Sample Project Report (3)
Sample Project Report (3)
OF
Under the Guideline Schemes for MSME , Govt. of MSME &
Government of India, Project Credit Guaranty Under the CGTMSE Ministry
of Finance
(Establishment of New Unit)
R/O - H.No.481,Gali No.11 Near Central Bank of India ,Ram Nagar Roorkee (UK)-247667
1. INTRODUCTION:
Plastics parts in engineering industry are replacing metal parts since last few years. It is
proved to improve their products, reduce costs and streamline the manufacturing process
by converting metal components and assemblies to plastic. Metal to plastic conversions
focus on improving the product or component integrity while reducing overall weight and
cost.
A key to success is the continual introduction and improvement of engineered plastic resins
that have the strength and durability to compete with metal. In addition, these plastic
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materials can provide better wear surfaces and have lower friction. For example, metal
bearings can be eliminated by designing bearing features directly into the plastic part.
Plastic components are often superior when it comes to high-impact strength, fatigue life or
recoverable deformation, and plastic parts can be molded into complex shapes at a much
lower cost than machining metal components.
In addition to part weight reduction, consistent dimensions and lower cost, metal to plastic
conversions often result in enhanced performance and product value.
The basic products manufactured from plastic for engineering equipment, domestic use
have advantages as under.
Improve Products:
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Injection molding machine
Reduce Costs:
Streamline Manufacturing:
INTRODUCTION
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use of disposable syringes produced from polypropylene resin by the process of injection
moulding. The components include the plunger, main body which is graduated to indicate
capacity, gasket, needle holder and the sheath cover for the needle.
The individual syringes are over wrapped in a polyethylene film pouch for subsequent
sterilization by ethylene oxide/gamma radiation.
Disposable syringes commonly are used in modern medicine for the injection of drugs and
vaccines or for the extraction of blood. The often are used instead of reusable syringes in
an effort to avoid spreading a disease. Among the common uses of disposable syringes are
the injecting of insulin by a diabetic person and the administering of a local anesthesia by a
dentist.
The advent of AIDS, serum Hepatitis and other dreaded infectious diseases have added
now dimension and this let to rapid increased use of disposable syringes in developing
countries. Use of disposable syringes is fast catching in India also and therefore offers good
scope. In view of this, the new units will not face any problems in marketing their product
in future.
3. RAW MATERIAL REQUIREMENTS
Medical grade Transparent & Color Polypropylene.
Pallets, bottles, jars, yogurt containers, hot beverage cups, and food packaging are some of
the products made with this material. Polypropylene is also frequently used in the
automotive industry to produce batteries, bumpers, instrument panels, interior elements,
and door trims.
Poly Propylene PP Pallet Granules This price range is for PP granules, the most common form of
PP used in manufacturing. The price of PP can vary depending on the grade, quantity, and location.
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4. MANUFACTURING PROCESS
Polypropylene granules are fed into an injection-moulding machine, where they are
plasticized and then injected into a Multi cavity mould. The mould is held under pressure
and material is cooled, the product is then ejected.
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Barrel and Plunger are made of PP by injection moulding whereas Gasket is made
separately.
Syringes produced are packed and then sterilized using Gamma Radiation or Ethylene
oxide. This project considers sterilization by Ethylene Oxide.
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5. DESIRED QUALIFICATIONS FOR PROMOTER:
Graduate in any discipline.
6. INDUSTRY LOOK OUT AND TRENDS
Plastic Injection molding is a manufacturing process for producing parts from both
thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel,
mixed, and forced into a mold cavity where it cools and hardens to the configuration of the
mold cavity.
After an industrial designer or an engineer designs a product, usually, molds are made by a
mold maker (or toolmaker) from metal, usually either steel or aluminum, and precision-
machined to form the features of the desired part.
Injection molding is widely used for manufacturing a variety of parts, from the smallest
component to entire body panels of cars. It is also used to create many things such as wire
spools, packaging, bottle caps, automotive dashboards, pocket combs, and most other
plastic products available today.
