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co
 Introduction
Aluminium recycling is the process by which scrap aluminium
can be reused in products after its initial production. The
process involves simply re-melting the metal, which is far less
expensive and energy intensive than creating new aluminium
through the electrolysis of aluminium oxide (Al2O3), which
must first be mined from bauxite ore and then refined using
the Bayer process. Recycling scrap aluminium requires only
5% of the energy used to make new aluminium. For this
reason, approximately 31% of all aluminium produced in the
United States comes from recycled scrap.

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 Aluminium recycling is economically beneficial to both the
aluminium and recycling industry. The capital cost for the
production of recycled aluminium is already recognized to be far
lower than making new aluminium. The financial benefit has also
spurred the development of the recycling program.

India's per-capita consumption of aluminium, it is 0.6 kilograms

per person. Whereas in developed markets the consumption level is
around 20 kilograms. "India obviously has a tremendous (potential)
market for recycled aluminium. Recycled aluminium was sure to
shadow growth in primary aluminium usage, which is projected to
more than double in the next five years. Recycled aluminium had a
huge competitive advantage as the cost of manufacturing was only
5 percent of primary aluminium.

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 Aluminium Ingot
Ingot and billet play an integral part in the production of many
aluminium products. Plate, sheet, foil, wire, rod, and bar
products are all produced by pressing or rolling ingot and billet.

Ingot and billet are cast from molten aluminium. In the cast
house, crucibles of molten aluminium empty their silvery liquid
either directly into molds or into a holding furnace where the
metal is kept molten at temperatures between 1,200 and 1,500
degrees Fahrenheit. Alloying elements are then added.

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 The process of casting aluminum ingots takes place through
the fusion and refining of aluminum scrap previously retrained
through the use of specific technological installations. The
process that allows to obtain aluminum ingots from aluminum
scrap is called smelting process.

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 Aluminium Ingots are produced through the smelting process.
Various grades of ingots are produced which are used for
production of castings in Auto Industry as well as electrical
applications. Ingots of various dimensions with maximum
purity of 99.7%. Ingots are the material that is cast into a
shape suitable for further processing. Ingots usually require a
second procedure of shaping, such as cold/hot working,
cutting, or milling to produce a useful final product. Aluminium
Ingots are re-melted and further processed into a large number
of products for various downstream applications.

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 Aluminum ingots can be used in different sectors, including
automotive, household appliances, lighting, construction,
mechanics and household goods. The ingots are sent to other
process or flattened into thin sheets, which are then used to
make new cans. Aluminum is becoming a favourite with
architects and builders opening up a potential for increasing
use of metal in the construction industry. Likewise, the use of
the metal is increasing in the auto sector.

Exports of aluminium ingots have been increasing on a y-o-y

basis, 21% from FY 2014-15 to FY 2015-16 and 52% from FY
2015-16 to FY 2016-17.

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 Aluminium plays a major role in the modern world through its
innumerable applications, because of its intrinsic and versatile
properties of lightness, strength to weight ratio, corrosion
resistance, electrical and thermal conductivity, nontoxicity
etc. Secondary Aluminum Production is the process of
recycling aluminum scrap into aluminum that can be used
again—an environmentally sound process that is 92 percent
more energy efficient than primary production. In fact,
aluminium scrap recycling has proven so valuable—both
economically and ecologically—that recovery and recycling has
become its own industry, and a highly successful one.

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 The aluminum industry works hard to encourage consumer
recycling by educating the public and advocating for the
expansion of municipal recycling programs. The recycling of
aluminium generally produces significant cost savings over the
production of new aluminium, even when the cost of collection,
separation and recycling are taken into account. Over the long
term, even larger national savings are made when the reduction
in the capital costs associated with landfills, mines, and
international shipping of raw aluminium are considered.

