HIGH CARBON WIRE MANUFACTURING UNIT [3570]
(1) STEEL WIRE – A kind of binding wire (tie wire), which includes a huge number of varieties that are widely used not only in manufacturing but also in everyday life. Steel wire for general purpose are made of mild steel with a diameter of 0.2-8.0 mm. Production is carried out using a method that is associated with repeated cold drawing. Steel wire of this quality is used in the manufacture of linking the rails and nails. Carbon steel wire is widely used in instrumentation for the production of consumer goods. Spring steel wire used in the manufacture of springs which wind around in the cold. The cable steel wire is used in the manufacturing process of various ropes, which are made from a specialized rod, which in turn guarantees non-plastic properties. It is also considered to be a very popular kind of steel wire for reinforcement of concrete products. A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear mechanical loads or electricity and telecommunications signals. Wire is commonly formed by drawing the metal through a hole in a die or draw plate. Wire gauges come in various standard sizes, as expressed in terms of a gauge number. The term wire is also used more loosely to refer to a bundle of such strands, as in ‘multistranded wire’, which is more correctly termed a wire rope in mechanics, or a cable in electricity. Wire comes in solid core, stranded, or braided forms. Although usually circular in cross-section, wire can be made in square, hexagonal, flattened rectangular, or other cross-sections, either for decorative purposes, or for technical purposes such as high-efficiency voice coils in loudspeakers. Edge-wound coil springs, such as the Slinky toy, are made of special flattened wire. (2) HIGH CARBON STEEL WIRE – High carbon steel wire is popularly known as black wire. It is a drawn steel wire which is manufactured from quality wire rods with high carbon content.
COST ESTIMATION
Plant Capacity 36 MT/Day
Land & Building (8000 sq.mt) Rs. 5.78 Cr
Plant & Machinery Rs. 2.35 Cr
Working Capital for 2 Months Rs. 10.26 Cr
Total Capital Investment Rs. 18.80 Cr
Rate of Return 18%
Break Even Point 66%
INTRODUCTION
(1) STEEL WIRE –
(2) HIGH CARBON STEEL WIRE
NOMINAL CHEMICAL & PHYSICAL PROPERTIES
ROPE WIRES
BARBED FENCING WIRE
BARBED WIRE TYPES:
SINGLE TWIST BARBED WIRE
POSSITIVE TWIST BARBED WIRE
NEGATIVE TWIST BARBED WIRE
TRADITIONAL TWISTED BARBED WIRE
TECHNOLOGY DATA:
USES AND APPLICATION
BARBED WIRE OBSTACLES SERVED FOUR BASIC PURPOSES:
(C) WIRE FOR RAILWAY SLEEPER
THESE WIRES ARE TWO TYPES
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
WIRE DRAWING PROCESS OVERVIEW
(1) WIRE ROD PREPARATION
MECHANICAL DESCALING OF WIRE ROD
CHEMICAL DESCALING (PICKLING) OF WIRE ROD
APPLICATION OF SOAP (LUBRICANT) CARRIER
(2) DRAWING
DRY DRAWING OF WIRE
WET DRAWING OF WIRE
(3) HEAT TREATMENT OF WIRE
BATCH ANNEALING OF LOW CARBON STEEL WIRE
CONTINUOUS (IN-LINE) ANNEALING OF LOW CARBON STEEL WIRE
CONTINUOUS (IN-LINE) ANNEALING OF STAINLESS STEEL WIRE
PATENTING
OIL HARDENING AND TEMPERING (OIL TEMPERING)
STRESS-RELIEVING
(4) IN-LINE PICKLING
(5) HOT DIP COATING
WIRE HOT DIP COATING
CONTINUOUS PICKLING OF WIRE
FLUXING
HOT DIPPING (GALVANIZING)
FINISHING
TESTING
NOMINAL SIZES
TOLERANCE
TENSILE STRENGTH
PROOF STRESS
TEST FOR PROOF STRESS
REVERSE BBD TEST
IDENTIFICATION AND MARKING
MANUFACTURING PROCESS OF BARBED WIRE
MATERIAL
MANUFACTURE
CHROMATING
FREEDOM FROM DEFECTS
TESTING 43
(A) TENSILE TEST
(B) DUCTILITY TEST
ZINC COATING
LINE WIRE
POINT WIRE
MARKING
COILING AND PACKING
TECHNOLOGY OF WIRE DRAWING
WIRE AND ROD DRAWING PROCESS FOR STEEL
DRAWING PROCESS
DRAWING EQUIPMENT
DRAW DIES
MECHANICS OF WIRE DRAWING
DRAWING DEFECTS
INDUSTRY ANALYSIS
2. THREAT OF POTENTIAL ENTRANTS
3. BARGAINING POWER OF SUPPLIERS –
4. BARGAINING POWER OF BUYERS
5. THREAT OF SUBSTITUTE GOODS/SERVICES
#2 BROAD FACTORS ANALYSIS (PEST ANALYSIS)
1. POLITICAL
2. ECONOMIC
3. SOCIAL
4. TECHNOLOGICAL
IMMEDIATE SALES
HIGH PROFIT CUSTOMER / RETAIL
DIVERSIFY MARKET EXPOSURE
HIGH PROFIT CUSTOMER / RETAIL
TARGET 100% UTILIZATION OF INSTALLED CAPACITY & MAINTAIN PROFITS
MAINTAIN WORKING CAPITAL FLOW SMOOTHLY
QUALITY & IN-TIME DELIVERY.
