Detailed Project Report on s.s.casting finished products

S.S. CASTING FINISHED PRODUCTS
[CODE NO. 3213]  


A foundry is a factory which produces metal casting from either ferrous or non-ferrous alloys. Metals are turned into parts by melting the metal into a liquid, pouring the metal in a mold, and then removing the mold material or casting. The most common metal alloys processed are aluminium and cast iron. However, other metals, such as steel, magnesium, copper, tin, and zinc, can be processed.


COST ESTIMATION

Plant  Capacity                                                 :    4.00 MT./day    
land & Building (20230 sq.mtrs)                  :    Rs. 18.08  Cr
Plant & Machinery                                           :    Rs. 18.44  Cr
Working Capital for 2 Months                       :    Rs. 3.42   Cr
Total Capital Investment                                :    Rs. 39.69  Cr
Rate of Return                                                   :   22%
Break Even Point                                               :    62%



INTRODUCTION    
TYPES OF FOUNDRY    
TYPES OF SAND MOLDING PROCESSES    
1) GREEN-SAND MOLDING:    
(A) PREPARATION OF THE PATTERN.    
(B) MAKING THE MOLD.    
(C) CORE SETTING.    
(D) CLOSING AND WEIGHTING    
ADVANTAGES    
LIMITATIONS    
(2) DRY-SAND MOLDS:    
ADVANTAGES    
DISADVANTAGES    
(3) CARBON-DIOXIDE GAS MOLDING    
(4) CEMENT BONDED SAND MOLDS.    
(5) SHELL MOLDING    
ADVANTAGES    
DISADVANTAGES    
MOLDINNG MATERIAL    
MOLDING SANDS (FOUNDRYSAND)    
PROPERTIES    
CONSTITUENTS OF MOLDING SAND    
A. SILICA SAND    
B. BINDER    
C. MOISTURE    
D. ADDITIVES    
E. COAL DUST    
F. CORN FLOUR    
G. DEXTRIN    
H. SEA COAL    
I. PITCH    
J. WOOD FLOUR    
J. PULVERIZED SILICA OR SILICA FLOUR    
TYPES OF MOULDING SAND    
1. GREEN SAND    
2. DRY SAND    
3. LOAM SAND    
4. PARTING SAND    
5. FACING SAND    
6. BACKING SAND    
7. SYSTEM SAND    
8. CORE SAND    
PATTERNS FOR SAND CASTING    
ADVANTAGES OF SAND CASTING    
DISADVANTAGES OF SAND CASTING    
USES AND APPLICATION    
1. TRANSPORT    
2. HEAVY EQUIPMENT    
3. HARDWARE    
TYPICAL APPLICATIONS ARE    
B.I.S. SPECIFICATION    
INDIAN FOUNDRY INDUSTRY LOOKS TO DOUBLE TURNOVER IN 3 YEARS    
MARKET POSITION    40
COMPETITION WITHIN THE SECTOR    
ALLIED MSME SECTOR IN DEEP TROUBLE    
SHORTAGE OF SKILLED MANPOWER    
GROWING BUSINESS CONFIDENCE    
CONCLUSION    
GROWING DEMAND OF FOUNDRY SECTOR    
OVERVIEW    
SIGNIFICANCE OF FOUNDRY INDUSTRY    
SIGNIFICANCE OF FOUNDRY INDUSTRY    
INDIAN AUTOMOBILE INDUSTRY OVERVIEW    
FOUNDRY INDUSTRY (CASTING)    
INDUSTRY STRUCTURE AND DEVELOPMENTS    
BACKGROUND    
GLOBAL TRENDS IN THE CASTING INDUSTRY    
INDIAN CASTING INDUSTRY    
MANUFACTURERS/SUPPLIERS OF S.S. CASTING    
