ALUMINIUM EXTRUSION (CAP: 9 MT/DAY)
[EIRI/EDPR/1234] J.C. 9888
INTRODUCTION
Aluminium is a versatile metal with properties as under.
1. STRENGTH:- It is the major dominant requirement. Aluminium and its alloys meet the requirements fully and efficiently.
2. LIGHTNESS:- Aluminium is a light metal with weight 1/3rd of steel and copper. High strength to weight ratio of aluminium makes it more useful than steel even.
3. RESISTANCE TO CORROSION:- Atmospheric weathering in industrial rural and sea coast environments call for suitable material and finish. Aluminium prevents corrosion effectively.
4. ELECTRICAL CONDUCTIVITY:- It is conductor of heat and electricity. This makes aluminium one of the best bus bar materials.
These properties have made aluminium highly useful in manufacture of aircraft, passenger cars, railway rolling stock, ship building, electrical eng. manufacture of cine and photographic equipments, radio components, window frames and doors, railings, refinery equipments, foils, extruded sections and pipes for a wide range of uses. Aluminium powder is also used in paints and anodising industries. Extruded aluminium products are finding growing exports prospects. Aluminium extruded products are mainly tubes, pipes and blanks. These are manufactured in various forms and can be broadly classified in (a) rods & (b) sections. Sections include leath hollow and solid sections. In extrusion, the cylindrical rod called billet, is squeezed hydraulically into any shape by forcing the hot billet through the die orifice. Extrusion presses of various sizes are available ranging from 200 ton to 5000 tons capacity. These presses can be designed from simple to very complicated type with intricate and most sophisticated components equipments.
Aluminium extrusion products are widely used in transport industry, rail road’s, electronics and housing industry etc. The manufacturing of extruded products started long back. But, the industry expanded rapidly during last two decades. In 1967-68. There only 3 units engaged in manufacturing aluminium extruded products but till 1983-84 the number has reached 12 with total installed capacity 25,490 MT year @113% capacity utilisation. Imparts of aluminium extruded products in the seventies had been quite high but the stress is being made to reduce it in order to save foreign exchange and hence partially it is taking place of import substitute. This is clear from the import in 1979-80 as high as 3,36,659 M.T. valued at Rs. 1,05,35,820/- to just 33753 M.T. in 1980-81 and 56,222 in 1981-82.
On the other hand, the export of aluminium extruded products is gradually on rise (From 27,591 M.T. in 1973-74 to 55,395 M.T. in 1981-82). Afghanistan, Algeria, Bahrain, Bangladesh, Burma Hong Kong, Kenya, Kuwait, Oman, Srilanka, U.A.E. etc. are the main middle East countries to whom aluminium extruded products like tubes, pipes and blanks are being exports at present aluminium extrusion products have penetrated a large area of applications and are manufactured in India with or without foreign collaborations. It requires moderately high level of technology and investments but the industry is quite profitable and finds ready market within and outside the country.
COST ESTIMATION
Plant Capacity 9 MT/Day
Land & Building (5 Acres) Rs. 5.84 Cr
Plant & Machinery Rs. 7.74 Cr
Working Capital for 2 Months Rs. 7.47 Cr
Total Capital Investment Rs. 22.50 Cr
Rate of Return 24%
Break Even Point 62%
CONTENTS
INTRODUCTION
USES AND APPLICATIONS
RAW MATERIAL AVAILABILITY
PROPERTIES
PROPERTIES OF RAW MATERIAL
PHYSICAL PROPERTIES
MECHANICAL PROPERTIES
BIS PECIFICATIONS
MARKET FORCASTING
MARKET SIZE AND INDUSTRY OUTLOOK
PROCESS FLOW CHART
MANUFACTURING PROCESS
THE ALUMINIUM EXTRUSION PROCESS
DIRECT EXTRUSION
INDIRECT EXTRUSION
EXTRUSION PROCESS DESCRIPTION
MANUFACTURING PROCESS IN DETAIL
PLANT LAYOUT
SUPPLIERS OF ALUMINIUM EXTRUDED PRODUCTS
SUPPLIERS OF ALUMINIUM ALLOYS
SUPPLIERS OF ALUMINIUM MASTER ALLOYS
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF EXTRUSION PRESSES
COMPLETE PLANT AND MACHINERY ALUMINIUM EXTRUSION
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF LATHE MACHINES
SUPPLIERS OF SHAPING MACHINE
SUPPLIERS OF MILLING MACHINE
SUPPLIERS OF DRILLING MACHINE
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF HEAT TREATING FURNACE
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF MEASURING TOOLS
SUPPLIERS OF CASTING MACHINE
SUPPLIERS OF EXTRUSION PRESS
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)
