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C A U T I O N
This project report has been prepared on the basis of
information available with our Institute and Project Coordinators.The intention here is to provide preliminary information to the
prospective entrepreneur. Prior to making a firm decision forinvestment in the project the entrepreneur must verify the
various feasibility aspects together along with the addressesfor the procurement of plant & machinery and raw materials
independently. The informations supplied in this report is
obtained from the reliable sources but it is not guaranteed, andthe money once paid will not be refunded back in any case. Claims
for incomprehensiveness of the project report will not be
entertained and no legal action in this regard would beentertained in any case (Subject to Rajkot Jurisdiction only).
Any matter relating to our standard points covered in the reportmay be modified with in 5 days time only from the date of
delivery.
INDIAN PROJECT RESEARCH INSTITUTE | Project Coordinator : Mr. Abhishek
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ALUMINIUM INGOTS FROM ALUMINIUM SCRAP[EDPR/0966] (J.C.9601)
C O T E N T S
1. INTRODUCTION 3
2. PROPERTIES OF ALUMINIUM 5
3. USES AND APPLICATIONS 7
4. B.I.S. SPECIFICATIONS 10
5. MARKET SURVEY 11
6. MANUFACTURER/SUPPLIER/EXPORTER
OF ALUMINIUM ALLOY INGOTS 22
7. MANUFACTURING PROCESS 32
8. PROCESS FLOW SHEET 36
9. PRINCIPLES OF PLANT LAYOUT 37
10. PLANT LOCATION FACTORS 42
11. EXPLANATION OF TERMS USED IN THE PROJECT REPORT 45
12. SUPPLIERS OF PLANT & MACHINERIES 47
13. SUPPLIERS OF RAW MATERIALS 68
APPENDIX - A
1. COST OF PLANT ECONOMICS A 1
2. LAND & BUILDING A 23. PLANT AND MACHINERY A 3
4. FIXED CAPITAL INVESTMENT A 5
5. RAW MATERIAL A 6
6. SALARY AND WAGES A 7
7. UTILITIES AND OVERHEADS A 8
8. TOTAL WORKING CAPITAL A 9
9. COST OF PRODUCTION A11
10. PROFITABILITY ANALYSIS A12
11. BREAK EVEN POINT A13
12. RESOURCES OF FINANCE A14
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INTRODUCTION
Aluminium is a metal with high strength-to-weight ratio, better
formability, high ductility, anti-corrosive properties, with thermal
and electrical conductivity. Because of these unique combination of
properties, aluminium(including its alloys) has substantially replaced
a number of traditional materials from their established uses e.g.
steel, copper, lead and zinc among metals and glass. Wood and paper
among non-metals. Aluminium is crucial for expansion of power
availability and electrification programme. It has a significant role
to play in saving energy in transportation sector, thus help reducing
the consumption petroleum products.
ALUMINIUM IN INDIAN ECONOMY:-
Aluminium plays a key role in the progress of industrial development
in India because it serves as basic input for a number of industries
apart from its use as a strafesic metal. Progressing a long way since
early fifties, with a meager production capacity of 5000 TPA it has
reached a level of 362000 tonnes by 1982-83. With the coming on stream
of National Aluminium Company (NALCO) project by 1987-88 asa major
producer in the country, the industry will attain a quantum jump to
the level of 580000 TPA. Thus, there will be a sea change in the
Indian aluminium scene. From a net importer of aluminium, India will
emerge as a country with surplus aluminium for some years to come
until the rising demand overtakes availability once again.
It is however, felt that the growth rate of demand could have been
higher but for the following factors.
a. Restricted indigenous availability of commercial grade aluminiuminhibitting the application of aluminium in place of other
conventinal materials in the transport building engineering and
other sectors.
b. Insufficient R & D efforts for new product application anddevelopment.
c. Inadequate market research and market development to diversifyinto new areas.
Development of high strength alloys good formability, improved
casting and welding techniques have opened up wide areas of
application of aluminium in the machinery and equipment sector.
