Detailed Project Report (DPR) on LT Cable, MV Cable, DC Solar Cable, Covered Cable and H.V. Cable Manufacturing Plant (Production Capacity: 150 MT/Day)

LT CABLE, MV CABLE, DC SOLAR CABLE, COVERED CABLE AND H.V. CABLE MANUFACTURING PLANT (PRODUCTION CAPACITY: 150 MT/DAY)

[EIRI/EDPR/4770] J.C.: 2990INR, 2990US$

Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.

There are two main types of wires: solid or stranded.

A solid wire is a single conductor that is either bare or insulated by a protective colored sheath. It offers low resistance and is perfect for use in higher frequencies. When inside a covering there are many thin strands of wires twisted together, it is called a stranded wire. Stranded wires are used where flexibility is important because which the wire can be used for a longer period. This type of wire have larger cross-sectional area than solid wires for the same current carrying capacity. Stranding is process of twisting together of small wires to form a single larger conductor. Used to provide flexibility, ease of handling and vibration resistance.

Copper Wire

Copper Wire is a single electrical conductor manufactured out of Copper Ore. This widely used conductor can either be insulated or uninsulated. Having a moderate conductivity, it’s used to transfer electricity with low voltage. Electrical wiring in buildings is the largest market for the copper industry worldwide. As per estimation, around half of the copper mines is consumed in manufacturing electrical wire and cable conductors.

COST ESTIMATION

Plant Capacity            150 MT/Day

Land & Building (21,600 sq.mt.)    Rs. 6.02 Cr

Plant & Machinery                    Rs. 10.84 Cr

Working Capital for 2 Months    Rs. 392.65 Cr

Total Capital Investment          Rs. 410.56 Cr

Rate of Return                          9%

Break Even Point                      61%

CONTENTS

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

MANUFACTURING PROCESS

TECHNOLOGY

FEATURES

MANUFACTURING PROCESS

DRAWING

ANNEALING

STRANDING

TWISTING

INSULATING

LAY-UP

SHEATHING

ARMORING

PACKING

MANUFACTURING FLOW CHART

SINGLE WIRE

MULTIPLE WIRE

FLEXIBLE WIRE

FLAT TWIN-CORD WIRE

POWER CABLE WIRE

ARMOUR CABLE

DRAWING

BUNCHING

STRANDING

EXTRUSION

COILING AND PACKING

MANUFACTURING PROCESS

(I) METHOD OF MAKING STRIP

(II) PROCESS OF COVERING

(III) METHOD OF MATERIAL ANNEALING

MACHINERY & EQUIPMENTS REQUIRMENT

A. MACHINERIES

A. ACCESSORY EQUIPMENT’S

B. INSPECTION AND TESTING EQUIPMENT

PRODUCTION PROCESS OF SOLAR CABLE

STEP 1: PURCHASE AND PREPARATION OF RAW MATERIALS

STEP 2: MANUFACTURE OF THE CONDUCTOR

STEP 3: MANUFACTURE OF THE INSULATING LAYER

STEP 4: SHEATH MANUFACTURING

STEP 5: CABLE ASSEMBLY

STEP 6: TESTING

MANUFACTURING PROCESS OF SOLAR CABLES

1. PREPARATION OF RAW MATERIALS:

2. CONDUCTOR CORE PREPARATION:

3. INSULATION LAYER PREPARATION:

4. SHEATHING LAYER PREPARATION:

5. TESTING AND PACKAGING:

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:

THE FOLLOWING SHALL CONSTITUTE ACCEPTANCE TEST:

(C) ROUTINE TEST:

THE FOLLOWING SHALL CONSTITUTE THE 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

HIGH VOLTAGE TEST (WATER IMMERSION TEST):

TEST ON COMPLETED CABLES (ACCEPTANCE AND ROUTINE TEST):

FLAMMABILITY TEST:

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

INDUSTRY /MARKET OVERVIEW

ECONOMIC OUTLOOK

GLOBAL ECONOMY

INDIAN ECONOMY

IMF KEPT THE GROWTH FORECAST FOR 2024 AT 6.3%, THE GROWTH RATE IT HAD PREDICTED IN APRIL, 2023.

INDEX OF INDUSTRIAL PRODUCTION

TABLE: INDEX OF INDUSTRIAL PRODUCTION YOY

SECTORAL PERFORMANCE

CONSUMPTION AND INVESTMENT

CAPITAL MARKET PERFORMANCE

INDEX MOVEMEN

MARKET CAPITALISATION OF INDIA AND ITS HISTORIC TREND

IMPACT OF THE RUSSIA INVASION ON ECONOMY

OUTLOOK

OVERVIEW OF WIRE AND CABLE INDUSTRY

GLOBAL WIRE AND CABLE MARKET HISTORIC TRENDS

THE CHART BELOW SHOWS THE GROWTH OF THE GLOBAL WIRE AND CABLES MARKET FROM 2020 – 2029 IN USD

GLOBAL WIRE AND CABLE MARKET FORECAST GROWTH

THE CHART AND TABLE BELOW SHOW THE YEAR-ON-YEAR GROWTH OF THE GLOBAL WIRE AND CABLES MARKET FROM 2023 – 2032.

