Detailed Project Report (DPR) on manufacturing plant of empty lpg steel cylinder varies from 11kg, 12.5kg, 22.5kg, 44kg, 54.5kg, 104kg etc.

MANUFACTURING PLANT OF EMPTY LPG STEEL CYLINDER VARIES FROM 11KG, 12.5KG, 22.5KG, 44KG, 54.5KG, 104KG ETC. [3672]

LPG Cylinder is an essential item for filling liquefied petroleum gas used for cooking purpose. The body of LPG cylinder is deep drawn in two pieces then these are welded together to make a compact unit without any leak and defect etc. LPG cylinders are in use in 5 Kg., 12 Kg., 14.2 Kg. & 19 Kg. capacities. To ascertain the quality, safety and performance certain regulations are applicable such as BIS standardization and Explosive License etc. While all the cylinders are spray-painted with a signal red colour. BPC cylinders have yellow ring around the bung. HPC cylinders in blue ring and IOC cylinder are fully red. In case of 19 Kg. cylinders the top is painted olive green.

The cylinders carry their complete history with regard to their serial number, Tare/ Gross weight, water capacity, ISE monogram test date, manufacturer identification and year of manufacturing. LP Gas cylinders can come in many different sizes depending on the application. The gross weight of an LP Gas cylinder is often one of the limiting factors in selecting the size, especially for domestic applications.

The diameter is also a very important factor because it has implications with the dimensions of the conveyors in the filling plant, and the pallets and racks used for storage etc. For domestic use, cylinders typically will have capacities ranging from 4kg to 15kg whereas for commercial and industrial use, these will range from 45kg to 50kg. Smaller cylinders i.e. 1kg to 3kg capacities are used for camping equipment and in developing countries where they often serve as an entry level for LP Gas applications in low income households - mainly for cooking. LP Gas cylinders will almost always be used in the vertical position although forklift cylinders are typically designed to be used horizontally with capacities ranging from 15kg to 22kg.

COST ESTIMATION

Plant Capacity      1800 Nos/Day  
Land & Building (3000 sq.mt.)  Rs. 2.04 Cr.    
Plant & Machinery                    Rs. 7.87 Cr.
Working Capital for 2 Months   Rs. 12.54 Cr.
Total Capital Investment          Rs. 22.88 Cr.
Rate of Return                         64%
Break Even Point                     35%