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Another important area is the utensils, household appliances and
consumer durables. Aluminium due to its conductivity, light weight,
durability and non toxicity constitutes the most fuel efficient and
hence the ideal material for kitchenwares. Widespread usuage of
aluminium utensils is, therefore, necessary in the larger context of
fuel saving. With the development of high strength alloys, and
attractive utensils and for increasing consumption of aluminium in
this sector.
The country is now entering a phase when ensuring adequateavailability of alumina will not be a problem for some years to come.
The emphasis has to shift to developing the new application areas.
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PROPERTIES OF ALUMINIUM
Aluminium is a silvery and crystalline sold metal. It is a light
metal having no melting temperature and can be easily casted aluminium
forms a protective coating of Al2O3 about 50 A which, makes it highly
resistant to ordinary corrosion.
Aluminium is attached by concentrate and dilute solutions of HCl,
hot concentration H2SO4, and prechloric acid, aluminium is pretoxic
and is non-combustible except in powder form.
Pure aluminium is a relatively poor casting mateerial. It'scastings are actually produced from alloys. The casting alloys are
those having properties peculiary suited for casting purposes. For
these alloys two types of properties must be considered, the casing
properties, those characteristics of alloy which determine the ease or
difficulty of producing acceptable castings, and the engineering
properties.
The aluminium-base alloys may in general be characterised as
eutectic systems, containing intermediate compounds or elements as the
excess phase, because of the relatively low solubilities of most of
the alloying elements in aluminium and complexity of the alloys thatare produced, any one aluminium-base alloys may contain several
metallic phases, which sometimes are quite complex in composition.
The principal alloying elements in aluminium-base casting alloys
are copper, silicon, magnesium, zinc, chromium, manganese, tin and
titanium. Improvement in strength and hardness and response to heat
treatment are obtained with proper percentage of copper magnesium,
zinc or certain combination of magnesium and silicon in aluminium
alloys. Excessive percentages of these elements, however, result in
complete lots of ductility and toughness.
The Aluminium metal processed in various forms has been found to
be suitable for a variety of domestic and industrial uses. The reasons
of its usage in wide range of shapes and sizes can be found in
physical and chemical properties of this metal. The most significant
properties of this material:
a)Amenability to thermal and mechanical treatments or malleability,b)Lower specific gravity,c)Good conducting properties-thermal and electrical,
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d)Can be alloyed to obtain desired improvements in strength,
e)Resistant to chemical attacksIt has been possible to process this metal in various forms to
obtain the products with the requisite properties Thus, although the
earlier usage of Aluminium was restricted to pots and pans, Aluminium
is now being used for a variety of uses like in aircraft, electronics,
roofing, packaging, building industry, etc.
ALUMINIUM FOIL:-
The Foil is a continuous web of aluminium metal rolled to thicknessranging from 0.005 mm to a maximum of 0.15 mm. Foil is available in
many forms, Le., hard, soft (annealed), lubricated, non-lubricated
plain, coated, coloured, printed, embossed and laminated to a variety
of paper and synthetic films.
Aluminium foil has significant properties as given below:
a)Good thermal and electrical conductivity,b)Good formability,c)Impermeability and non-absorptivity to water, grease, oil &
light;
d)Odourless and tasteless,e)Good adhesion to a variety of compounds,f)Excellent printability,g)Resistance to oxidation and chemical attacksOwing to these properties, aluminium foil is preferred to other
packaging materials as flexible materials cannot match these
characteristics of aluminium foil.
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USES AND APPLICATIONS
Aluminium is the most widely used non-ferrous metal. Global
production of aluminium in 2005 was 31.9 million tonnes. It exceeded
that of any other metal except iron (837.5 million tonnes). Forecast
for 2012 is 4245 million tons, driven by rising Chinese output.
Aluminium is almost always alloyed, which markedly improves it
mechanical properties, especially when tempered. For example, thecommon aluminium foils and beverage cans are alloys of 92% to 99%
aluminium.
The main alloying agents are copper, zinc, magnesium, manganese,
and silicon (e.g., duralumin) and the levels of these other metals are
in the range of a few percent by weight.
Some of the many uses for aluminium metal are in:
Transportation (automobiles, aircraft, trucks, railway cars,marine vessels, bicycles, etc.) as sheet, tube, castings, etc.
