Detailed Project Report on mineral wool

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Description
How to Start Business

MINERAL WOOL (3536)

Mineral wool is described as insulation material made of wool of glass and stone wool. It is applicable from the cellar up to the roof in a new building or at the renovation of old buildings. Mineral wool often is defined as any fibrous glassy substance made from minerals (typically natural rock materials such as basalt or diabase) or mineral products such as slag and glass. Mineral wool has a unique range of properties combining high thermal resistance with long-term stability. Mineral wool can be divided into two main categories: glass wool and the stone/slag wool. The products are used in essentially the same applications and differ mainly in the raw materials and melting methods following the melting stage, the processes and environmental issues are essentially identical. Glass wool is made from a mixture of natural and recycled glass (recycled bottles, car windscreens and window panes) which is melted at 1,450 °C, where the glass that is produced is converted into fibers. It is typically produced in a method similar to making, forced through a fine mesh by and cooling on contact with the air. The cohesion and mechanical strength of the product is obtained by the presence of a that “cements” the fibers together. Ideally, a drop of binder is placed at each fiber intersection. This fiber mat is then heated to around 200 °C to resin to give it strength and stability. The final stage involves cutting the wool and packing it in rolls or panels (referred to as slabs or batts). Contrary to popular belief that mineral wool properties are defined solely by density, different fibre diameters, lengths, binder contents, additives, cutting and packaging can give a diverse product range.

COST ESTIMATION

Plant Capacity                                     40 Ton/Day
Land & Building (10000 sq.mt)     Rs. 6.84 Cr
Plant & Machinery                          Rs. 3.71 Cr
Working Capital for 2 Months         Rs. 3.59 Cr
Total Capital Investment                   Rs. 14.45 Cr
Rate of Return                                    36%
Break Even Point                               55%

INTRODUCTION
GLASS WOOL
COMPOSITION OF GLASS WOOL ARE GIVEN IN%
FEATURES OF GLASS WOOL
LIMITATIONS
STONE WOOL
ROCKWOOL (STONE WOOL, SLAG WOOL)
COMPOSITION OF STONE WOOL ARE GIVEN IN%
COMPOSITION OF STAG WOOL ARE GIVEN IN%
CHARACTERISTICS
PROPERTIES
ADVANTAGES
USES AND APPLICATION
ITS USES INCLUDE
MINERAL WOOL APPLICATIONS
INSULATION’S ACOUSTIC STRENGTHS
TYPICAL SOUND LEVELS
INDUSTRIAL APPLICATIONS
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(1) MELTING PROCESS
(2) FIBRE FORMATION
(A) POWELL PROCESS
(B) DOWNEY PROCESS
(3) FINAL PRODUCT FORMATION
MANUFACTURING PROCESS OF GLASS WOOL
ELECTRIC MELTING
FABRISATION PROCESS
MANUFACTURING PROCESS OF STONE WOOL
THE MAIN STEPS ARE GIVEN BELOW
MANUFACTURING PROCESS INVOLVES FOLLOWING STEPS
TECHNOLOGY
TYPES OF FURNACES USED
BLOWING PROCESS
MELTING AND BLOWING TEMP
COLLECTION OF WOOL
MARKET POSITION
MINERAL WOOL MARKET WILL REACH $15 BILLION IN 2022
EXPORT DATA OF STONE WOOL
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA
TOP SUPPLIERS
TOP PORTS OF DISCHARGE
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS FOR MINERAL WOOL
BUYERS OF MINERAL WOOL
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF BASALT FIBRE
SUPPLIERS OF DOLOMITE POWDER
SUPPLIERS OF BLAST FURNACE SLAG
SUPPLIERS OF PHENOL FORMALDEHIDE
SUPPLIERS OF MINERAL OIL
SUPPLIERS OF COKE
SUPPLIERS OF COMPLETE PLANT FOR MINERAL WOOL
EOT CRANE
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE

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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