Professional Documents
Culture Documents
OF
SS INDUSTRIES
Prepared By GSK & CO.,
Chartered Accountants
2.
03
06
3.
4.
08
15
5.
16
6.
17
7.
APPROVALS REQUIRED
19
8.
SCHEDULE OF IMPLEMENTATION
20
9.
21
10.
PROJECT ECONOMIES
25
11.
SWOT ANALYSIS
28
12.
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13.
SUPPLIERS LIST
30
14.
CONCLUSION
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company has also requested for the working capital limits of Rs 65.00 lakhs and
Domestic L.C 50.00 Lakhs.
Project Cost:
The total estimated project cost of the proposed manufacturing unit is
164.26Lakhs and the details are given in the table below:
A. PROJECT COST
(Rs in Lakhs)
1.
2.
3.
4.
Description
Plant & Machinery
Electrical Equipment including transformer
Civil Works
IDC
Total
Amount
152.26
3.00
7.50
1.50
164.26
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and the refund of the Indirect taxes, as per the Telangana new Industrial
policy 2015.
Working Capital
The applicant has requested for the working capital limits of Rs 65.00 lacs and Rs
50.00 lakhs Letter of Credit for the purchase of the raw materials to meet the day
to day expenses of the company and to bridge the working capital gap.
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Introduction.
Plastic extrusion of tube, hose and pipe is a steady-state process for converting a
thermoplastic raw material to a finished or near-finished annular product. The raw
material is usually in the form of plastic pellets or powder. The conversion takes
place by forming a homogeneous molten mass in the extruder and forcing it under
pressure through an extrusion die orifice that defines the shape of the product's
cross section. The formed material, or extrudate, is cooled and drawn away from
the die exit at a controlled rate. The extrudate can then be wound on a spool, cut
to a specified length, or directed into another in-line process. By contrast with
injection molding or blow molding, which are cyclic processes, extrusion is a steadystate process. This steady-state characteristic produces some unique benefits and
challenges as a manufacturing process. Extruded products are very long and
continuous, and have a cross section that is usually constant with respect to the
axis or direction of production. Injection-molded products are discrete items with
varying cross sections in each axis. The fact that the extrusion of tube, hose and
pipe is a steady-state process will be discussed in many areas of this article.
The terminology used for describing tube, hose and pipe varies from industry to
industry.
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For the use in this article, tube products are 1 in outer diameter or less, and are
products that need to be flexible in their use. Examples of tubing include medical
catheters or flexible pneumatic tubing. Hose products are generally 1 in outer
diameter and greater, and are products that also are flexible in their use. Garden
or irrigation hose are good examples of hose products. Pipe products are generally
rigid in form when compared to tubing and hose, and can be any diameter in size.
Pipe products can range from diameter water pipe made from CPVC, up to 60
diameter corrugated drainage pipe made from HDPE. These naming conventions are
arbitrary and are used for convenience.
Equipment.
The major components of a tube, hose, or pipe extrusion system are often divided
into components that are upstream of the extruder, the extruder itself, and those
that are downstream of the extruder. Upstream components include resin handling
equipment for conveying the raw materials to the extruder, and resin conditioning
equipment that will pre-heat the resin, or control the moisture content of the resin
before it enters the extruder feed throat. The downstream components include a
molten resin filter or screen changer, the extrusion die assembly, the quench or
vacuum sizing tank, any product measurement instruments, the extrusion line speed
controller in the form of a belt puller or nip roll set, and finally a product cut-off
device or winding equipment. There are additional extrusion process methods that
will take the extruded product directly into another in-line process for the addition
of a reinforcement braiding or for the addition of other coatings or resin
layers.
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Materials.
Extrusion techniques can be used to process most thermoplastics and some
thermoset plastics. The resins most commonly extruded for tube, hose and pipe
products include high and low density polyethylene, polypropylene, polyurethane,
polystyrene, fluoropolymers, nylon, polyester, ABS, and flexible and rigid PVC. A
characteristic that often differentiates extruded resins from injection-molded
resins is the melt viscosity of the plastic at normal processing temperatures.
Extruded plastics often have a higher melt viscosity, which allows the extrudate to
retain the shape imparted to it by the die while the extrudate is in the quenching
stages.
Combinations of various resins can be used to gain special physical, biological, or
chemical properties. Many additives can be used during the extrusion process to
enhance processing characteristics of the polymer or to alter product properties.
Such additives include lubricants, thermal stabilizers, antioxidants, radiopacifying
agents, and colorants.
Processing Parameters.
The parameters important to extrusion processing are similar to those of injection
molding processes. Resin temperature, resin pressure, resin moisture content,
screw speed, and screw motor amperage are usually controlled or monitored to
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The Extruder.