Packaging (cans, foil, etc.) Construction (windows, doors, siding, building wire, etc.) A wide range of household items, from cooking
utensils to baseball bats, watches.
Street lighting poles, sailing ship masts, walking poles, etc. Outer shells of consumer electronics, also cases for equipment
e.g. photographic equipment.
Electrical transmission lines for power distribution MKM steel and Alnico magnets Super purity aluminium (SPA, 99.980% to 99.999% Al), used in
electronics and CDs.
Heat sinks for electronic appliances suchas transistors and CPUs.
Substrate material of metal-core copper clad laminates used inhigh brightness LED lighting.
Powdered aluminium is used in paint, and in pyrotechnics suchas solid rocket fuels.
Aluminium can be reacted with hydrochloric acid or with sodiumhydroxide to prodce hydrogen gas.
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A variety of countries,including France, Italy, Poland, Finland, Romania, Israel, and
the former Yugoslavia, have issued coins struck in aluminium or
aluminium-copper alloys.
Some guitar models sports aluminium diamond plates on the surfaceof the instruments, usually either chrome or black.
The per capita consumption of aluminium in India is about 0.4 Kg as
compared to the average of about 4 Kgs. in the world, about 18 kgs.
Japan and 27 Kgs. of USA. This indicates an ample scope for promotion
of the use of aluminium in the country in the various sectors of our
economy.
The pattern of consumption relects the priorities of a country
consistent with its resources and stage of development. Where as in
India, a developing country, while over 50 % of the consumption is
accounted for by electrical sector reflecting compulsions of building
up the indusirial infra-structure for power generation and
distribution, in USA, containers and packaging is the largest sector
indicating the emphasis for proper packaging of consumer goods. In
Japan, the highest consumption to aluminium is in the building and
construction sector because of the need for light buildings.
The foil is used for packaging of many products, some of which are
given below:
Pharmaceutical tablets
Bulk & unitized packing of
tea and coffee
Prepared meals
Bakery products
Frozen meat, fish
Milk bottle caps
Wine Lube Oil, greases
Powdered milk
Confectionery
Biscuits
Photographic film
Gift wraps
Household wraps
Butter, margarine
Cigarettes
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Product Range
Light Gauge Foil:
7, 8, 9 and 12 micron
Medium Gauge Foil:
15-50 micron
Heavy Guage Foil:
60-200 micron
Tagger Foil/ Container
Foil:
50-100% micron
TRIPLE LAMINATE FOR
PACKAING
Web Stock Foil:
15, 20, 30 and 40 micron
Pharma Foil :
Unrprinted and Printed
(5 colours )
25, 30 and 40 micron
poly laminated foil
FOUR PLY PACKAGING Blister Pack Foil :
Unrprinted and Printed (5
colours )
20 , 25 and 30 micron
Cigarette Foil:
Plain and Coated
HOUSE FOIL Lidding Foil:
Unrprinted and printed
30-38 and 40 microns
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B.I.S. SPECIFICATIONS
IS: 617-1975 Aluminium and aluminium alloy ingots castings for gerierd
engineering purposes (IIIrd revision with mould metals).
IS: 20-1977 Cast aluminium alloys for manufacture of utensils (IIIrd
revision).
IS: 2066-1962 - Coading and classification for non ferrous scrap metal
& residues. Section I of this standard deals with non ferrous scrap
metal e.g. aluminium brass bronze copper lead tin nickle & zinc
section - II deals with metallurgical residues e.g. slags, skimming
drosses etc. An appendix specifies conditions of slags.
IS: 8970-1991 - Aluminium foil laminates for packaging (first
revision)
IS 7161:1973 - Vegetable parchment orgrease proof paper :
Aluminium foil laminate for wrapping butter
IS 10257:1982 - Aluminium foil stock
Above Specifications may be obtained from
Bureau of Indian Standards,
9, B.S. Zafar Marg,
New Delhi - 110 002.