PROCESS OF SAND CASTING OF STAINLESS STEEL    
1. RAW MATERIALS AND RAW MATERIAL HANDLING    
(A) SS 304 SCRAPE. SS, 410 SCRAP AND ALL TYPES OF FERRO
   ALLOY METALS    
(B) SILICA SAND    
(C) CHROMITE SAND    
(D) ZIRCON SAND    
(E) OLIVINE SAND    
(F) BENTONITE    
(G) RESINS    
(H) CEREAL BINDERS    
(I) IRON OXIDE    
2. SAND PREPARATION (TRANSPORT, SIEVING, COOLING, MIXING)    
(A) RECONDITIONING WITH GREEN SAND MOULDING    
(B) MOULDING WITH NATURAL SAND    
(C) GREEN SAND MOULDING
3. PATTERN MAKING    
A. MANUAL FABRICATION    
B. COMPUTER NUMERICAL CONTROL MACHINING METHOD    
C. FAST FREEFORM FABRICATION    
4. MOULD AND CORE PRODUCTION    
CORE FABRICATION PROCESS    
FABRICATION OF CORE BOXES    
FABRICATION OF SAND MOULD    
STEPS INVOLVED IN MAKING A SAND MOLD    
METHODS OF SAND MOLDING    
A) BENCH MOLDING    
B) FLOOR MOLDING    
C) PIT MOLDING    
D) MACHINE MOLDING    
COATING PROCESS ON MOULD    
5. RUNNING, GATING, FEEDING AND FILTRATION    
6. MELTING AND METAL TREATMENT    
(A) ELECTRIC ARC FURNACE (EAF)    
NATURE OF ATMOSPHERIC EMISSIONS    
(B). INDUCTION FURNACE (IF)    
CORELESS INDUCTION FURNACE    
ADVANTAGES:    
DISADVANTAGES:    
NATURE OF EMISSIONS    
7. METAL TREATMENT OF STEEL    
8. CASTING PROCESS WITH SAND MOLD    
(A) POURING    
(B) SOLIDIFICATION    
(C) SHAKE-OUT    
9. FINISHING AND POST CASTING OPERATIONS    
COATING    110
(A) REMOVAL OF THE RUNNING SYSTEM    
(B) SAND REMOVAL    
C) REMOVAL OF BURRS    
OTHER APPLIED TECHNIQUES INCLUDE:    
10. HEAT TREATMENT    
HEAT TREATMENT OF STAINLESS STEEL    
SOLUTION TREATMENT AND QUENCHING    
11. QUALITY CONTROL    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
STAINLESS STEEL SCRAP    
FERRO ALLOYS    
CHROME SALT AND CHROMIC ACID    
FOUNDRY SAND    
BENTONITE POWDER    
DEXTRINE    
NITRIC ACID    
PICKLING CHEMICALS    
SUPPLIERS OF OIL AND GREASE    
SUPPLIERS OF PLANT AND EQUIPMENTS    
INDUCTION FURNACE    
ANNEALING FURNACE    
INTENSIVE SAND MIXTURE AND MULLER    
SAND SIEVING MACHINE    
SQUEEZE MOLDING MACHINE    
SHAKEOUT MACHINE    
SHELL MOLDING MACHINE    
CORE SHOOTER MACHINE    
DRYING OVEN    
FOUNDRY TOOLS    
SUPPLIERS OF SHOT BLASTING MACHINE    
SUPPLIERS OF MOLDING BOXES    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF PRECISION MEASURING TOOLS    
NDT INSPECTION EQUIPMENT    
BENCH GRINDER    
DRILLING MACHINE    
CNC MACHINES, CNC MACHINE TOOLS & LATHES    
CNC LATHE MACHINE    
POWER HACKSAW    
GRINDING MACHINE    
CNC MACHINING CENTRE    
HARD CHROME PLATING PLANT    
EOT CRANES    
D.G. SETS    
POWER TRANSFORMERS    
COOLING TOWER    
ETP PLANTS    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SUBMERSIBLE WATER PUMP    


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