Selection criteria.
The performace requirements of the extruder are being successfully met when the
desired ouputs are being attained, with adequate resin melting and melt
homogeneity, at a constant discharge pressure and melt temperature. When an
extruder is selected for a process, the following extruder parameters need to be
considered:
Extruder diameter.
L/D raio.
Feedscrew design.
Feedscrew RPM range and interchangeability.
Available torque and horsepower.
Gearbox design and thrust capacity.
The distribution of barrel heating zones.
The type of barrel cooling.
The need for venting the barrel.
The need for feedscrew cooling. The design of the feedscrew and the hardfacing
of the barrel liner. The control instrumentation arrangement.
The extruder is discussed in other areas of this book in great detail. Suffice it to
say that for this article that the job of the extruder in the manufacturing of tube,
hose and pipe, is to deliver a homogeneous melt material, at a fixed and uniform
rate, at a fixed head pressure, and a fixed melt temperature. It is much easier
stated than accomplished. As many variables are in action together in this system,
as the variables interact, they will cause process variations of greater or lesser
magnitude that will manifest themselves in the extruded product quality.
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Page 24
Swimming pools and spas.
Writing instruments.
Lawn and garden.
Automotive.
Consumer products / packaging.
Appliances.
Marine.
Industrial hose.
a)
RAWMATERIALS
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The raw materials required for the production of the products are
PVC(POLY VINYL CHLORIDE) Resine , CPW (CHLORINATED PARAFIN
WAX) and DOP ( DI OCTYLE PSYLIDE)
b)
Water
The water consumption for the process is 1 Cubic Meters per day for doing
hydro test for Equipment for finding out leakages in welding. The total
requirement of water works out can be met out of the bore well.
c)
Effluents
The effluents are the tin stabilizers and the colors foe the coloring
d)
Manpower
e) Power
The power requirement is 100 hp and source of Power is drawn from
TCPDCL and 750 KVA Generator is purchasing to avoid Power cut
Problems.
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Project Cost:
32
Description
Plant & Machinery
Electrical Equipment including transformer
Civil Works
IDC
Amount
152.26
3.00
7.50
1.50
Total
164.26
B. MEANS OF FINANCE
(Rs in Lakhs)
Description
Amount
54.26
110.00
Total
164.26
Total
D/E Ratio
2.03
Debt component
66.97%
equity Component
33.03%
The current proposal is for the establishing manufacturing plant for Dradied Hose
Pipes , Garden Tubing Pipes, Lldpe Krishi Pipes , with a total built up area of 1400
sft ( which shall include the Machinery erection ,building, civil) and , the total
project cost is Rs 164.26 lakhs of which the company has requested for the term
loan of Rs 110.00 lakhs for the purchase of the machinery and the establishment of
the unit like the building and the machinery as detailed in, the company shall infuse
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the remaining
Rs 54.26 lakhs
In Tanzania all the approvals and the permissions are provide by a single
window approving authority called Tanzania Investment Centre ( TIC).
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Authority
Registrar with
Partnership
TCPDCL
Department of
Commercial
Taxes
DIC
District Industries
Centre
Purpose
Certificate
of
Incorporation
Power
Status
Completed
Value
Added Tax &
CST
All Approvals
& SSI
Ssi
Registration
Completed
Completed
Completed
Completed
8.SCHEDULE OF IMPLEMENTATION
Particulars
Date of
Date of Completion
Commencement
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`Land Acquisition
Civil Works
Plant & Machinery
-
Placement of Orders
- Delivery
Erection & Commissioning
Trail Runs
Commercial Production
01-05-2015
01-06-2015
Completed
1-07-2015
01-09-2015
15-09-2015
01-10-2015
31-05-2015
31-08-2015
Completed
31-08-2015
15-09-2015
30-09-2015
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The company has started its expelling unit under leased premises at plot no
90 sy no 63 of 120 sq yards of1400 sft in pedda amberpet village, RR Dist
with a installed capacity of 75 TPD and the operating capacity at 60%, and
started its commercial activity from October 2015
REVENUE ASSUMPTIONS
The first full year of operation is for the FY 2016-17
1. The financial year is taken from 1st October 2015 to 31 st March 2016.
2. The total number the working days are taken at 300 days per annum.
Revenue projections
The total products are
1. Flexible garden Hose Pipe
2. Braded Hose pipe
The total installed capacity of the product is 600 MT per annum for both
the
product
and
the
operating
capacity
is
Capacity
Selling
price
in Rs per ton
Flexible
garden
Hose Pipe
Braded Hose pipe
100.00%
82,000/100.00%
1,10,000/-
EXPENDITURE ASSUMPTIONS
1.The purchase price of the rawmaterial is as follows for Flexible garden
pipe
Particulars
Percentage
of the
computation
Rs per ton
32
50.00%
84000
CPW
49.50%
57000
0.50%
300000
The purchase price of the rawmaterial is as follows for Garden Hose pipe
Particulars
Pvc Resine for Flexible garden Hose
pipe
Percentage
of the
computation
Rs per ton
50.00%
84000
CPW
30.00%
57000
19.75%
98000
0.25%
300000
2. Other expenses
a. Power is taken at 20,000 units per month at 7.00 per unit.