NOTE :- The use of the ISI Certification Mark is governed by the
provisions of the Indian Standards Institution (Certification Marks)
Act and the Rules and Regulations made thereunder. The ISI Mark on
products covered by an Indian Standard conveys the assurance that they
have been produced to comply with the requirements of that standardunder a well-defined system of inspection, testing and quality control
which is devised and supervised by ISI and operated by the producer.
ISI marked products are also continuously checked by ISI for
conformity to that standard as a further safeguard. Details of
conditions under which a licence for the use of the ISI Certification
Mark may be granted to manufacturers or processors, may be obtained
from the Indian Standards Institution.
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MARKET SURVEY
Indian Aluminium Industry, though of comparatively origin, has
progressed very fast and at present it ranks first among nonferrous
metals, both in production and in consumption. The history of
aluminium industry in India started in 1929 with the manufacture of
aluminium utensils from imported aluminium sheets and coils.
India entered the field of aluminium smelting in 1943 when a
small plant was set up by the Indian Aluminium Company (INDAL) at
Alupuram in Keral. Excepting electricity, the plant operation was
based on imported raw materials. The production during the year of
inception was only 1292 tons. West Bengal was the state for the
setting-up of second Aluminium smelter in 1944 by Aluminium
Corporation of India (ALUCOIN) at Jaykay Nagar, Asnsol, having a
capacity of 9000 TPA.
It was only after 1960 that aluminium industry in India made a
rapid growth. At present there are five primary aluminium producing
companies in the country. Two of these namely Bharat Aluminium Company
(Balco) and National Aluminium Company (MALCO) are in private sector.
The aluminium corporation in India (ALUCOIN) started initially as
private sector company, is lying closed since 1973 but its fabrication
facilities have since been taken by BALCO.
It was only after 1960 that aluminium industry in India made a
rapid growth. At present there are five primary aluminium producing
companies in the country. Two of these namely Bharat Aluminium Company
(Balco) and National Aluminium Company (MALCO) are in private sector.
The aluminium corporation in India (ALUCOIN) started initially as
private sector company, is lying closed since 1973 but its fabrication
facilities have since been taken by BALCO.
The first public sector plant BALCO at Korba in MP came in
production in the year 1975 with its smelter capacity of 2500 TPA. At
present its production capacity is 100000 TPA. NALCO, which is the
latest and now the largest integrated plant, is expected to commence
its production in 1987 at Angul in Orissa and will have metal
production capacity of 21800 TPA.
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LICENSED AND INSTALLED CAPACITY OF PRIMARY ALUMINIUM IN INDIA
India is considered the fifth largest producer of aluminium in
the world, following Australia, Guinea, Brazil and Jamaica. It has
huge reserves of high-grade bauxite. It is estimated at about 3037
million tonnes for all categories of bauxite (proved, probable and
possible). With the present level of consumption of aluminum (assuming
1.2 million tonnes of aluminium production with 7 million tonnes of
bauxite), the identified reserves would have an estimated life of over
350 years. India's reserves are estimated to be 7.5 per cent of the
total deposits and installed capacity is about 3 per cent of the
world. In terms of demand and supply, the situation is not only self-
sufficient, but it also has export potential on a competitive basis.
India's annual export of aluminium is about 82,000 tonnes. The global
consumption of aluminium is estimated to grow at 3 to 4per cent from
2000 to 2007. This provides a market signal for potential growth of
Indian aluminium industry and export of both alumina and aluminium.
About a decade back, the primary Indian aluminium producers were
BALCO, NALCO, INDAL, HINDALCO and MALCO. Of the five, two (BALCO and
NALCO) were in the public sector while the other three were in the
private sector. MALCO was 'sick' and on the path to closure. Public
sector enterprises then enjoyed preferential treatment in the form of
explicit protectionism. Therefore, the cost of production of BALCO was
benchmarking the selling prices in the domestic market. With the
inception of NALCO in 1981, the production pattern shifted in favour
of the public sector. This happened as BALCO with a capacity of
100,000 tonnes per annum and NALCO with an installed capacity 230000
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TPA, boosted the output share of primary aluminium from the publicsector. The domestic market was dominated primarily by the public
sector though prior to this, HINDALCO and INDAL were the main players.