Injection molding is the most common method of part manufacturing.
It is ideal for producing high volumes of the same object. Some advantages of injection
molding are high production rates, repeatable high tolerances, and the ability to use a wide
range of materials, low labour cost, minimal scrap losses, and little need to finish parts
after molding. India automotive industry is expected to grow in another ten years.
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The Indian automotive industry is growing at a very high rate with sales of more than one
million passenger vehicles per annum.
The overall growth rate is 10-15 per cent annually.
The entire car market was likely to witness a fair amount of churning in the coming years.
This will definitely be a driving force for a high demand of auto components. India is the
world’s second largest manufacturer of two-wheelers, fifth largest manufacturers of
commercial vehicles as well as largest manufacturer of tractors.
It is the fourth largest passenger car market in Asia and home to the largest motorcycle
manufacturer. Coming to the Auto-component sector, the total market size of the auto-
components industry is estimated at over Rs 700 billion.
The industry estimates that the Indian components industry will grow to over Rs 950 billion
by 2010.
The overall investment in the components industry is estimated at Rs 288 billion.
Indigenous firms like Bharat Forge, Sundaram Fasteners, Minda Industries and Gabrial
India Ltd. are in the limelight. There is a boom in the auto components segment because of
strong demand and robust economy.
Also, the industry has strong forward and backward linkages with almost every other
engineering segment. The component production range includes engine parts 31%, drive
transmission and steering parts 19%, suspension and braking parts 12%, electrical parts
10%, equipments 12%, body and chassis 9% and others 7%.
The auto component suppliers are emerging as systems suppliers with capacity to design
and develop critical parts.
The Indian automobile components industry has, no doubt, significant cost advantages,
primarily due to lower labour cost. There is a very wide scope and good market potential of
products manufactured in this sector.
Few Indian Major Players are as under: Hanil Lear India Pvt. Ltd. Hi-Tech Elastomers Ltd.
Machino Plastics Ltd. Tata Auto Plastic Systems Ltd. Varroc Engineering Pvt. Ltd.
7. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY:
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8. RAW MATERIAL REQUIREMENTS:
The major raw materials required for the project are different type of plastics- mainly PP,
I.e. Polypropylene. Other raw materials required will be plasticizer, color additives, binding
chemicals, and packing materials. Most of the raw materials are available easily in the
Indian market.
9. MANUFACTURING PROCESS:
In injection molding process, the cold, hard plastic material is loaded into the machine via
hopper, plasticized by heating and then injected under pressure into a cold mold, where it
sets and is then ejected as the finished products. The three successive main stages that are
followed in the procedure of manufacturing are Feeding of Glass filled PP + colorant raw
material into the hopper, Injection molding process. Finishing of the molded product. Glass
filled PP + colorant Fixing of mold in machine, Injection Molten PP material in mold, Cooling
and Opening of mold, Ejection of component and Packing.
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The feed zone,
where the plastic first enters the screw and is conveyed along a constant root diameter, the
transition zone, where the plastic is conveyed, compressed and melted along a root
diameter that increases with a constant taper, and the metering zone, where the melting of
the plastic is completed and the melt is conveyed forward along a constant root diameter
reaching a temperature and viscosity to form parts.
All the machines and equipment are available from local manufacturers. The entrepreneur
needs to ensure proper selection of product mix and proper type of machines and tooling
to have modern and flexible designs. It may be worthwhile to look at reconditioned
imported machines, dies and tooling. Some of the machinery and dies and tooling suppliers
are listed here below:
1. Kabra Extrusiontechnik
402, Lalita Complex, Jain Mainder Road,
Oppiosite Hdfc Bank, Navrangpura,
Ahmedabad, Gujarat 380009. Phone: 079 2656 4828
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2. S. A. Engineering Works
No. 17/2, Periyasamy Street, Sunambu Kalavai,
Kuniyamuthur, Coimbatore-641008, Tamil Nadu, India
Phone: +91-9362233362; +91-9047476299, +91-422-2233362
6. Uday Enterprises
Khasra No. 1108, Village Makanpur, Behind Indian Child School
Opposite Janta Flat No. 433, Nyay Khand 1,
Indirapuram, Ghaziabad - 201010,
Uttar Pradesh, India
Phone: +91-9212320224.