INTRODUCTION    
SIZES OF LPG CYLINDER    
CONSTRUCTION OF LPG CYLINDER    
1. BODY    
2. BUNG    
3. SHROUD    
4. FOOT RING    
5. VALVES    
(A) SELF-CLOSING, CLIP-ON VALVE    
(B) HAND WHEEL OPERATED VALVE    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
QUALITY STANDARD:    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
MATERIAL    
(A) FOR PRESSURE PARTS    
(B) NON-PRESSURE PARTS    
GENERAL    
THE MAIN STEPS ARE GIVEN BELOW    
QUALITY CONTROL    
(A) MATERIAL SPECIFICATIONS:    
(B) WELDING SPECIFICATION    
(C) MANUFACTURING PROCESS SPECIFICATION    
(A) CYLINDER BODY    
(B) VALVE PROTECTION RING-STAY PLATE ASSEMBLY    
(C) FOOTRING    
(D) HEAT TREATMENT    
(E) SURFACE PREPARATION & PAINTING:    
(F) TESTING:    
(G) SCREEN PRINTING/STENCILLING:    
(H) STAMPINGS & PUNCHING:    
1. STAMPING ON BUNG:    
2. STAMPING ON THE STAY PLATES:    
(I) VALVE FIXING:    
(J) WEIGHMENT OF CYLINDER:    
(K) PACKING:    
GLOBAL MARKET OVERVIEW    
LPG PRODUCTION GROWTH IS STRONG IN THE US AND CANADA, BUT
   OTHER REGIONS ARE ALSO GROWING QUICKLY    
THE US MUST EXPORT LPG BECAUSE DOMESTIC DEMAND CAN’T KEEP
   UP WITH SHALE-BASED PRODUCTION – EVEN AT LOWER OIL PRICES    
THE US WILL REMAIN THE WORLD’S LARGEST LPG EXPORTING COUNTRY    
GLOBAL LPG DEMAND GROWTH WILL CONTINUE TO BE LED BY ASIA
   AND THE MIDDLE EAST    
RESIDENTIAL/COMMERCIAL LPG DEMAND IS GROWING STEADILY BUT CHEMICALS DEMAND IS GROWING FASTER    
WITH LATIN AMERICA SATURATED AND EUROPE VERY COMPETITIVE,
   MOST INCREMENTAL US EXPORTS WILL NEED TO MOVE TO ASIA    
LPG IS A SUPPLY-DRIVEN MARKET. SOME SUPPLY FORECAST UNCERTAINTIES:    
REFINING    
ASSOCIATED GAS    
NON-ASSOCIATED GAS    
BIO-LPG    
THE LPG MARKET MUST (EVENTUALLY) CLEAR. SOME DEMAND
   FORECAST UNCERTAINTIES:    
RESIDENTIAL / COMMERCIAL    
CHEMICALS    
AUTOGAS    
INDUSTRIAL    
OTHER THINGS THAT KEEP LPG RESEARCHERS UP AT NIGHT…    
WATERBORNE LOGISTICS    
GEOPOLITICS    
SUPPLY DISTANT FROM DEMAND CENTERS    
DISRUPTIVE TECHNOLOGIES    
CRUDE OIL PRICES: A MODEST GLOBAL OIL PRODUCTION DEFICIT WILL
    SUPPORT A GRADUAL, BUT RISING PRICE TREND IN 2017-18    
CRUDE OIL SUPPLY DISRUPTIONS: GLOBAL SPARE CAPACITY IS NOW
   AT ABOUT ONE THIRD OF ITS 2010 LEVEL    
“HIGH-GRADING”: US PROPANE PRODUCTION HAS GENERALLY BEEN FOLLOWING CRUDE OIL PRODUCTION WITH AN INFLUENCE BY NATURAL
   GAS – UNTIL RECENTLY…    
PERMIAN PRODUCTION: WITH HIGHER RESERVES AND PRODUCTIVITY,
   HAVE WE UNDERESTIMATED THE PRODUCTION FORECAST?    
GLOBAL LPG DEMAND: WILL ASIAN DEMAND BE STRONG ENOUGH TO CONSUME THE GLOBAL LPG SURPLUS?    
DEMAND COMPETITION: WILL A GLUT OF LNG DISPLACE LPG DEMAND
   IN KEY COUNTRIES?    
US LPG EXPORT CAPACITY: CAPACITY COULD BE TIGHT AGAIN IN
   THE 20’S UNLESS THERE IS FURTHER EXPANSION    
THE VLGC FLEET: CURRENTLY OVERSUPPLIED, BUT HOW DOES
   MARPOL IMPACT THE FLEET?    
LARGEST WORLD PRODUCERS    
USA HAS BECOME ON OF THE LARGEST EXPORTERS OF LPG
    IN THE WORLD.    
LARGEST WORLD CONSUMERS    
ASIAN CONSUMERS REPRESENT THE BIGGEST SHARE OF THE
   GLOBAL DEMAND.    
WORLD CONSUMERS BY SECTOR – 2015    
LPG FINAL CONSUMPTION BY SECTOR    
RESIDENTIAL SECTOR IS THE LARGEST COMPONENT OF THE GLOBAL
   DEMAND. ADDITIONALLY, CHEMICAL INDUSTRY IS GETTING MORE
   RELEVANT.    
LARGEST WORLD EXPORTERS AND IMPORTERS    
USA LPG SURPLUS GOES MAINLY TO THE ASIAN MARKET.    
PLANT LAYOUT    
MANUFACTUERS/SUPPLIERS OF LPG CYLINDER    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF M.S. SHEETS    
SUPPLIERS OF LPG CYLINDER VALVE    
SUPPLIERS OF BUNG    
SUPPLIERS OF SHROUD AND FOOT RING    
SUPPLIERS OF MIG WELDING WIRE ELECTRODE    
SUPPLIERS OF POWDER COATING PAINT    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF SHEARING MACHINE    
SUPPLIERS OF DEEP DRAWING PRESS    
SUPPLIERS OF CIRCLE CUTTING MACHINE    
SUPPLIERS OF POWER PRESS    
SUPPLIERS OF TRIMMING MACHINE    
SUPPLIERS OF MIG WELDING MACHINE    
SUPPLIERS OF HEATREATMENT FURNACE    
SUPPLIERS OF SAND BLASTING MACHINE    
SUPPLIERS OF BENCH GRINDER    
SUPPLIERS OF DRILLING MACHINE    
SUPPLIERS OF LPG CYLINDER TESTING MACHINE    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF DG SETS    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF POWDER COATING MACHINE    
SUPPLIERS OF HOT DIP GALVANISING PLANT    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF PAINTING EQUIPMENTS    

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)