The shift from the private to the public sector and again from
the public sector back to the private sector has been a notable change
in Indian industry. Presently, of the 714,000 TPA installed capacity
in the country for production of primary aluminium, the public sector
commands 330,000 TPA (49.21 per cent) and the private sector accounts
for 384,000 TPA (53.78per cent.) This represents a gradual but
deterministic shift in the production pattern. With BALCO'S
disinvestments on the cards, the share of the private sector willincrease at the commensurate rate (i.e. expected to be 67.8 per cent
in private sector). Earlier, HINDALCO and BALCO were the trendsetters
for prices in the country. Earlier, domestic sale of aluminium had
administrative prices along with distribution controls.
With liberalisation, the prime strategies are the joint venture
investments, technology acquisition/offers, international marketing
tie-ups, buy back arrangements and subcontracting, technical,
managerial and marketing expertise. As a part of reform, several
policy changes have been enunciated to ensure hassle free entry of
private investment. Similarly, as part of moving towards
privatisation, the government is withdrawing its presence from as many
areas as possible, through closure and sale of equity or
disinvestments.
Prospects for the aluminium industry seem to be bright as
aluminium is being used increasingly in energy efficient vehicles. For
instance, the space shuttle, the HUMMER vehicle, and the Ferrari 360
Modena all are made of high performance aluminium. Material automakers
are increasingly choosing to improve fuel economy, reduce emission and
enhance vehicle performance.
Aluminum is likely to surpass plastic in the coming years as it
will be used more in light vehicles. The recent announcement from the
Ford Motor Company to improve fuel economy in its SUVs is another
signal that aluminium usage will increase even faster. Automakers are
responding to consumer demands for cleaner, more efficient and safer
cars and trucks. Hybrid-electric technologies get much attention, but
cost and complexity are preventing their immediate, widespread use. It
is a recognised fact that aggressive weight reduction is the best way
to improve fuel economy, emissions and performance. For these reasons,
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as well as improved corrosion resistance and recyclability, automakersare more and more turning to lightweight, high-strength aluminium.
NALCO and BALCO have been identified for disinvestments. The
government has decided to disinvest up to 51 per cent of equity held
in BALCO through sale to strategic partners. NALCO has authorised
capital worth Rs 1300 crore and Rs 644.31 crore paid up capital and
loan of 980 million of Euro-dollar. The government's stake in NALCO is
about 87 per cent, which may be diluted further as it has set a target
of disinvesting upto Rs 10,000 crore through the sale of equity held
by the government in PSUs.
As a result of the process of liberalisation of trade in
aluminium, India has emerged as a net exporter of aluminium, on
competitive terms. Government monopoly, in terms of aluminium
production, removal of price and distribution control over aluminium,
has been diluted in favour of private sector. The ownership pattern in
private sector has undergone changes. With the takeover of INDAL by
the HINDALCO, it has emerged as the major producer of aluminium in the
country. It could be safe to conclude that Indian aluminium industry
is a success story of the reforms, liberalisation, globalisation and
privatisation drive in India.
Demand prospects bright for aluminium
Domestic aluminium producers will be relieved, as aluminium
prices ended the year on a firm note, after falling halfway through
the year.
On Wednesday, Hindalco Industries Ltd touched a new 12-month high
of Rs. 243 before closing a bit lower. The rise in its share price may
have been prompted either by expectations of better performance in its
domestic operations or even at its Canadian subsidiary Novelis Inc.Domestic aluminium producers will be relieved, as aluminium prices
ended the year on a firm note, after falling halfway through the year.
Aluminium prices on the London Metal Exchange (LME) have risen by
just 7% to $2,404 (Rs. 1,08,420) a tonne, compared with the year's
opening level. That is a meagre increase, especially when you consider
that its base metal cousin, copper, did extremely well, rising by
about 26% in the same period. But aluminium has done well since June,
when it fell to a low of about $1,850 a tonne.
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Demand for aluminium was quite solid during the year, as theworld economy overall was in better shape, despite China's efforts to
cool economic growth and shivers caused by Europe's economic worries.
Alcoa Inc. estimated aluminium production in 2010 to increase by 13%.