4. LIST OF DOMESTIC AND INTERNATIONAL DISTRIBUTION CHANNELS
5. POSITIONING OF THE COMPANY AND ITS PRODUCTS:-
6. MARKETING OPPORTUNITIES/MARKETING RISKS
MARKETING RISK USUALLY COVERS WITH FOLLOWING POINTS
AND ADDRESSED:-
7. STATUS AND TRENDS OF RELATIONSHIPS
8. PROSPECTS FOR FUTURE GROWTH AND DEVELOPMENT
9. PIPELINE ANALYSIS
10. PRINCIPAL AVENUES FOR GENERATING NEW BUSINESS.
11. SALES FORCE PRODUCTIVITY MODEL
12. COMPENSATION
13. SALES CYCLE
14. ABILITY TO IMPLEMENT MARKETING PLAN WITH CURRENT
AND PROJECTED BUDGETS.
15. DESCRIPTION OF THE COMPETITIVE LANDSCAPE WITHIN EACH
MARKET SEGMENT INCLUDING:
PRICE - STRENGTH
PRICE – WEAKNESS
SERVICE – STRENGTH
SERVICE – WEAKNESS
16. DESCRIPTION OF EACH PRODUCT
HIGH CARBON WIRES FOR CONTROL CABLES
HIGH CARBON WIRES FOR WIRE STRAND AND WIRE ROPES.
HIGH CARBON WIRES FOR TEXTILE
17. A) HISTORICAL AND PROJECTED GROWTH RATES
B) MARKET SHARE 76
C) SPEED AND NATURE OF TECHNOLOGICAL CHANGE
D) TIMING OF NEW PRODUCTS, PRODUCT ENHANCEMENTS
E) COST STRUCTURE AND PROFITABILITY.
WIRE ROPE MARKET TREND
INDIA STEEL WIRE ROPE MARKET SIZE AND OVERVIEW
MARKET SEGMENTATION:
BY DOMESTIC AND EXPORTS SALES
BY INDUSTRY APPLICATION
BY WIRE COATING
BY ROPE COMPOSITION
BY ORGANIZED AND UN-ORGANIZED PLAYERS
BY TYPE OF LAY
COMPETITIVE LANDSCAPE
FUTURE OUTLOOK TO INDIA STEEL WIRE ROPE MARKET
MARKET POSITION
MARKET FACTS FOR WIRE INDIA 2018
INDIAN ECONOMY OVERVIEW
MAIN PRODUCT GROUPS
TARGET GROUPS
THE OVERALL STEEL WIRE PRODUCTION SCENARIO IS AS FOLLOWS:
WIRE MARKET RESEARCH REPORTS, ANALYSIS & TRENDS
WIRE AND CABLE INDUSTRY CURRENT TRENDS
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF STEEL WIRE
SUPPLIERS OF RAW MATERIALS
STEEL WIRE ROD
ZINC
LEAD
PICKLING ACIDS
PACKING MATERIALS
PICKLING CHEMICALS
SUPPLIERS OF PLANT AND EQUIPMENTS
WIRE MAKING PLANT
WIRE DRAWING MACHINE
WIRE WINDING MACHINE
PICKLING TANK
WIRE STRAIGHTENING MACHINE
ANNEALING FURNACE
WIRE POINTING MACHINE
EOT CRANE
POWER TRANSFORMER
ELECTRICAL PANEL
ELECTRIC MOTOR
COOLING TOWER
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
JIGS AND FIXTURE
SUBMERSIBLE WATER PUMP
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)