b. The water consumption is 30000 iters per month @ 1 Rs per liter
Administrative and Selling expenditures are taken at 0.50% of the sales
Repairs and maintenance
Repairs & Maintenance
Buildings
Plant & Machinery
Electricals & Misc. Fixed Assests
0.50%
0.50%
0.50%
Particulars
No
Salary per
Month n Rs
Salary per
head per Annum
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Direct Wages
Supervisor
35000
Accounts Officer
15000
Electrician
15000
20
8000
19
Peons
5000
Operators
15000
Marketing
15000
UnSkilled Labor
38
1.92
40.32
30
40.32
9. The bank interest rates are taken at 12.00 % for term loan and 13.00%
for working capital.
10. The depreciation rates are considered at the following rates as per
Income Tax act .
Particulars
Dep as per
Income
Tax
Dep
as per
com
act
3.34%
Factory
10%
Buildings
Plant
&
15%
5.28%
Machinery
Electricals &
25%
7.07%
Misc. Fixed
Assests
11.Income tax rates is taken at 32.5% as per Income tax including surcharge
of 5%
12. Mat is considered at 20.01 %
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during the
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PBT figures are shown in the table below. The detailed calculations are
presented in Appendix 7.
Particulars
2015-
2016-
2017-
2018-
2019-
2020-
2021-
16
17
18
19
20
21
22
PBT (in
Rs )lakhs
22.68
51.96
62.13
70.72
77.73
82.24
84.72
2015-
2016-
2017-
2018-
2019-
2020-
2021-
16
17
18
19
20
21
22
PAT (in
Rs )lakhs
18.15
39.19
44.96
49.84
53.80
56.20
57.33
Equity:
The equity contribution by the promoters towards project facility is Rs
54.26 Lakhs which is 33.03% of the total project cost.
Debt:
The term loan proposed by the promoters is Rs 110.00 lakhs, which involves
only for the purchase of the machinery which is given as per the Annexure
Internal Rate of Return
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The internal rate of return (IRR) of the project after adding up non-cash
expenditure items such as Depreciation, Preliminary and pre-operative
expenses written off during the years under consideration and interest on
Term Loan works out to 30.39%. This is significantly higher than the
benchmark considered for the industry.
Breakeven Analysis
The breakeven analysis indicates that the operations breakeven at about
53.92 % of capacity utilisation during the first year of operations and
49.49% in the second year of operation. The high breakeven during the first
year of operations is primarily due to reduced number of operating days.
From third year onwards, the breakeven is 44.95% and registers a declining
trend signifying the robustness of the project.
Debt Service Coverage Ratio
The average DSCR is projected to be 2.50, well above the norm of 1.5. This
indicates ability of the -project to service the debt. Hence considering the
scheme the DSCR will further strengthen.
Particulars
No.
Amount
(In.Rs
lakhs)
1.
54.26
32
2.
Term Loan
110.00
Total
164.26
11.1
Strengths
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11.2
Weaknesses
Availability of skilled labour.
11.3
Opportunities
Government policy is in favor of the industries as per the new
industrial policy of Telangana .
VAT refund by the state government.
Capital subsidy and the power subsidy and the interest rebate.
11.4
Threats
Rapid industry growth attracts several competitors.
Since the promoters are in this activity for the past 20 years , they have a very
good inland and the export market to execute , the company has already taken the
following steps for its marketing through
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Very strong clientele as the promoters are already in the field for the last
20 years .
One of the partners is already a reputed distributor in Andhra Pradesh and
Telangana.
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14. CONCLUSIONS
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1. Capacity Utilization
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record of the company shows that they could achieve 100% capacity
utilization in the past for manufacture of similar products.
The projects BEP for the project is at 49.49% level of installed capacity in
the second year. This factor stresses on the strength of the proposed
activity for financing the project.
The Average DSCR for the project is at 2.50 times, which is above the
benchmark.
The Internal Rate of Return of the project is 30.39% and, the same is
considered reasonable, and above the benchmark level.
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