Global primary aluminium production rose by 3.5% in 2010, till
November, compared with the year-ago period, based on data from the
International Aluminium Institute(IAI).
Despite a 3.5% increase in production, LME inventories fell from
4.6 million tonnes (mt) in January 2010 to 4.3 mt. Physical
inventories of primary aluminium with companies, measured by the IAI,
have risen marginally, by about 5% to 1.3 mt. Alcoa forecasts worldaluminium consumption to increase from 39 mt in 2010 to 73 mt in 10
years, achieving a compounded annual growth rate of 6.5%.
In the April-November period, India's aluminium output rose by
8%, chiefly due to ramp-up of production at Vedanta Aluminium Ltd's
Jharsuguda smelter, according to the ministry of mines statistics.
Domestic players are expanding capacity, anticipating rising demand
which cannot be catered to by existing capacities.
Most global players, too, are expanding capacities. Despite an
increase in supply, Alcoa expects that the market will remain tight in
the next decade, due to demand outstripping supply. Indian firms are
expanding existing capacities and also setting up new plants. Some
have come up in 2010, but the bigger plants will come up in the next
few years. India's demand is expected to grow faster than global
demand, as its industrial growth sustains momentum, especially the
major users of aluminium industries such as real estate, automobiles
and engineering.
Aluminium prices are influenced by demand from financial
investors and from actual users of the metal. The current rush forcommodities provides a firm floor for prices, but it could quickly
disappear causing prices to wobble. This was visible in June, as fears
surrounding Europe spooked investors. The inventory overhang in
aluminium too continues but, having weathered it for a year, it does
not seem to be worrying investors. UC Rusal, a large aluminium
producer, believes that most LME inventories are covered by financial
transactions and will not come into the market before mid-2012.
Indian aluminium producers are in a good position, with aluminium
prices already up about 30% since the lows of June. But it has
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underperformed compared with commodities such as copper. The questionis if that will change in 2012, for that will determine how much of an
upside there is for investors in aluminium stocks. As of now, there is
little to suggest a runaway movement in aluminium prices. In 2011,
Indian firms will benefit more from their capacity additions, which
will contribute to a better financial performance.
Hindalco Industries Limited Q3 FY 2007-2008 Results
Hindalco Industries Ltd., the flagship company of the Aditya
Birla Group, today announced its unaudited financial results for the
quarter ended December 31, 2007.
Net sales and operating revenues stood at Rs.4,531.7 crores as
compared to Rs.4,656.2 crores in the corresponding period in FY 07.
The net profit for the quarter is Rs.542.7 crores vis-avis Rs. 643.9
crores in the corresponding period of previous year.
These results need to be viewed in the context of macroeconomic
parameters as these adversely impacted the quarter under review.
Domestic Aluminium ingot prices are down by around 20% due to the
rupee appreciation. A 10% lower aluminium LME, 41% lower Tc/Rc in
copper and soaring international crude prices have exerted
considerable pressure on margins. This was mitigated to some extent by
sweating capacities, improving realization through an enriched
product/market mix, optimizing efficiency levels and producing highest
ever aluminium metal in a quarter. Of the total revenues of Rs.
4,531.7crores, the aluminium business contributed Rs. 1,729 crores.
Aluminum metal sales volume rose by 12% along with higher proportion
of value added products.
The profit before interest and tax for aluminium business was at
Rs.578.9 crores as against Rs. 755.5 crores in the correspondingquarter in the earlier year, as stated earlier, mainly due to the
rising rupee and fall in global alumina realization.
In the copper business, revenues stood at Rs.2806.2 crores driven
by higher sales volumes and an enriched product mix. The profit before
interest and tax was Rs. 94 crores against Rs. 159.5 crores in the
corresponding quarter last year.
As mentioned earlier, a 41% lower TcRc and lower duty
differential on imports constrained the copper business.The effect of
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these were partially offset by improvement in the market mix withhigher sales in domestic market, lower grid power usage on improved
captive power availability, energy consumption and better realization
from by-product sale. Moreover, steep appreciation of Indian Rupee
against US Dollar adversely impacted segment results of Copper by an
estimated Rs.54 crores for the quarter under review as a result of
restatement of net foreign currency exposures as on December 31, 2007.
