AIR CONDITIONER MANUFACTURING
(INDOOR UNITS AND OUTDOOR UNITS)
[CODE NO.3423]
An air conditioner is a machine which keeps the air in a building cool and dry.
The purpose of an air conditioner is to maintain a comfortable indoor environment. The comfort we are used is to determined by a combination of 3 factors.
• Temperature
• Humidity
• Air Distribution
For this reason, the main purposes of air conditioners are to:
• Control room temperatures (cooling/heating).
• Control room humidity levels (drying, humidifying).
• Optimise air flow (circulation, distribution).
• Clean the air (filtration)
Working principle
An air conditioner collects hot air from a given space, processes it within itself with the help of a refrigerant and a bunch of coils and then releases cool air into the same space where the hot air had originally been collected. This is essentially how all air conditioners work.
Many folks believe that an air conditioner produces chilled air with the help of machines installed inside it, allowing it to cool a room so quickly. That might also explain why it consumes so much electricity. In reality, however, that’s a misconception. An air conditioner is not a magical device; it just uses some physical and chemical phenomena very effectively to cool a given space.
When you switch an AC on and set your desired temperature (say, 20 degrees Celsius), the thermostat installed in it senses that there is a difference in the temperature of the room’s air and the temperature that you’ve chosen.
A thermostat constantly monitors the temperature of the system so that it’s maintained near a user’s desired point.
This warm air is drawn in through a grille at the base of the indoor unit, which then flows over some pipes through which the refrigerant (i.e., a coolant fluid) is flowing. The refrigerant liquid absorbs the heat and becomes a hot gas itself. This is how heat is removed from the air that falls on the evaporator coils. Note that the evaporator coil not only absorbs heat, but also wrings out moisture from the incoming air, which helps to dehumidify the room.
This hot refrigerant gas is then passed on to the compressor (located on the outside unit). Being true to its name, the compressor compresses the gas so that it becomes hot, since compressing a gas increases its temperature.
This hot, high-pressure gas then travels to the third component – the condenser. Again, the condenser remains true to its name, and condenses the hot gas so that it becomes a liquid.
COST ESTIMATION
Plant Capacity : 400.00 Nos./day
land & Building (4000 Sq.mtr) : Rs. 4.30 Cr
Plant & Machinery : Rs. 3.42 Cr
Working Capital for 2 Months : Rs. 18.40 Cr
Total Capital Investment : Rs. 26.60 Cr
Rate of Return : 86%
Break Even Point : 21%
INTRODUCTION
HERE’S A SIMPLIFIED DIAGRAM OF THE AIR-CONDITIONING PROCESS
ROOM AIR CONDITIONER
SIZING AND SELECTING A ROOM AIR CONDITIONER
OTHER FEATURES TO LOOK FOR INCLUDE
SPLIT AIR CONDITIONER
CONSTRUCTION
PARTS OF SPLIT AIR-CONDITIONER
WALL MOUNTED INDOOR UNIT
EVAPORATOR COIL OR THE COOLING COIL
AIR FILTER
COOLING FAN OR BLOWER
DRAIN PIPE
LOUVERS OR FINS
OUTDOOR UNIT
REFRIGERANT PIPING OR TUBING
USES AND APPLICATION
B.I.S. SPECIFICATION
MARKET AIR CONDITIONERS
ROOM AIR CONDITIONERS
FOCUS SHIFTS TO INVERTER ACS – TO BE AT 50% OF SALES BY FY20
(10-12% IN FY16)
CY17 OUTLOOK – IMD EXPECTS ‘ABOVE NORMAL SUMMER SEASON’
ROOM AIRCON INDUSTRY SHIFTS TO INVERTERS
INVERTER ACS TO ACCOUNT FOR 30% OF INDUSTRY VOLUMES IN
FY18E AND 50% IN FY20E
VOLTAS MAY NOT SEE MEANINGFUL GAINS EVEN WITH LG’S COMPLETE
EXIT FROM FIXED-SPEED ACS
HIGH COMPETITIVE INTENSITY
BRAND, DISTRIBUTION, SERVICE CENTER NETWORK AND DEALER
MARGINS ARE KEY
SUMMER STRATEGIES OF AC MANUFACTURERS
BLUE STAR – IMPRESSIVE LINE-UP OF AC MODELS; MARKET SHARE
TARGET AT 13%
VOLTAS – TARGETING 15-20% GROWTH THIS SUMMER SEASON
LG INDIA – LOOKING FOR 30% GROWTH IN CY17
DAIKIN INDIA – TARGET TO EXPAND REACH AND MARKET SHARE;
DOUBLING CAPACITY AT NEEMRANA TO 1.2M UNITS
PANASONIC – ‘A BETTER LIFE, A BETTER WORLD’ – AIMS FOR 30-35%
GROWTH IN FY18
GODREJ APPLIANCES – EYEING 20% SHARE IN INVERTER/5-STAR
AC SEGMENT
SAMSUNG – INVERTER RANGE LAUNCHED IN AFFORDABLE LUXURY
SEGMENT
VIDEOCON – TARGETS 13% SHARE AND TO INCREASE PRESENCE
IN TIER 2/3 CITIES
DETAILED EXPORT DATA OF SPLIT AC
DETAILED IMPORT DATA OF SPLIT AC
MANUFACTURERS/SUPPLIERS OF SPLIT AC
PROCESS FLOW CHART
PRODUCTION PROCESS
(1) PROCUREMENT OF RAW MATERIALS
THE MANUFACTURING PROCESS
(1) MAKING THE PARTS
(A) CONSTRUCTING THE CASING, BRACKETS, AND OTHER SUPPORTS
(B) PUNCH PRESSING THE SHEET METAL FORMS
(C) CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL
AND STRUCTURAL STEEL
(D) CLEANING THE PARTS
(E) POWDER COATING
(F) FABRICATION OF COIL
(G) FINISHING THE EVAPORATOR AND CONDENSER COILS
(2) ASSEMBLY
(3) CHARGING AND FINISHING
(4) QUALITY CONTROL
(A) PRODUCTION ROUTINE TESTS
(I) GENERAL RUNNING TEST —
(II) PRESSURE TEST OR LEAKAGE TEST —
(III) INSULATION RESISTANCE TEST —
(IV) HIGH VOLTAGE TEST —
(V) PERFORMANCE TEST —
(VI) LEAKAGE CURRENT TEST —
(VII) EARTHING RESISTANCE TEST —
(B) TYPE TESTS
(6) MARKING
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
ALUMINIUM FIN STOCK FOIL
COPPER TUBE
M.S SHEETS
ABS GRANULE
BRAZZING WIRE
MIG WELDING WIRE ELECTRODE
REFRIGERANT GASES
PICKLING CHEMICALS
SUPPLIERS OF AC COMPRESSOR
AIR CONDITIONER PARTS
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF FIN PRESS
SUPPLIERS OF FIN DIE
SUPPLIERS OF VERTICAL EXPANDER
SUPPLIERS OF HAIRPIN BENDER
SUPPLIERS OF AUTOMATIC BRAZING MACHINES
CNC PRESS
POWDER COATING MACHINE
INJECTION MOLDING MACHINE
SUPPLIERS OF IDU ASSEMBLING LINE
SUPPLIERS OF BRAZING MACHINES
SUPPLIERS OF REFRIGERANT CHARGING UNIT
SUPPLIERS OF REFRIGERANT (HALIDE) LEAK DETECTOR
ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
AIR POLLUTION CONTROL EQUIPMENTS
AIR COMPRESSORS
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
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
