Graphite Crucibles
Product Code
29127 and 29128
Quality and Standards
IS 1748:1981
Production Capacity: Qty.
Quantity: 420 MTs.
Value : Rs. 25200000
Value
Rs.1,45,03, 000
Uploaded on
June 2007
Introduction
Graphite Crucibles are refractory containers specially shaped for metallurgical operations. These are made of a mixture of Graphite, Refractory Clay, Grog and other additives. These crucibles are termed as clay bonded Graphite crucibles according to the raw materials used. The crucibles are available with or without spout. These crucibles are used for melting ferrous, non-ferrous metals alloys and noble metals.
Market Potential
The main market for the product is foundry industry. With the growing industrial sector the need for specialized metal and alloy castings is increasing day-by-day. With the advent of many multinational automobile industrial units, many auto spare are manufactured in large numbers in Haryana, Delhi, Punjab and Maharashtra States. There is a good demand in these States for graphite crucibles. As per an assessment 8.5% growth in foundry and Casting Industry is estimated in the country. The use of Graphite Crucibles shall accordingly increase. There is a good scope of development of modern smallscale industries with the growing prospects of special casting metallurgical industry both for domestic and export market.
Basis and Presumptions
- The envisaged production capacity is based on single shift basis on 300 working days in a year.
- The unit will purchase the technology from National Metallurgical Laboratory, Jamshedpur which have developed improved technologies for Graphite Crucibles.
- The costs given are based on the current market rates and may vary from time to time.
- The wages are as per the prevailing norms.
Implementation Schedule
Activity
Period
Preparation of Project Report and preliminary work with institutions, site selection
2
Follow-up action for Term Loan sanction
1
Acquisition of land and construction of buildings, selection of machinery, placing orders
3
Supply of machineries and erection
2
Getting power connection, completion of other formalities with various agencies, working capital, loan sanction etc., trial run and production
1
Total implementation of the project including commencement of production
12
Technical Aspects
Process of Manufacture
The manufacturing process of the products is based on the improved technology developed by National Metallurgical Laboratory, Jamshedpur. The raw materials such as graphite, Refractory/plastic clay, grog and other additives are mixed in a pan mixer after taking proper batch proportions. The wet mass is then kept for ageing. The aged mix is then extruded in a de-airing pugmill and blanks are made. The crucibles are prepared from the blanks either by pressing in a hydraulic press or by jiggering. The shaped crucibles are then dried, glazed and fired in a kiln to develop strength and glaze.
Quality Control and Standards
The following BIS specifications may be referred for day-to-day quality control:
IS 1748:1981
Sizes of Graphite Crucibles
IS 8977:1978
Clay bonded Graphite Crucibles
IS 9927:1981
Methods for determination of life of Graphite Crucibles
IS 11321:1985
Graphite for Graphite Crucibles
Production Capacity
Clay-Graphite Crucibles of different sizes upto No. 500
Quantity
450MT (per annum)
Value
Rs. 19530000
Motive Power 60 HP.
Pollution Control
The unit should be equipped with proper flue-gas exhaust system and dust collectors to control environment pollution. It has to follow the guidelines prescribed by State Pollution Control Board.
Energy Conservation
It is suggested to construct a low thermal mass kiln for firing of the product to save energy.
Financial Aspects
A. Fixed Capital
(i) Land and Building
(Rs.)
Land 1 Acre
1200000
Office: 50sqm. @5000 sq. m . Manufacturing sheds:
250000
400sqm @ 4000 sq. m.
1600000
Stores: 50sqm @5000 sq. m.
250000
Workers quarters 200 sq. m. @ 4200 sq. m.
840000
Water well, pump, pipelines and compound wall etc.
200000
Total
4340000
(ii) Machinery and Equipments
Description
Qty.
Value (Rs.)
Roller Crusher, Single roller size 350 x 300mm with a 7.5HP motor and accessories
1
120000
Disintegrator 14” size with 5HP Motor
1
50000
Pan Mixer, 0.5MT capacity with a 3 HP motor and other
accessories
1
140000
Deairing pugmill, capacity 250 kg/hr. with a 5HP motor
vacuum pump and other accessories
1
300000
Hydraulic press with all accessories cap: 1MT/day
1
345000
Jigger and Jolly with individual 1HP/2HP motor and
accessories for making large size crucibles
4
60000
Electro Magnet
1
65000
Saggar Press, Hand operated with ram
1
90000
Glazing equipment comprising of a glaze tank, compressor, booth, spray gums and other fittings
1
85000
Wheel barrows for internal transportation of large crucibles
4
16000
Rotary screen for grading of grog with a 3Hp motor and
other accessories erected on a platform
1
40000
Weighing scales 250kg. and 25kg.
1
15000
Test Eqpt. Misc. Eqpt. and tools
1
50000
5 Tonne capacity oil fired down draft kiln with good thermal insulation (back-up) and with a 25 metres high chimney, thermocouples and other draft measuring equipment
1
1000000
Installation and wiring
LS
150000
Office furniture and equipments
50000
Pollution Control equipments and dust collator
200000
Total
2776000
(iii) Preliminary and Pre-operative expenses like deposits, project cost (non-refundable) and other unforeseen expenditure)
50000
Total
2826000
(iii) Pre-operative Expenses
150000
Total
2976000
B. Working Capital (per month)
(i) Staff and Labour (per month)
Designation
Nos.
Salary / (Rs.)
Total (Rs.)
