creativeplc com how to start new plastic injection moulding

7/21/2019 Creativeplc Com How to Start New Plastic Injection Moulding

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How To Start Injection Moulding Company

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STARTING PLASTICS INJECTION MOULDING MANUFACTURINGPLANT

If you have reached this page then somehow you are associated with Injection Moulding of

Plastics, if not then you can still find some useful information about starting a business.

Starting any business need planning. Planning includes the following points to be studied and

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Yuken Proportional Valves

Servo Valve Repair Service

Variable Displacement Pu

Things to Know

Mainteance of MouldingMachinesUsed Injection MouldingMachines

Products & Services

A Guide to Injection

Moulding

discussed with experienced professionals, friends before actually starting a company.

Purpose of Starting

Experience in Injection Moulding

Financial background

Technical knowledge about Plastics Processing

Location of Plant – very important

End Customers and Location

Products to be manufactured / Job Work

Type of Products to be made Commercial / Industrial / Automotive / Aerospace

Legal Status of the Company Proprietor / Partnership / LLP / Pvt. Ltd. / Ltd.

Number of Partners / Directors

It all starts with your knowledge and experience in the Plastics Processing Industry, especially

Injection Moulding. I restrict my discussion to starting a small Proprietorship / Partnership

company doing Job work or moulding commercial plastics components.

Now a days many people who are not associated with plastics are also starting Injectionmoulding plant, by way of necessity / opportunity available.

Most people think about their budget first and decide about the size of the plant accordingly.

For a new comer starting Injection Moulding plant with little experience in the field, seems to

be easier with smaller machines initially. But you have to look at the over all project cost

before deciding what capacity machine to be purchased.





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Let us assume that one has decided to start with 100Tons Injection Moulding Machine to

manufacture Commercial items like 20 liter Water Jar Cap or house hold items.

PROJECT REQUIREMENT AND COST

Sl.No. Plant Requirements Details1 Plant Size in Square Feet 400 – 600 Sq.ft

2 Amount of Rent per Month @ 20 per sq.ft 8000 – 12000 minimu

3 If rental Premises Cost of Advance 10 Months of rent is n

4 Cost of Machine – assuming Used Machine 6.0 to 8.0 Lakhs d

and condition of the

5 A Frame with 2tons Chain Pulley Block 50000/-

6 Power Required for Machine Approx 35hp

7 Cooling Water Pump Power 1hp

8 Cooling Tower and Piping 60000/-

9 Mould clamps and Tools 30000/-

10 Hydraulic Oil for Machine about 200liters 25000/-

11 Machine loading and unloading erection 25000/-

12 Machine Transportation if not in the same city 5000 – 15000/-

13 Electrical fittings, wiring in the Building 30000/-

14 Accessories like Scrap Grinder, Oven If required

15 If own products then cost of Mould

16 Working Capital considering 6 months rent, wages, and

other expenses

3.0 lakhs

17 Number of employees assuming accounts work to be taken

care by owner./ consultant

6 for 24 hours operati

18 Registration with Sales Tax 10000/-

19 Stationery Printing

20 Office Furniture

TOTAL INVESTMENT








Monthly ExpensesDescription Details

Electricity Bill

Wages and staff welfare

Miscellaneous Expenses

Telephone / Mobile Expenses

Transportation Expenses T

Interest on Investment @ 18% per annum

Insurance for Equipment T

Total Monthly Expenses

**** assuming accounts related work is carried by owner. Otherwise you may have to pay

another Rs 1000/- Per month for filing sales tax returns.

Annual Expenses

Audit fees.

Filing of Income tax returns

Annual Sales tax assessment

Bonus for Employees

Festival / Pooja Expenses if any

Insurance for Equipment and plant

Statuary Requirements








License to be taken from local Panchayat / Muncipality /

Corporation to run the Business.

Profession tax to be deducted from employees and paid to

the corporation

Monthly Sales Taxes to paid before 20th of Every month after

filing returns online.

If Registered with Central Excise then Duties to be paid

before 5th of every month

if Registered with Service Tax then same to be paid before

5th of every month.

TDS to be deducted and paid for payments made to sub-contractors, service providers.

Registration with ESI and PF to be made if no of employees are more than 15.

Filing Income Tax returns every year.

NOC from Pollution Control Board.

Working Capital Requirement

About six month's expenses to be the basis for working capital, so it is about 5,00,000/- in this

case. This amount needs to be kept aside and should not be used for buying equipments and

machines

If the Machine is in good condition then it will not give any trouble otherwise spending for the

machine repairs will also to be accounted.








Billing and Revenues

Assuming 100 tons Injection moulding machine is being used for producing commercial plas

then costing is done based on shift rate or based on weight of Materials converted in Kgs.