As per the allocation of business rules under the Constitution, labour is in the concurrent
list of subjects. It is dealt with by the MOLE at the Central and Departments of Labour
under State Governments in respective States / UTs. The MOLE has enacted workplace
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safety and health statutes concerning workers in the manufacturing sector, mines, ports
and docks and in construction sectors.
11. TRAINING CENTERS AND COURSES
There is no such training required to start this business but, basic Electrical or IC bachelor’s
degree is plus point for enterpriser. Promoter may train their employees in such specialized
institutions to grow up the business. There are few specialized Institutes provide degree
certification in chemical Technology, few most famous and authenticate Institutions are as
follows:
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PROJECT AT A GLANCE - TOP SHEET
8 Debt Service :
Coverage Ratio
10 Project : 1 Months
Implementation
Period
12 Employment : 5-15
13 Power Requirement : 40 KW
14 Major Raw materials : Medical grade Transparent Polypropylene/75kg,Medical grade Color Polypropyle
3 COST OF PROJECT
A. Fixed Capital Investment
a. Land : 0 Own
Margin Money Subsidy received From UK MSME will be kept in term deposit as per norms of
UK MSME in the name of Beneficiary for three years in the financing branch.
3.2 STATEMENT SHOWING THE REPAYMENT OF TERM LOAN & WORKING CAPITAL :
TERM LOAN
Interest @
Year Opening Balance Installment Closing Balance 10.00%
1st 6426000 0 6426000 642600
2nd 6426000 918000 5508000 642600
3rd 5508000 918000 4590000 550800
4th 4590000 918000 3672000 459000
5th 3672000 918000 2754000 367200
6th 2754000 918000 1836000 275400
7th 1836000 918000 918000 183600
8th 918000 918000 0 91800
WORKING CAPITAL
Interest @
Year Opening Balance Installment Closing Balance 10.00%
1st 855000 0 855000 85500
2nd 855000 122143 732857 85500
3rd 732857 122143 610714 73286
4th 610714 122143 488571 61071
5th 488571 122143 366429 48857
6th 366429 122143 244286 36643
7th 244286 122143 122143 24429
8th 122143 122143 0 12214
5 Rawmaterials :
Particulars Unit Rate/unit Reqd.Unit Amount in Rs.
Medical grade Transparent 20000 75.00 20000 1500000.00
Polypropylene/75kg
Medical grade Color Polypropylene/82 kg 15000 82.00 15000 1230000.00
Polypropylene (PP Pallet Granules)/ 40 14000 40.00 14000 560000.00
kg
0 0 0.00 0 0.00
0 0 0.00 0 0.00
0 0 0.00 0 0.00
0 0 0.00 0 0.00
0 0 0.00 0 0.00
0 0 0.00 0 0.00
Total 3290000.00
5.1 Wages :
No. of Wages Amount in Rs.
Particulars
Worker Per Month (Per Annum)
skilled1 2 14000.00 336000.00
Skilled2 1 18000.00 216000.00
Skilled2 Marketing team 1 20000.00 240000.00
0 0 0.00 0.00
0 0 0.00 0.00
0 0 0.00 0.00
0 0 0.00 0.00
Total 4 792000.00
6 Administrative Expenses :
6.1 Salary
skilled office staff 1 12000.00 144000.00
0 0 0.00 0.00
0 0 0.00 0.00
0 0.00 0.00
0 0.00 0.00
Total 1 144000.00
Manufacturing Expenses
Raw Material 3290000.00
Wages 792000.00
Repair & Maintenance 77550.00
Power & Fuel 100000.00
Other Overhead Expenses 10000.00