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 The Indian Aluminium industry’s enthusiasm to grow smelting
capacity on an ambitious scale here and abroad. Aluminium
industry in India is moving towards overcapacity, since supply
is likely to grow in excess of demand going forward. Demand for
aluminium is estimated to grow at 4 to 6% per annum. The
demand for the metal is expected to pick up as the scenario
improves for user industries like power, infrastructure and
transportation, which are all on the move. From around 1.6 mn
tonne of demand in 2013-14, the demand by end 2019-20 is
expected to touch a near 2.4 mn tonne, and is projected at
close to 3.4 mn tonne by 2024-25.

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 Cost Estimation

Capacity: 25 MT/Day
Plant and Machinery: 200 Lakhs
Working Capital: 1500 Lakhs
Rate of Return (ROR): 58%
Break Even Point (BEP): 30%
Cost of Project: 1800 Lakhs

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 Machinery/ Equipment Photographs

CAN SHREDDING MACHINE AIR COMPRESSOR

ALUMINIUM MELTING HYDRAULIC CRUCIBLE FURNACE

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 INGOT CASTING ROTARY CONVEYOR

FUEL STORAGES
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Major Queries/Questions Answered in the Report?

1. What is Aluminium Ingots Manufacturing

industry?

2. How has the Aluminium Ingots Manufacturing

industry performed so far and how will it perform
in the coming years ?

3. What is the Project Feasibility of Aluminium Ingots

Manufacturing Plant ?

4. What are the requirements of Working Capital for

setting up Aluminium Ingots Manufacturing plant?

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5. What is the structure of the Aluminium Ingots
Manufacturing Business and who are the
key/major players ?

6. What is the total project cost for setting up

Aluminium Ingots Manufacturing Business?

7. What are the operating costs for setting up

Aluminium Ingots Manufacturing plant ?

8. What are the machinery and equipment

requirements for setting up Aluminium Ingots
Manufacturing plant ?

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9. Who are the Suppliers and Manufacturers of Plant
& Machinery for setting up Aluminium Ingots
Manufacturing plant ?

10. What are the requirements of raw material for

setting up Aluminium Ingots Manufacturing plant ?

11. Who are the Suppliers and Manufacturers of Raw

materials for setting up Aluminium Ingots
Manufacturing Business?

12. What is the Manufacturing Process of Aluminium

Ingots?

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13. What is the total size of land required for setting up
Aluminium Ingots Manufacturing plant ?

14. What will be the income and expenditures for

Aluminium Ingots Manufacturing Business?

15. What are the Projected Balance Sheets of

Aluminium Ingots Manufacturing plant ?

16. What are the requirement of utilities and

overheads for setting up Aluminium Ingots
Manufacturing plant?

17. What is the Built up Area Requirement and cost for

setting up Aluminium Ingots Manufacturing
Business?

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18. What are the Personnel (Manpower)
Requirements for setting up Aluminium Ingots
Manufacturing Business?

19. What are Statistics of Import & Export for

Aluminium Ingots?

20. What is the time required to break-even of

Aluminium Ingots Manufacturing Business?

21.What is the Break-Even Analysis of Aluminium

Ingots Manufacturing plant?

22.What are the Project financials of Aluminium

Ingots Manufacturing Business?

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23. What are the Profitability Ratios of Aluminium
Ingots Manufacturing Project?

24. What is the Sensitivity Analysis-Price/Volume of

Aluminium Ingots Manufacturing plant?

25. What are the Projected Pay-Back Period and

IRR of Aluminium Ingots Manufacturing plant?

26. What is the Process Flow Sheet Diagram of

Aluminium Ingots Manufacturing project?

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27. What are the Market Opportunities for setting
up Aluminium Ingots Manufacturing plant?

28. What is the Market Study and Assessment for

setting up Aluminium Ingots Manufacturing
Business?

29. What is the Plant Layout for setting up

Aluminium Ingots Manufacturing Business?