1500 or per Kg Rs. 10/- is now norm in the market.

Revenue Calculation Shift Rate 1500/-

Per Day 4500/-

Per Month assuming 25 days of production 112500/-

So the revenues are just sufficient to pay the monthly expenses. If Owner is able to reduc

expenses, then that expense can be saved to survive. For this, Machine should run without a

days and there should be orders for the same. If any one fails then it will become loss.

To avoid this any one starting company should start with little higher capacity machine like 200so that monthly revenues will be more and wages would be same so that income increa

Electricity bills are most expenses should be paid monthly without fail.

For this reason we strongly recommend not to start with lower capacity machine. Adding seco

in one year will reduce the administration expenses like wages and increase the growth prospec

Assumptions made in Project Report

Materials processed are PP, HDPE, LDPE. Etc which does not need preheating.

Location : Tamilnadu. Other places local taxes may wary like octori

Labour availability and cost low / medium.








Un-official expenses not taken into account

Some times accommodation to be provided for employees is not accounted.

If ABS, Nylon, Polycarbonate, etc then Cost of Pre-heating the material and its equipment cost

also to be considered in the project cost.

If doing job work for any Automotive Supplier then maintaining Quality standards like ISO9000,

registering with Central Excise is also to be done.

Service Tax Implications

If billing done to one single customer and if it exceeds 4.0 lakhs per annum then

Registration with service tax is mandatory and service tax to be charged, if

customer is not an assessee of Central Excise. If not Job work, then Sales Tax

rate based on the components produced to be levied and the same to be paid to the CTO

(commercial Tax Officer ) every month by filing returns.

Other issues to be taken care

Safety during machine operation. Several instances are there where employees

have lost fingers / hands / life due to poor maintenance of shop floor and

machines. Safety of the Mould is also uptmost important. Many times operators

use metal rods to remove the stuck components from the mould which will

damage the mould. Also clamping of the mould to be done propperly with right torque. Bolt

should enter the platen atleast 30mm.

Recently one of our customer who started a new company lost half of his hand even before

company is up and running. Safety issues needs to be seriously taken care of from the








beginning of the operations. Internal wiring to done with proper earthing to the Machines.

Several companies gutted completely due to short circuit, losses running into cores of rupees.

Any unexpected loss to a new company that too in the first year is too much to bear and

should take extreme care in maintaining the shop floor and employee safety.

It is always suggested to make detailed study before stepping into starting a new company.

Decisions should not be taken on assumptions / hypothetical thinking. Discussing with

experienced professionals in the filed is mandatory.







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Support Network :

After sales Support available in INDIA for all the products sold by Creative. We have wide network of associates across India to support

customers in time. Since these products are made in India getting spares is easier and low cost.

We have wide network of associates across India for after sales service, in cities Bangalore, Bengaluru, Chennai, Coimbatore, Trichy,

Madurai, Tirunelveli, Pudukottai, Pondicherry, Salem, Vellore, Hyderabad, Kurnool, Nandyal, Nellore, Rajamandry, Vijayawada, Vizag /

Vishakapatnam, Tirupati, Chittoor, Tumkur, Mysore, Goa, Mumbai, Pune, Aurangabad, Jalgaon, Nasik, Ahmedabad, Surat, Vadodara,

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Support from

At creative we provide professional support to the customers to buy suitable machines and

offer after sales support through out the life of the machine. Some times we even say not to

venture into based on the market conditions prevailing. Some times we suggest to go for bigger

capacity machines instead of smaller machines.

So far we helped lot of new companies who have grown well and doing good business. We

helped companies to reduce the Electricity bills. We helped companies, who want to close by

selling their machines. Simply we are one point source for all your need for setting up , running

an Injection Moulding Plant.





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Delhi, Amritsar, Ludhiana, Jammu, Uttaranchal, Kolkata, Jaipur, Nagpur, Kanpur, Lucknow, Rudrapur, Ahmed Nagar, Ranchi, Kerala,

Thiruvananthapuram, Palakkad, Cochin,Thrissur etc.

More than a dozen dealers are selling Used Injection Moulding Machines in Chennai alone. Most of those dealers do not offer after sales

support. At Creative we provide third party support for any brand like Arburg, Battenfeld, Cincinnati Milacron, Chalese, Dr. BOY, Demag,

Engel, Ferromatic, Hishiya, Haitian, Haitai, Hwashin, JSW, Kraussmaffei, Niigata, Sandretto, Super Master, Jet Master, CMP,

Jagmohan, Rana Sons, Victor, Windsor etc.

Note : Brand names and trade marks mentioned here belongs to respective owners.

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