For the corresponding quarter of the previous year, this had an
estimated favourable impact of Rs.86 crores on such results.
Consequently, the Copper segment results for the quarter under review
are lower than the corresponding quarter of the previous year by an
estimated noncash impact of Rs.140 crores on this account.
Operational review
All the aluminium plants operated at consistently high capacity
utilisation. Brownfield expansions have resulted in increasing metal
production by 9%. The downstream assets purchased in the last two
years are fully utilized, in addition to consistent production from
other plants. Production of value added products (VAP) viz. Rolled
products and Extrusions production extended by 6 per cent and 10 per
cent respectively. Alumina production was marginally less than last
year predominantly due to the hooking of existing alumina refinery
with expanded facility at Muri.
Copper
Copper cathodes and CC rods production increased by 7% and 38 %
respectively on YoY basis on the back of the ramp up of the copper-III
smelter and consistent production from smelter-I. The operations at
copper smelter -II continue to be suspended.
Expansion projectsMuri
The expansion of the Muri Alumina refinery from 110,000 tpa to
450,000 tpa is under commissioning in a phased manner. The entire
steam and power requirement is being met by the new captive power
plant. The production from the expanded facility is expected to be
stepped up progressively in Q4FY08.
Hirakud
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Phase II of the expansion of the smelting capacity from 100,000tpa to 143,000 tpa is on track. The scaling up of the power generation
capacity from 267.5MW to 367.5MW will go on stream by the fourth
quarter of this fiscal.
Belgaum
The allotment of the lease for bauxite mines for expanding the
alumina refinery capacity at Belgaum, Karnataka from 350 ktpa to 650
ktpa is awaited.
Aditya Aluminium
Aditya Aluminium, the integrated aluminium project, encompassing
1-1.5 million tpa alumina refinery, 260,000-325,000 tpa aluminium
smelter and 750 MW captive power plant is progressing as planned. The
major portion of the total land required for the project has been
acquired. Environmental clearances have been obtained for Smelter, the
Captive Power Plant (CPP) and the refinery. Joint venture Company is
formed for the coal block. The water drawal agreement is also
finalized. Construction power already in place, the regulatory
clearances obtained for transmission lines for operation power. The
Smelter is expected to be commissioned by March, 2011 and the refinery
by May, 2011.
Mahan
The Mahan Aluminum project with a smelter capacity of 325 ktpa
and CPP of 750 MW is on schedule. The land acquisition for the project
is underway. The Company has been allotted a coal block in a JV withthe Essar group for the coal requirement of the CPP. Preliminary
Environmental clearances have been obtained. The power connectivity
for commencing construction has been approved. The Water resource
department has provided the necessary facilities as well. The
production of coal is likely to start by Oct'09. The Smelter is
expected to roll on by September 2012.
Latehar
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For the Latehar project with a smelter capacity of 325 ktpa andCPP of 750 MW, Tubed Coal mine has been allocated jointly with Tata
Power. Preliminary Environmental clearances have been obtained. Land
acquisition is in progress. Power for construction activity is
sanctioned. The expected date of commissioning is September 2013.
Utkal
Work on Utkal Alumna's 1.5 MTPA Alumina Refinery is underway. The
Company has acquired the land for the plant and facilities. Mining
activities will start by March 2009. The civil works for Alumina
refinery and CPP is in progress. The commissioning of the Plant isexpected by March 2010. Hindalco Almex Aerospace Limited
This project for manufacture of high strength aluminium alloys
for applications in the aerospace, sporting goods and surface
transport industries is on target. Key equipment has begun to arrive
at site for installation.
Industry outlook
Global primary aluminium consumption has witnessed a strong
growth of 10 % from April through December 2007. US production levels
have seen a high growth but demand from residential construction
market and transport markets continues to remain weak. Demand from
Western Europe has been relatively stronger due to firm transport and
engineering markets. China is the strongest driver of the demand as
the metal grew at 34.7%, in this period, with demand from the power,
transport and construction markets bolstering growth.