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Table of Contents
of the
Project Report

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1. PROJECT LOCATION

1.1. District Profile and Geotechnical Site Characterization

1.1.1. General
1.1.2. Location & Geographical Area
1.1.3. Topography
1.1.4. Demographics
1.1.5. Map
1.1.6. Administrative set up

2. INTRODUCTION

3. USES AND APPLICATION

3.1. Aluminium in Electrical Sector

3.2. Aluminium in Transportation Sector
3.3. Aluminium in Building and Architecture Sector
3.4. Consumer Durables
3.5. Channing and Packaging
3.6. Competing Materials

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4. PROPERTIES OF ALUMINIUM

4.1. Optical Properties

4.2. Chemical Properties

5. B.I.S. SPECTIFICATIONS

6. MARKET SURVEY

7. FINANCIALS & COMPARISON OF MAJOR INDIAN PLAYERS/COMPANIES

7.1. About Financial Statements of CMIE Database

7.2. Profits & Appropriations
7.3. Total Liabilities
7.4. Total Assets
7.5. Net Cash Flow from Operating Activities
7.6. Section – I
7.6.1. Name of Company with Contact Details
7.6.2. Name of Director(S)
7.6.3. Plant Capacity

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7.6.4. Location of Plant
7.6.5. Capital Expenditure Projects
7.6.6. Name of Raw Material(S) Consumed With Quantity & Cost
7.7. Section – II
7.7.1. Assets
7.7.2. Cash Flow
7.7.3. Cost as % Ge of Sales
7.7.4. Forex Transaction
7.7.5. Growth in Assets & Liabilities
7.7.6. Growth in Income & Expenditure
7.7.7. Income & Expenditure
7.7.8. Liabilities
7.7.9. Liquidity Ratios
7.7.10. Profitability Ratio
7.7.11. Profits
7.7.12. Return Ratios
7.7.13. Structure of Assets & Liabilities (%)
7.7.14. Working Capital & Turnover Ratios

8. EXPORT IMPORT STATISTICS DATA OF INDIA

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8.1. Export Statistics Data on Aluminium Ingot
8.2. Import Statistics Data on Aluminium Ingot

9. PRESENT MANUFACTURERS

10. MANUFACTURING PROCESS

11. PROCESS FLOW DIAGRAM

12. SUPPLIERS OF PLANT AND MACHINERY

13. SUPPLIERS OF RAW MATERIAL

14. MACHINERY, RAW MATERIAL & PRODUCT PHOTOGRAPHS

14.1. Machinery Photographs

14.2. Raw Material Photographs
14.3. Product Photographs

15. PLANT LAYOUT

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 Project Financials
• Project at a Glance Annexure

• Assumptions for Profitability workings ………………………..1

• Plant Economics…………………………………………………..2
• Production Schedule………………………………………………3
• Land & Building……………………………………………….……4
Factory Land & Building
Site Development Expenses

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• Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)

• Other Fixed Assets………………………………………..........….......6

Furniture & Fixtures
Pre-operative and Preliminary Expenses
Technical Knowhow
Provision of Contingencies

• Working Capital Requirement Per Month……………………….…7

Raw Material
Packing Material
Lab & ETP Chemical Cost
Consumable Store

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 • Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses

• Salary and Wages …………………………………………....……..9

• Turnover Per Annum ……………………………………….....…10

• Share Capital…………………………………………………….....11
Equity Capital
Preference Share Capital

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 • Annexure 1 :: Cost of Project and Means of Finance

• Annexure 2 :: Profitability and Net Cash Accruals

 Revenue/Income/Realisation
 Expenses/Cost of Products/Services/Items
 Gross Profit
 Financial Charges
 Total Cost of Sales
 Net Profit After Taxes
 Net Cash Accruals

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• Annexure 3 :: Assessment of Working Capital requirements

 Current Assets
 Gross Working Capital
 Current Liabilities
 Net Working Capital
 Working Note for Calculation of Work-in-process

• Annexure 4 :: Sources and Disposition of Funds

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 • Annexure 5 :: Projected Balance Sheets

 ROI (Average of Fixed Assets)

 RONW (Average of Share Capital)
 ROI (Average of Total Assets)

• Annexure 6 :: Profitability Ratios

 D.S.C.R
 Earnings Per Share (EPS)
 Debt Equity Ratio

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 • Annexure 7 :: Break-Even Analysis

 Variable Cost & Expenses

 Semi-Variable/Semi-Fixed Expenses
 Profit Volume Ratio (PVR)
 Fixed Expenses / Cost
 B.E.P

