Detailed Project Report (DPR) on high carbon wire manufacturing unit

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)