ALUMINIUM SLUG
[EIRI/EDPR/4335] J.C.: 2518XL
INTRODUCTION
An aluminium slugs for collapsible tube is obtained on a machine that cuts many slugs from a straight bar or coiled stock. The thickness, shape and size of the slug are set by a stop in the machine. A feeding mechanism feeds the aluminum bar or coil stock up against the stop and then a knife pushes against the aluminum material and shears of the slug. This is done at a fairly high speed of production. The cut slugs are then sent to a cold heading machine that reverse extrudes each aluminium slugs into a straight can shape. A plunger pushes against the slug inside a hole in a die and the material flows up the plunger to form a can. This is done in a full automatic production line where aluminium slugs are fed into the start unit of the line. They are then extruded, during which lips are rolled onto them. The inside of the shaped cans are lacquered, and next labels are rolled onto them. The finished empty cans are bunched together, strapped and stacked on pallets ready to ship. All the steps are done on one production line with no human touch from start to finish.
Aluminum collapsible tubes are one of the most common packaging solutions in cosmetic, health care, pharmaceutical, food and adhesive industries. They are ideal for packing low viscosity products, such as lotion, cream, ointment and adhesive.
The tube collapses as the contents are squeezed out, effectively preventing suck back of air or contaminants and thus maximizes shelf life of product.
Aluminium collapsible tubes, covered under IS: 3107-1979 (First revision), are suitable for a wide range of liquids, semi-liquids, pastes & formulations containing soluble constituents. All collapsible aluminium tubes with short screwed nozzle are well specified in this standard. The aluminium collapsible tubes with other types of nozzles designs eg. Eye ointment tube, are covered under IS: 7852-1975.
Aluminium collapsible tubes are manufactured from Aluminium grade 19500 as per IS: 737-1974. The wrought aluminium & alloys for general engineering purposes belong to this specification. The collapsibility & permeability w.e.f. moisture and easy workability are the main characteristics of the aluminium slugs used for manufacturing collapsible tubes.
Aluminium of 99.70% purity is cast, rolled to predetermined thickness & blanked to provide cylindrical shapes of a defined diameter. These metal pieces are generally referred to in the industry as slugs. Slugs are heat treated to bring them to desired metallurgical state for fabricating into a collapsible tube. Mechanical fabrication an aluminium tube is accomplished in five stages of production, carried out automatically on a mass-production flow line.
COST ESTIMATION
Plant Capacity 6 MT/Day
Land & Building (3625 sq.mt.) Rs. 3.32 Cr
Plant & Machinery Rs. 4.91 Cr
Working Capital for 1 Month Rs. 2.28 Cr
Total Capital Investment Rs. 11.07 Cr
Rate of Return 46%
Break Even Point 48%
CONTENTS
INTRODUCTION
USES & APPLICATIONS
ALUMINIUM SLUGS FOR COLLAPSIBLE TUBES
MARKET OVERVIEW
THE ALUMINUM SLUGS CAN BE SEGMENTED BY SHAPE, BY APPLICATION, AND BY END USE INDUSTRY.
ON THE BASIS OF SHAPE, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:
ON THE BASIS OF APPLICATION, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:
ON THE BASIS OF END USE INDUSTRY, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:
THE GLOBAL ALUMINUM SLUGS CAN BE SEGMENTED ON THE BASIS OF REGION SUCH AS:
PRESENT MANUFACTURER
PROPERTIES – RAW MATERIAL
THE CHEMICAL COMPOSITION OF WROUGHT ALUMINIUM AND ALUMINIUM ALLOY SHEET & STRIP CONFORM TO THE FOLLOWING TABLE:
MECHANICAL PROPERTIES
THE MECHANICAL PROPERTIES OF SHEET AND STRIP SHALL COMPLY WITH THE REQUIREMENT GIVEN IN TABLE:
ALUMINIUM CASTING
WROUGHT ALLOYS
FORMABILITY
RAW MATERIALS SUPPLIER
ALUMINIUM INGOT
ALUMINIUM SLUGS CHARACTERISTICS
THE APPLICATION AREA OF ALUMINUM SLUGS
SIZES OF SLUGS
SLUGS PACKAGING
MANUFACTURING PROCESS
CASTING
ALUMINIUM FLAT ROLLING
SHEARING
METAL SHEET PRESS
ANNEALING
TESTING & QUALITY CONTROL
CLEANING & PACKAGING
PROCESS FLOW
PROCESS STEPS
PLANT & MACHINERY (BROADLY)
PLANT AND MACHINERY SUPPLIERS/CONTRACTOR
FURNACE
ROLLING MILL MACHINERY
HYDRAULIC PRESS
DRILLING MACHINE
PLANT AND MACHINERY (GLOBAL)
UTILITIES REQUIREMENT (ESTIMATED - MONTH)
WASTE MANAGEMENT (ESTIMATED)
WATER
WASTE
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
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)
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