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2 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.
3 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.
4 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.
5 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.
6 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.
7 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 to FY and 52% from FY to FY
8 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.
9 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.
10 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 , the demand by end is expected to touch a near 2.4 mn tonne, and is projected at close to 3.4 mn tonne by
11 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
12 Machinery/ Equipment Photographs CAN SHREDDING MACHINE AIR COMPRESSOR ALUMINIUM MELTING HYDRAULIC CRUCIBLE FURNACE
13 INGOT CASTING ROTARY CONVEYOR FUEL STORAGES
14 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?
15 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?
16 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?
17 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?
18 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?
19 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?
20 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?
21 Table of Contents of the Project Report
22 1. PROJECT LOCATION 1.1. District Profile and Geotechnical Site Characterization General Location & Geographical Area Topography Demographics Map 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
23 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 Name of Company with Contact Details Name of Director(S) Plant Capacity
24 Location of Plant Capital Expenditure Projects Name of Raw Material(S) Consumed With Quantity & Cost 7.7. Section II Assets Cash Flow Cost as % Ge of Sales Forex Transaction Growth in Assets & Liabilities Growth in Income & Expenditure Income & Expenditure Liabilities Liquidity Ratios Profitability Ratio Profits Return Ratios Structure of Assets & Liabilities (%) Working Capital & Turnover Ratios 8. EXPORT IMPORT STATISTICS DATA OF INDIA
25 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 Machinery Photographs Raw Material Photographs Product Photographs 15. PLANT LAYOUT
26 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
27 Plant & Machinery....5 Indigenous Machineries Other Machineries (Miscellaneous, Laboratory etc.) Other Fixed Assets 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
28 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 Turnover Per Annum Share Capital...11 Equity Capital Preference Share Capital
29 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
30 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
31 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
32 Annexure 7 :: Break-Even Analysis Variable Cost & Expenses Semi-Variable/Semi-Fixed Expenses Profit Volume Ratio (PVR) Fixed Expenses / Cost B.E.P
33 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
34 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
35 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
36 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
37 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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39 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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41 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:
42 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.
43 Tags Aluminium Recycling, How is Aluminium Recycled? Recycling Aluminum, How to Recycle Aluminum? Aluminium Scrap Recycling, Aluminium Chip/Scrap Recycling Process Plant, Aluminium Recycling in India, Scrap Aluminium for Recycling, Aluminium Recycling Plant, Recycling of Aluminium, Aluminium Recycling Process, Recycling Aluminum (Aluminium), Aluminium Scrap Recycling, Aluminium (Aluminum) Recycling Process, Aluminum Ingots, Aluminium Ingots from Aluminium Scrap, Project Report on Aluminium Ingots from Aluminium Scrap, Project Report of Aluminium Recycling Plant, Cost of Aluminium Recycling Plant in India, Aluminium Scrap Recycling Plant, Manufacturing of Aluminium Ingots, Aluminum Ingot Making Project, Aluminium Ingot Production from Aluminium Scraps, Aluminium Industry, Aluminium Ingot Manufacturing Plant, Aluminum Ingot Manufacture, Aluminum Ingot Production, Aluminum Ingot Production Process, Aluminium Ingots Manufacturing Project Report, Process for Production of Aluminum Ingots, Aluminum Ingots, Aluminum Ingot Making Plant, Production Process of Aluminum Ingot,
44 How to Start Aluminum Ingot Manufacturing Industry Aluminum Ingot Production project ideas, Projects on Small Scale Industries, Small scale industries projects ideas, Aluminium Recycling Based Small Scale Industries Projects, Project profile on small scale industries, How to Start Aluminum Ingot Production Industry in India, Aluminium Ingot Production from Aluminium Scraps Projects, New project profile on Aluminum Ingot Production industries, Project Report on Aluminium Ingot Production from Aluminium Scraps, Detailed Project Report on Aluminium Recycling, Project Report on Aluminium Recycling, Pre-Investment Feasibility Study on Aluminium Recycling, Techno-Economic feasibility study on Aluminium Ingot Production from Aluminium Scraps, Feasibility report on Aluminium Ingot Production from Aluminium Scraps, Free Project Profile on Aluminium Recycling, Project profile on Aluminium Recycling, Download free project profile on Aluminium Recycling, Industrial Project Report, Project consultant, Business consultant, Project identification and selection, Preparation of Project Profiles, Startup Project for Aluminium Ingot Production from Aluminium Scraps
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