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    Detailed Project Report on hard anodizing industry with cookwares and kitchenwares

    Detailed Project Report on hard anodizing industry with cookwares and kitchenwares
    Detailed Project Report on hard anodizing industry with cookwares and kitchenwares
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      HARD ANODIZING INDUSTRY WITH COOKWARES AND KITCHENWARES
       [CODE NO.3121 ]  



      Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts. The process is called
      anodizing because the part to be treated forms the anode electrode of an electrical circuit.

      Anodizing increases corrosion resistance and wear resistance, and provides better adhesion for paint primers and glues than bare metal. Anodic films can also be used for a number of cosmetic effects, either with thick porous coatings that can absorb dyes or with thin transparent coatings that add interference effects to reflected light. Anodizing is also used to prevent galling of threaded components and to make dielectric films for electrolytic capacitors. Anodic films are most commonly applied to protect aluminium alloys, although processes also exist for titanium, zinc, magnesium, niobium, and tantalum. This process is not a useful treatment for iron or carbon steel because these metals exfoliate when oxidised; i.e. the iron oxide (also known as rust) flakes off, constantly exposing the underlying metal to corrosion.

      Anodising changes the microscopic texture of the surface and changes the crystalstructure of the metal near the surface. Thick coatings are normally porous, so a sealing process is often needed to achieve corrosion resistance. Anodised aluminium surfaces, for example, are harder than aluminium but have low to moderate wear resistance that can be improved with increasing thickness or by applying suitable sealing substances. Anodic films are generally much stronger and more adherent than most types of paint and metal plating, but also more brittle. This makes them less likely to crack and peel from aging and wear, but more susceptible to cracking from thermal stress.

      Preceding the anodizing process, wrought alloys are cleaned in either a hot soakcleaner or in a solvent bath and may be etched in sodium hydroxide (normally with added sodium gluconate), ammonium bifluoride or brightened in a mix of acids. Cast alloys are normally best just cleaned due to the presence of

      intermetallic substances unless they are a high purity alloy such as LM0.

      The anodised aluminium layer is grown by passing a direct current through an electrolytic solution, with the aluminium object serving as the anode (the positive electrode). The current releases hydrogen at the cathode (the negative build-up of aluminium oxide. Alternating current and pulsed current is also possible but rarely used. The voltage required by various solutions may range from 1 to 300 V DC, although most fall in the range of 15 to 21 V. Higher voltages are typically required for thicker coatings formed in sulphuric and organic acid. The anodising current varies with the area of aluminium being anodised, and typically ranges from 0.3 to 3 amperes of current per square decimetre (20 to 200 mA/in²).

      Aluminium anodising is usually performed in an acid solution which slowly dissolves the aluminium oxide. The acid action is balanced with the oxidation rate to form a coating with nanopores, 10-150 nm in diameter. These pores are what allow the electrolyte solution and current to reach the aluminium substrate and continue growing the coating to greater thickness beyond what is produced by autopassivation. However, these same pores will later permit air or water to reach the substrate and initiate corrosion if not sealed. They are often filled with coloured dyes and/or corrosion inhibitors before sealing.

      Because the dye is only superficial, the underlying oxide may continue to provide corrosion protection even if minor wear and scratches may break through the dyed layer.

      The most widely used anodising specification, MIL-A-8625, defines three types of aluminium anodising. Type I is Chromic Acid Anodising, Type II is Sulphuric Acid Anodising and Type III is sulphuric acid hard coat anodizing


      COST ESTIMATION

      Plant  Capacity                                :       10000.00 SQ.FT/day
      Land & Building (2000 Sq.Mtr)    :    Rs. 5.44  Cr
      Plant & Machinery                          :    Rs. 3.38  Cr
      Working Capital for 2 Month        :    Rs. 63.11 Lacs
      Total Capital Investment               :    Rs. 9.78  Cr
      Rate of Return                                :    31%
      Break Even Point                           :    53%



      INTRODUCTION                                    
      TYPES OF ANODISING                                
      TYPE-I(CHROMIC ACID ANODISING)                            
      SPECIFICATION                                    
      CONSIDERATIONS FOR HARD ANODISING                        
      MATERIALS:                                    
      PROPERTIES:                                    
      GENERATE CLEAR CRYSTALLINE COATINGS                        
      INCREASE OF SURFACE HARDNESS AND ABRASION RESISTANCE        
      INCREASE CORROSION RESISTANCE                            
      BENEFITS                                    
      ADVANTAGES                                    
      USES AND APPLICATIONS                                
      B.I.S SPECIFICATION                                
      MARKET SURVEY                                    
      COMPETITIVE ADVANTAGES                                
      CHALLENGES                                    
      FUTURE GROWTH OF KITCHENWARE PRODUCTS                    
      OVERVIEW OF INDIAN KITCHENWARE INDUSTRY                    
      OVERVIEW OF METAL FINISHING AND KITCHENWARE INDUSTRY (GLOBAL)    
      EXPORT DATA OF KITCHENWARE                            
      EXPORT OF KITCHENWARE (%AGE)                            
      EXPORT DESTINATION OF KITCHENWARE                        
      PRESENT MANUFACTURERS AND SUPPLIERS OF KITCHENWARE & COOKWARE                    
      SWOT ANALYSIS                                            
      PROCESS FLOW CHART                                    
      PROCESS OF HARD ANODISING                                
      SURFACE PREPARATION                                    
      CHEMICAL CLEANING                                        
      THERE ARE TWO METHODS OF CHEMICAL ETCHING                
      ELECTROPOLISHING                                        
      CHEMICAL POLISHING                                        
      HARD ANODISING                                        
      RINSING                                                
      PLANT LAYOUT                                            
      SUPPLIERS OF RAW MATERIALS                                
      HARD ANODIZING                                        
      CAUSTIC SODA                                            
      HYDROCHLORIC ACID                                        
      DEGREASING CHEMICALS                                    
      PACKING MATERIALS                                        
      SUPPLIERS OF PLANT AND MACHINERIES                        
      HARD ANODISING PLANT                                    
      BENCH POLISHING MACHINE                                
      EOT CRANES                                            
      DG SETS                                                
      POWER TRANSFORMERS                                    
      COOLING TOWER                                            
      AIR POLLUTION CONTROL EQUIPMENTS                            
      AIR CONDITIONING EQUIPMENTS                                
      AIR COMPRESSOR                                        
      PLATEFORM WEIGHING MACHINE                                
      MATERIAL HANDLING EQUIPMENTS                            
      FIRE FIGHTING EQUIPMENTS                                
      SUBMERSIBLE WATER PUMP                                    
                                                 

      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      

       

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