Industry Overview
Electrical wires and cables are essential components for carrying electrical current and transmitting power or signals across residential, commercial, industrial, infrastructure, and utility applications. A wire generally consists of a single conductor, commonly copper or aluminium, while a cable comprises two or more insulated conductors enclosed within protective layers.
Electrical wires are broadly classified as solid or stranded. Solid wires provide low resistance and are suitable for applications where rigidity and high-frequency performance are important, while stranded wires are formed by twisting multiple smaller wires together to provide greater flexibility, ease of handling, and vibration resistance. Copper remains an important conductor material because of its electrical conductivity, strength, ductility, corrosion resistance, thermal conductivity, solderability, and ease of installation.
PVC insulated copper cables are widely used for electricity distribution, domestic and industrial wiring, control systems, telephone and railway signalling, substations, street lighting, and other electrical installations. PVC insulation and sheathing provide electrical and mechanical protection, moisture resistance, flexibility, flame retardance, and resistance to various chemicals. The manufacturing process covered in the project includes wire drawing, annealing, stranding, insulation, quality control, and coiling and packing. The report also addresses cable construction, testing procedures, plant layout, location factors, project implementation, market position, and suppliers of raw materials, machinery, and supporting equipment.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (4000 sq.mt.) | Rs. 4.49 Cr |
| Plant & Machinery | Rs. 92 Lac |
| Working Capital for 2 Months | Rs. 49.03 Cr |
| Total Capital Investment | Rs. 54.61 Cr |
| Rate of Return | 35% |
| Break Even Point | 32% |
Content Index
- INTRODUCTION
- TYPES OF ELECTRICAL WIRES
- THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
- COPPER WIRE
- PROPERTIES
- PROPERTIES OF COPPER WIRE:
- ELECTRICAL CABLE
- PVC COPPER CABLE
- PROPERTY
- APPLICATION
- ADVANTAGES
- ADVANTAGES OF PVC CABLES
- SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
- CONSTRUCTION
- CONDUCTOR
- 1. SOLID/STRANDED
- A. SOLID
- B. STRANDING
- 2. CIRCULAR/ SHAPED
- A. CIRCULAR
- B. SHAPED
- INSULATION
- THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
- LAYING UP
- INNERSHEATH
- A. EXTRUDED INNERSHEATH
- B. TAPPED INNERSHEATH
- ARMOURING
- OUTERSHEATH
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- (1) DRAWING
- (2) ANNEALING
- (3) STRANDING
- (4) INSULATION
- (5) QUALITY CONTROL
- CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
- (A) TYPE TEST
- 1. THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
- PHYSICAL TESTS FOR INSULATION AND SHEATH
- (B) ACCEPTANCE TEST:
- (C) ROUTINE TEST:
- CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
- TEST FOR THICKNESS OF INSULATION OF POWER CABLE
- APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION OF POWER CABLE
- PROCEDURE FOR TESTING OF THICKNESS OF INSULATION OF POWER CABLE
- ANNEALING TEST FOR WIRES AND CONDUCTORS
- PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
- TENSILE TEST OF CONDUCTORS
- APPARATUS REQUIRED FOR TENSILE TEST:
- METHOD OF TENSILE TEST OF CONDUCTORS
- PROCEDURE
- PERSULPHATE TEST OF CONDUCTOR
- WHY COPPER WIRES ARE TINNED?
- METHODS
- METHOD A:
- METHOD B:
- TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)
- WRAPPING TEST FOR CONDUCTORS
- (6) COILING AND PACKING
- MARKET POSITION
- MARKET OVERVIEW
- EXHIBIT 1: CONSUMER ELECTRICALS SECTOR VALUATION SNAPSHOT
- EXHIBIT 2: CABLES AND WIRES INDUSTRY REGISTERED 23% CAGR IN VOLUME TERMS LED BY STRONG DEMAND FROM POWER DISTRIBUTION
- EXHIBIT 3: C&W MARKET IN REVENUE TERMS IS EXPECTED TO DOUBLE OVER FY18-23E
- EXHIBIT 4: CABLES AND WIRES DEMAND DRIVERS
- EXHIBIT 5: COMPANIES (HAVELLS & FINOLEX) WITH HIGHER SHARE OF HOUSING WIRES HAVE REGISTERED STRONG MARGINS EXPANSION
- EXHIBIT 6: DISTRIBUTION CHANNEL
- EXHIBIT 7: MOST OF THE ELECTRICAL PLAYERS HAVE DIVERSIFIED OVER THE LAST FIVE YEARS
- EXHIBIT 8: DEMAND FOR COPPER IS QUITE HIGHER IN EV
- EXHIBIT 9: NITIAYOG EV PLAN 2030
- EXHIBIT 10: EV INFRASTRUCTURE DEMAND FORECAST
- EXHIBIT 11: TRANSMISSION PROGRESS AS ON FEB’19
- EXHIBIT 12: FEEDER SEGREGATION PROGRESSING STEADILY
- EXHIBIT 13: METRO CONSTRUCTION SENDS ARE EXPECTED TO ~DOUBLE OVER THE NEXT FIVE YEARS
- EXHIBIT 14: RAILWAY ELECTRIFICATION WORK SANCTIONED
- EXHIBIT 15: INFRASTRUCTURE SPEND GROWTH TO REMAIN HIGH
- EXHIBIT 16: URBAN POPULATION AS A % OF TOTAL POPULATION
- EXHIBIT 17: HOUSE SANCTIONED UNDER PMAY (URBAN)
- EXHIBIT 18: HOUSE SANCTIONED UNDER PMAY (GRAHMIN)
- EXHIBIT 19: SHARE OF HOUSEHOLDS OF TOTAL POWER CONSUMPTION IS EXPECTED TO INCREASE OVER THE NEXT 5 YEARS
- EXHIBIT 20: SHARE OF ORGANIZED PLAYERS WILL IMPROVE TO 74% BY FY23E
- PLANT LAYOUT
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TOTAL LOAD:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- SUPPLIERS OF PVC COPPER WIRE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF COOPER WIRE ROD
- SUPPLIERS OF PVC COMPOUND CABLE GRADE
- SUPPLIERS OF PACKAGING MATERIALS
- SUPPLIERS OF PLANT AND EQUIPMENTS
- SUPPLIERS OF WIRE DRAWING MACHINE
- SUPPLIERS OF PVC EXTRUSION PLANT
- SUPPLIERS OF ANNEALING FURNACE
- SUPPLIERS OF WIRE STRANDING MACHINE
- SUPPLIERS OF WIRE STRANDING MACHINE
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF DG SETS
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF ETP PLANTS
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
Appendix
- 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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