INDIAN WIRE AND CABLE INDUSTRY MARKET

GROWING SHARE OF ORGANIZED PLAYERS

COVID IMPACT ON WIRE AND CABLE INDUSTRY

GROWTH & DEMAND DRIVERS OF WIRE AND CABLE INDUSTRY

CABLES AND WIRES DEMAND DRIVERS

SUPERIOR QUALITY PRODUCT IN HOUSING WIRES LED TO HIGHER MARGINS FOR ORGANIZED PLAYERS

HOUSING SECTOR:

NHB INDIA HOUSING PRICE INDEX*

HOUSING DEMAND-SUPPLY UNITS IN TOP 8 CITIES 2016-2020

INFRASTRUCTURE:

PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES

2. POWER

INDUSTRIAL EXPANSION AND STRONG GDP GROWTH DRIVING POWER DEMAND

1. RAILWAYS:

1. GROWING DEMAND

2. POLICY SUPPORT

3. INFRASTRUCTURE DEVELOPMENT

4. TELECOMMUNICATION

STRONG GROWTH IN BROADBAND DRIVES INTERNET ACCESS REVENUES

KEY COMPANIES IN THE MARKET

CHALLENGES FACED BY THE INDUSTRY

CYCLICAL MARKET

CONVERSION INDUSTRY AND WORKING CAPITAL

DE-REGULATION LOWERS BARRIERS OF ENTRY

INCREASED RAW MATERIAL PRICES

GOVERNMENT INITIATIVES UNDERTAKEN FOR INDUSTRY

1. HOUSING FOR ALL

PROGRESS OF PMAY:

PRADHAN MANTRI AWAS YOJANA-URBAN (PMAY-U)

PRADHAN MANTRI AWAS YOJANA GRAMIN (PRADHAN MANTRI AWAS YOJANA RURAL)

1. GOVERNMENT’S FOCUS ON IMPROVING ELECTRIFICATION

1. MAKE IN INDIA

2. SMART CITIES MISSION

COMPETITIVE ANALYSIS & KEY INDUSTRY PLAYERS

1. PORTER FIVE FORCES ANALYSIS

• THREATS OF NEW ENTRANTS

• BARGAINING POWER OF SUPPLIERS

• BARGAINING POWER OF BUYERS

• THREATS OF SUBSTITUTE PRODUCTS OR SERVICES

• COMPETITION AMONG THE EXISTING COMPETITORS

IMPLICATIONS OF PORTER FIVE FORCES ON WIRE & CABLE COMPANY

1. MANUFACTURING PROCESS

1. CONDUCTOR

3. CABLES & WIRES PLAYERS IN THE INDUSTRY

MOST OF THE ELECTRICAL PLAYERS HAVE DIVERSIFIED OVER THE LAST FIVE YEARS

1. FINOLEX CABLES LIMITED

2. KEI INDUSTRIES LIMITED

3. POLYCAB INDIA LIMITED

4. HAVELLS INDIA LIMITED

1. RR KABEL LIMITED

2. V-GUARD INDUSTRIES LIMITED

7. PLAZA WIRES LIMITED

PRODUCT PROFILE OF PLAZA CABLES:

TOTAL REVENUE CONTRIBUTION

KEY INDUSTRIAL REGULATIONS AND POLICIES

GENERAL CORPORATE COMPLIANCE

THE COMPANIES ACT, 2013

SEBI REGULATIONS

THE ARBITRATION AND CONCILIATION ACT, 1996

TAX RELATED REGULATIONS

INCOME TAX ACT, 1961

GOODS AND SERVICE TAX ACT, 2017

CUSTOMS ACT, 1962

THE GUJARAT STATE TAX ON PROFESSIONS, TRADERS, CALLINGS AND EMPLOYMENTS RULES, 1976

BUSINESS / TRADE RELATED LAWS / REGULATIONS

THE ELECTRICAL WIRES, CABLES, APPLIANCES AND PROTECTION DEVICES AND ACCESSORIES (QUALITY CONTROL) ORDER, 2003

THE INDIAN ELECTRICITY RULES, 1956

THE BUREAU OF INDIAN STANDARDS ACT, 2016 (“BIS ACT”)

LEGAL METROLOGY ACT, 2009 (THE “LM ACT”) AND THE LEGAL METROLOGY (PACKAGED COMMODITIES) RULES, 2011 (THE “LMRULES”)

E-WASTE (MANAGEMENT AND HANDLING) RULES, 2022 (“E-WASTE RULES”)