Works Manager
1
12000
12000
Technical supervisor
2
8000
16000
Accountant
1
7000
7000
Clerk
2
4000
8000
Mechanic (Maintenance)
1
4000
4000
Skilled operators
4
5000
20000
Semi-skilled workers
4
4500
18000
Firemen
2
4800
9600
Unskilled labour
10
3000
300000
Watchmen
2
3000
6000
Total
400600
Perks @ 22%
88132
Total
488732
(ii) Raw Materials (per month)
Particular
Qty. (MT)
Rate/ MT
Total
Graphite Powder (Flaky and Lump IS 11321 grade)
14MT
20000
280000
Crucible Grog
2MT
5000
10000
Silicon Carbide granules
2MT
60000
120000
Fireclay and Plastic Clay
40MT
1800
72000
Fireclay Grog
3MT
1800
5400
Coke Dust/Granules
10MT
3500
35000
Glaze and Chemicals
LS
35000
Consumables
LS
10000
Packing Materials
LS
15000
Total
582400
(iii) Utilities (per month)
Rate (Rs.)
Power and Water
50 kWH
30000
Furnace oil
8 kL @ 30000 per kL
240000
Total
270000
(iv) Other Contingent Expenses (per month)
(Rs.)
Postage and stationery
2000
Transport and Conveyance
10000
Advertisement and Publicity
10000
Telephone
4000
Maintenance
8000
Insurance
2500
Other Contingent Expenses
5000
Total
41500
Total recurring expenditure (per month) (i+ii+iii+iv)
1382632
Total Capital Investment
i) Fixed capital
7316000
Working capita l (2 month)
2765264
Total
10081264
Financial Analysis
Cost of Production (per annum)
(Rs.)
Total recurring cost
16591584
Depreciation on building @5%
217000
Depreciation on plant and Machinery @10%
192600
Depreciation on kiln @15%
150000
Depreciation on office furniture @20%
10000
Interest on total capital investment @13%
1310564.32
Total
18471748.32
Total Sales Turnover (per annum)
Rs
By sale of 420MT of Graphite Crucibles (After allowing nearly 7% rejections) @ of 60000 per MT
25200000
Profit (per annum)
Sales – Cost of production
Rs. 25200000– 18471748.32
6728251.68
Net Profit Ratio
Net profit per year x 100
-------------------------------
Turnover per year
6728251.68x 100
----------------------
25200000
26.7
Rate of Return (per annum)
Net profit per year x 100
-------------------------------
Total investment
6728251.68 x 100
----------------------
10081264
66.74
Break-even Point
Fixed Cost (per annum)
(Rs.)
Depreciation on building @5%
217000
Depreciation on Plant and Machinery @10%
177600
Interest on capital investment @13%
1310564.32
40% of salaries
2345913.6
40% of other Contingent expenses
187200
Insurance
30000
Total
4418277.92
B.E.P
Fixed Cost × 100
--------------------------
Fixed cost + Net Profit
4418277.92 x 100
-------------------------------
4418277.92 + 6728251.68
39.64
Addresses of Plant and Machinery Suppliers
- M/s. Keshab Engn. Co. Ltd.
Bose Park, P.O. Sikchar,
24, Paraganas (North),
(West Bangal)
- M/s. Amic Industries (P) Ltd.
10, B.T. Road,
Kolkata - 700 056
- M/s. Pappu Veeranna and Sons
Dhowleswaram Rajahmundry,
East Godavari District
- M/s. Hari Machines Ltd.
Rajgangapur - 770 017
- M/s. Gloheat Instruments (P) Ltd.
No. 73, 6th Main, 3rd Phase 4,
P. O. Box No. 5042, Peanya
Industrial Area, Bangalore.
Raw Material Suppliers
- M/s. Patna State Graphite Minerals Co.
Titagarh (PO), (Orissa)
- M/s. Laxmi Narayan Agarwal Co.
Sambhalpur, (Orissa)
- M/s. Hindustan Graphite Refining and Products Co.
Opp. Petrol Pump, G.T. Road Kovvur,
West Godavari Dist., (A.P)
- M/s. Hari Machines Ltd.
Rajgangapur - 770 017 M/s. Grindwel Narton (P) Ltd.
4th Floor, 114 MG Road,
Bangalore
- M/s. Indian Metal and Ferro Alloys
Terubali, Rayagada Dist.,
(Orissa)
- M/s. Elector Thermics
C-5, SBH Colony,
Hyderabad - 500 034
- M/s. East India Minerals
Fireylal Chowk, Ranchi,
(Jharkhand)
Shuttle Kiln Fabricators
- M/s. Unifire
Shakespere, 16-12, Sarani,
4th Floor, Kolkata
- M/s. Bengallium Industrial Funales
24-B, Carmae Street,
Kolkata - 700 016
- M/s. Techno Thermo Projects Pvt. Ltd.
225/2, C.I.T. Road, Scheme VII-M,
Kolkata - 700 054
- M/s. N.M. Kiln Pvt. Ltd.
A-706, Rail Vihar, Seetu
15-11, Jharza Road,
Gurgaon - 122 001
- M/s. Sharma Kiln Technology
206, Hare Krishna Complex,
Opp. Kottawala Flats,
Ashram Road,
Ahmedabad - 380 007
- M/s. Associated Industrial Furnaces
2/5, Sarai Julane, 1st Floor,
Okhla Road,
New Delhi - 110 025
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com