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 • Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume

 Resultant N.P.B.T
 Resultant D.S.C.R
 Resultant PV Ratio
 Resultant DER
 Resultant ROI
 Resultant BEP

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 • Annexure 12 :: Shareholding Pattern and Stake Status
 Equity Capital
 Preference Share Capital
• Annexure 13 :: Quantitative Details-Output/Sales/Stocks
 Determined Capacity P.A of Products/Services
 Achievable Efficiency/Yield % of Products/Services/Items
 Net Usable Load/Capacity of Products/Services/Items
 Expected Sales/ Revenue/ Income of Products/ Services/
Items

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 • Annexure 14 :: Product wise Domestic Sales
Realisation

• Annexure 15 :: Total Raw Material Cost

• Annexure 16 :: Raw Material Cost per unit

• Annexure 17 :: Total Lab & ETP Chemical Cost

• Annexure 18 :: Consumables, Store etc.

• Annexure 19 :: Packing Material Cost

• Annexure 20 :: Packing Material Cost Per Unit

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 • Annexure 21 :: Employees Expenses

• Annexure 22 :: Fuel Expenses

• Annexure 23 :: Power/Electricity Expenses

• Annexure 24 :: Royalty & Other Charges

• Annexure 25 :: Repairs & Maintenance Expenses

• Annexure 26 :: Other Manufacturing Expenses

• Annexure 27 :: Administration Expenses

• Annexure 28 :: Selling Expenses

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 • Annexure 29 :: Depreciation Charges – as per Books (Total)
• Annexure 30 :: Depreciation Charges – as per Books (P &
M)
• Annexure 31 :: Depreciation Charges - as per IT Act WDV
(Total)
• Annexure 32 :: Depreciation Charges - as per IT Act WDV
(P & M)
• Annexure 33 :: Interest and Repayment - Term Loans
• Annexure 34 :: Tax on Profits
• Annexure 35 :: Projected Pay-Back Period and IRR

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 Reasons for Buying our Report:

• This report helps you to identify a profitable project for investing

or diversifying into by throwing light to crucial areas like industry

size, market potential of the product and reasons for investing in the

product

• This report provides vital information on the product like it’s

characteristics and segmentation

• This report helps you market and place the product correctly by

identifying the target customer group of the product

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• This report helps you understand the viability of the project by

disclosing details like machinery required, project costs and

snapshot of other project financials

• The report provides a glimpse of government regulations

applicable on the industry

• The report provides forecasts of key parameters which helps to

anticipate the industry performance and make sound business

decisions

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 Our Approach:

• Our research reports broadly cover Indian markets, present analysis,

outlook and forecast for a period of five years.

• The market forecasts are developed on the basis of secondary

research and are cross-validated through interactions with the

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information from such sources is processed by us and included in the

report

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Scope of the Report

The report titled “Market Survey cum Detailed Techno Economic

Feasibility Report on Aluminium Ingots from Aluminium Scrap”
provides an insight into Aluminium Ingots from Aluminium Scrap
market in India with focus on uses and applications, Manufacturing
Process, Process Flow Sheets, Plant Layout and Project Financials of
Aluminium Ingots from Aluminium Scrap project. The report assesses
the market sizing and growth of the Indian Aluminium Ingots from
Aluminium Scrap Industry. While expanding a current business or while
venturing into new business, entrepreneurs are often faced with the
dilemma of zeroing in on a suitable product/line. And before
diversifying/venturing into any product, they wish to study the
following aspects of the identified product:

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• Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period

We at NPCS, through our reliable expertise in the project

consultancy and market research field, have demystified the
situation by putting forward the emerging business opportunity
in the Aluminium Ingots from Aluminium Scrap sector in India
along with its business prospects. Through this report we have
identified Aluminium Ingots from Aluminium Scrap project as a
lucrative investment avenue.

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 Niir Project Consultancy Services (NPCS)
can provide Detailed Project Report on
Aluminium Recycling Plant.
Production of Aluminium Ingots from
Aluminium Scrap, Aluminium Scrap Recycling
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