PLASTIC WASTE MANAGEMENT (PWM) RULES, 2016 AND AMENDMENTS THERETO

ENVIRONMENT LAWS

NATIONAL ENVIRONMENTAL POLICY, 2006

FOLLOWING ARE THE OBJECTIVES OF NATIONAL ENVIRONMENTAL POLICY:-

ENVIRONMENTAL LEGISLATIONS

THE NOISE POLLUTION (REGULATION AND CONTROL) RULES, 2000

HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRAN BOUNDARY MOVEMENT) RULES, 2016 (“HAZARDOUS WASTE RULES”) AND AMENDMENTS THERETO

ENVIRONMENT IMPACT ASSESSMENT NOTIFICATION OF 2006

PUBLIC LIABILITY INSURANCE ACT, 1991

REGULATIONS RELATED TO FOREIGN TRADE AND INVESTMENT

THE FOREIGN DIRECT INVESTMENT

FOREIGN EXCHANGE MANAGEMENT ACT, 1999 (“FEMA”) AND REGULATIONS FRAMED THEREUNDER

DUTY DRAWBACK SCHEME

OWNERSHIP RESTRICTIONS OF FIIS

FOREIGN TRADE POLICY 2023

LAWS RELATED TO EMPLOYMENT OF MANPOWER

THE INDUSTRIAL (DEVELOPMENT AND REGULATION) ACT, 1951

THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE, 2020

THE CODE ON SOCIAL SECURITY, 2020

EMPLOYEES PROVIDENT FUND AND MISCELLANEOUS PROVISIONS ACT, 1952

THE EMPLOYEES COMPENSATION ACT, 1923

THE EMPLOYEES’ STATE INSURANCE ACT, 1948 (THE “ESI ACT”)

THE FACTORIES ACT, 1948

THE MINIMUM WAGES ACT, 1948

PAYMENT OF GRATUITY ACT, 1972, AS AMENDED (THE “GRATUITY ACT”)

THE MATERNITY BENEFIT ACT, 1961

THE PAYMENT OF BONUS ACT, 1965

THE EQUAL REMUNERATION ACT, 1979

THE CHILD LABOUR PROHIBITION AND REGULATION ACT, 1986

THE TRADE UNION ACT, 1926 AND TRADE UNION (AMENDMENT) ACT, 2001

THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION, PROHIBITION AND REDRESSAL) ACT, 2013

THE INDUSTRIAL DISPUTES ACT, 1947 (“ID ACT”) AND INDUSTRIAL DISPUTE (CENTRAL) RULES, 1957

LAWS RELATING TO INTELLECTUAL PROPERTY

TRADEMARKS ACT, 1999

THE PATENTS ACT, 1970

THE DESIGNS ACT, 2000 (DESIGNS ACT)

THE COPYRIGHT ACT, 1957

OTHER GENERAL RULES AND REGULATIONS

THE MICRO, SMALL AND MEDIUM ENTERPRISES DEVELOPMENT ACT, 2006 (“MSME ACT”)

STATE LAWS

MUNICIPALITY LAWS

OTHER REGULATIONS

PROPERTY RELATED LAW

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF COOPER WIRE ROD

SUPPLIERS OF PVC COMPOUND CABLE GRADE

SUPPLIERS OF PACKAGING MATERIALSSUPPLIERS 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 COOLING TOWER

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

BUNCHING MACHINE MANUFACTURERS

STRANDING MACHINE MANUFACTURERS

MATERIAL HANDLING EQUIPMENTS

LABORATORY TESTING EQUIPMENTS

STEEL WIRES

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF JIGS AND FIXTURE

SOLAR CABLE MANUFACTURERS

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:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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

GENERATION AND MANAGEMENT OF WASTES

SOLID WASTES

LIQUID WASTES

GASEOUS EMISSION

OTHERS

INDUSTRIAL WASTE MANAGEMENT

SEWERAGE SYSTEM

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

SAFETY DATA SHEETS

ENVIRONMENTAL/SAFETY LIABILITY

PRE-PROJECT ACTIVITIES

PROPOSED IMPLEMENTATION SCHEDULE

PLANT LAYOUT

STATUTORY APPROVALS FROM GOVERNMENT

LIST OF DOCUMENTS REQUIRED FOR LICENSES

SWOT ANALYSIS

1. STRENGTH

2. WEAKNESS

3. OPPORTUNITY

4. THREATS

ORGANIZATION CHART

ORGANIZATIONAL STRUCTURE

1. MANAGER

DUTIES AND RESPONSIBILITIES

2. THE MANUFACTURING DEPARTMENT DUTIES AND RESPONSIBILITIES: -

3. ADMINISTRATION AND FINANCE DEPARTMENT

DUTIES AND RESPONSIBILITIES:-

FINANCE SECTION

DUTIES AND RESPONSIBILITIES:-

4. MARKETING AND SALES DEPARTMENT

FUTURE DEVELOPMENT

ENVIRONMENTAL IMPACT OF THE PROJECT

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)