Detailed Project Report (DPR) on match box industry (automatic plant)

MATCH BOX INDUSTRY (AUTOMATIC PLANT)
 [CODENO. 3181]

    The origin of the safety match industry in India goes back to the beginning of this century. Around 1910 immigrant Japanese families who settled in Calcutta began making matches with simple hand- and power-operated machines. Local people soon learned the necessary skills and a number of small match factories sprang up in and around Calcutta.

    These small match factories could not meet the total requirements of the country however, and India began to import matches from Sweden and Japan. During the First World War, when Swedish matches could not be imported, the Indian market was fed mainly by imported matches from Japan and by the locally made ones which followed the Japanese pattern introduced in Calcutta.
 
After the war, factories in Calcutta were unable to compete with imports, and handmade match production shifted to southern India, especially in the Ramanathapuram and Tirunelveli districts of Tamil Nadu State.

This shift was due to the pioneering efforts of P. Iya Nadar and A. Shanmuga Nadar who went to Calcutta to learn the process from Purna Chandra Ray, a local businessman, who had learned the trade in Germany. The Nadars set up a number of manual match production units in extremely poor regions of Tamil Nadu, where a combination of the dry climate, cheap labour and availability of raw materials from nearby Kerala created ideal conditions for match production. The first sulphur match that would bum when brought into contact with a rough surface was produced in South India in 1923, and the first safety match, in the form we know today, in 1932.

COST ESTIMATION

Plant  Capacity                              :    150000.00 Match Box/day
land & Building (1200 sq.mt.)    :    Rs. 2.13  Cr
Plant & Machinery                         :    Rs. 1.48  Cr
Working Capital for 1 Month       :    Rs. 15.39 Lacs
Total Capital Investment             :    Rs. 3.87 Cr
Rate of Return                              :    22%
Break Even Point                         :    59%

INTRODUCTION    
HISTORICAL BACKGROUND    
PROCESSING AND ANCILLARY INDUSTRIES    
AILANTHUS MALABARICA, DC    
RAW MATRIALS    
SUITABILITY OF WOOD REQUIRED FOR INDIAN MATCH INDUSTRY    
PROPERTIES    
B.I.S. SPECIFICATIONS    
INDIAN AND GLOBAL MARKET POSITION OF MATCH BOXES    
NUMERO UNO    
UNUSUAL COMPETITOR    
NON – EXTINGUISHING    
DETAILED EXPORT DATA OF MATCH BOXES    
DETAILED IMPORT DATA OF MATCHBOX    
EXPORT OF SAFETY MATCHES    
FUTURE OF MATCHBOX INDUSTRY    
PRESENT MANUFACTURERS/EXPORTERS OF MATCH BOXES    
KINDS OF MATCHES    
PROCESS    
QUALITY ASSURANCE IS OUR PAST, PRESENT & FUTURE    
PREPARATION OF SPLINTS AND BOXES    
THE STANDARD FORMULATION FOR PREPARING TIP COMPOSITION
   ARE AS FOLLOWS:    
PREPARATION OF MATCH BOX SIDE COMPOUND    
CONTINUOUS MATCH MAKING MACHINE    
MANUFACTURE OF SAFETY MATCHES IN THE NON MECHANISED SECTOR    
DIPPING OPERATION IN THE NON-MECHANISED SECTOR    
PROCESS DESCRIPTION FOR THIS PROJECT    
THE MANUFACTURING PROCESS    
CUTTING THE MATCHSTICKS    
TREATING THE MATCHSTICKS    
FORMING THE MATCH HEADS    
PACKAGING THE MATCHES    
QUALITY CONTROL    
THE FUTURE    
PRINCIPLES OF PLANT LAYOUT    
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
SPECIFIC FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
COMPLETE SUPPLIERS OF PLANT & MACHINERY    
FOREIGN SUPPLIERS OF MACHINERY    
EXPORTERS AND SUPPLIERS OF MATCH SPLINTS (RAW MATERIALS)    
POTASSIUM CHLORATE    
POTASSIUM DICHROMATE    
RED PHOSPHORUS    
ADHESIVES    
PRINTING INK    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET