the wire can be used for a longer period. This type of wire have larger cross-sectional area than solid wires for the same current carrying capacity. Stranding is process of twisting together of small wires to form a single larger conductor. Used to provide flexibility, ease of handling and vibration resistance.

Copper Wire

Copper Wire is a single electrical conductor manufactured out of Copper Ore. This widely used conductor can either be insulated or uninsulated. Having a moderate conductivity, it’s used to transfer electricity with low voltage. Electrical wiring in buildings is the largest market for the copper industry worldwide. As per estimation, around half of the copper mines is consumed in manufacturing electrical wire and cable conductors.

COST ESTIMATION

Plant  Capacity                               :       1.00 MT./day
land & Building                              :    Rented
Plant & Machinery                         :     Rs. 91.55 Lacs
Working Capital for 1 Month       :    Rs.  1.8   Cr
Total Capital Investment              :    Rs.  2.20  Cr
Rate of Return                               :    143%
Break Even Point                           :    33%

INTRODUCTION    
TYPES OF ELECTRICAL WIRES    
THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.    
COPPER WIRE    
PROPERTIES    
PROPERTIES OF COPPER WIRE:    
ELECTRICAL CABLE    
PVC COPPER CABLE    
PROPERTY    
APPLICATION    
ADVANTAGES    
ADVANTAGES OF PVC CABLES    
SOME OF THE MAJOR ADVANTAGES OF PVC CABLES    
CONSTRUCTION    
CONDUCTOR    
INSULATION    
THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:    
LAYING UP    
INNERSHEATH    
ARMOURING    
OUTERSHEATH    
USES AND APPLICATION    
APPLICATIONS    
B.I.S. SPECIFICATION    
MARKET POSITION    
CURRENT STATUS    
PRODUCT SECTORS    
GROWTH DRIVERS    
GROWTH AREAS    
CHALLENGES    
THE FUTURE    
GOVERNMENT INITIATIVE    
PRODUCT PROFILE    
GOVERNMENT REGULATIONS    
GOVERNMENT INITIATIVES    
DEMAND-SUPPLY DYNAMICS    
DEMAND GROWTH    
DEMAND DRIVERS    
IMPORT EXPORT TREND    
IMPORT EXPORT TREND    
CAPACITY ADDITION    
PRICE TREND    
COMPETITIVE SCENARIO    
RESOURCE RISK    
FINANCIAL RISK    
EXPORT DATA OF PVC COPPER FLEXIBLE    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF INSULATED COPPER CABLE    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF PVC COPPER WIRE    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
MANUFACTURERS/SUPPLIERS OF PVC COPPER WIRE    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(1) DRAWING    
(2) ANNEALING    
(3) STRANDING    
(4) INSULATION    
(5) QUALITY CONTROL    
CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:    
(A) TYPE TEST    
1.THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.    
PHYSICAL TESTS FOR INSULATION AND SHEATH    
(B) ACCEPTANCE TEST:    
(C) ROUTINE TEST:    
CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES    
TEST FOR THICKNESS OF INSULATION OF POWER CABLE    
APPARATUS REQUIRED TO TEST FOR THICKNESS OF INSULATION
  OF POWER CABLE    
PROCEDURE FOR TESTING OF THICKNESS OF INSULATION
   OF POWER CABLE    
ANNEALING TEST FOR WIRES AND CONDUCTORS    
PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS    
TENSILE TEST OF CONDUCTORS    
APPARATUS REQUIRED FOR TENSILE TEST:    
METHOD OF TENSILE TEST OF CONDUCTORS    
PROCEDURE    
PERSULPHATE TEST OF CONDUCTOR    
WHY COPPER WIRES ARE TINNED?    
METHODS    
METHOD A:    
METHOD B:    
TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)    
WRAPPING TEST FOR CONDUCTORS    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
COPPER WIRE ROD    92
PVC COMPOUND CABLE GRADE    
PACKING MATERIALS    
SUPPLIERS OF PLANT AND EQUIPMENTS    
WIRE DRAWING MACHINE    
PVC EXTRUSION PLANT    
ANNEALING FURNACE    
WIRE STRANDING MACHINE    
WIRE STRATNING MACHINE    
ELECTRICAL MEASURING INSTRUMENTS    
EOT CRANES    
DG SETS    
POWER TRANSFORMERS    
COOLING TOWER    
ETP PLANTS    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
AIR COMPRESSORS    
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
    

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