Copper
The bullish run on the copper prices has been halted due toglobal economic and financial woes and the trend is likely to be
downward. With many major smelters announcing annual maintenance
shutdown during April -June'07, the availability of concentrates would
improve, resulting in a higher spot TCRC.
Company outlook
Going forward, higher volumes from asset sweating of existing
plants, the brownfield expansions and continued cost focus together
with effective working capital management to maximise free cash flow
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will be the major growth drivers. However a stronger Rupee willcontinue put pressure on the profit margins.
Source: Hindalco Industries Limited (Business Wire India)
CHARACTERISTICS OF ALUMINIUM FOIL MARKET
The applications of Foil could be divided into two major groups
i.e packaging applications and non-packaging applications Packaging
applications include the products given above For these products, the
requirement of packaging is such that it should protect the product
from physical and chemical changes and climatic hazards Non-packagingapplications include heat exchangers tube fins in air conditioners,
capacitors and cable wraps, in which specific properties of the foil
such as conductivity are used.
As compared to other flexible packaging material, aluminium foil
has proved to be the superior material as far as protection of
material, convenience in usage and surface finish are concerned.
However, in India, aluminium foil has proved to be costly because of
higher price of basic material and higher excise duty. Many a time, it
is not available in requisite quantity.
Owing to the high price and uncertain availability of the foil in
the past, many of the user industries like pharmaceutical industry
switched over to other packaging material such as glasine poly
laminate Some companies introduced blister packs and some companies
reduced thickness of the foil Circumstances have thus proved that
usage of packaging medium for consumer items depends on its
availability, price, and shelf-life desired for the product Depending
upon the situation, the appropriate packaging medium is selected
The usage pattern, being very sensitive to price andavailability, keeps on changing from time to time depending upon the
economies of usage of aluminium foil vis-a-vis that of other materials
In India aluminium foil industry, there are frequent changes in
the usage patterns and specifications of foils, as compared to the
foreign countries and therefore, the usage of the foil has remained
restricted in variety as well as in quantitative terms
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The growth of foil industry, has thus not kept pace with thegrowth of its major user industries The past production of foil shows
an overall growth rate of about 7% only.
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Market Break Down of Usages Aluminium
Range of Properties and Uses of Aluminium Alloy
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MANUFACTURER/SUPPLIER/EXPORTER OF ALUMINIUM ALLOY INGOTS
Ashapura Steel
Address: 114/ A, R.K. Wadi,
Shop No. 8, 2nd Parsiwada Lane,
Mumbai, Maharashtra - 400 004
Phone: +(91)-(22)-66394870/66394492
Fax: +(91)-(22)-23821566
Mobile / Cell Phone: +(91)-9820469696/9320006141
Website: http://www.ashapurasteel.com/non-ferrous.html
Jindal Impex
Address: E-384, Phase-VI,
Focal Point, Ludhiana,
Punjab - 141 010, India
Phone: +(91)-(161)-5021500
Fax: +(91)-(161)-2678784
Mobile / Cell Phone: +(91)-9872969707/9878572700
Website: http://www.jindalimpex.com/
J J Aluminium Private Limited
Address: Plot No. 117, Road No.6,
Kathwada G.I.D.C., Kathwada, Odhav,
Ahmedabad, Gujarat - 382 430, India
Phone: +(91)-(79)-22901182
Fax: +(91)-(79)-22901182
Mobile / Cell Phone: +(91)-9825773828/9825047875
Vijay Prakash Gupta & Sons
Address: No. 3019, Street No. 2,
Chuna Mandi, Paharganj,
New Delhi - 110 055, India
Phone: +(91)-(11)-23586472/23584321
Fax: +(91)-(11)-23585757
Mobile / Cell Phone: +(91)-9811125181
Nisarg Casting
Address: 54/b/1, Changodar Industrial Estate,
Near Presion Bearing, Chnagodar,
Ahmedabad, Gujarat - 382 213, India
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Phone: +(91)-(2717)-250128Mobile / Cell Phone: +(91)-9978914205/9426015205
G. K. Founders Private Limited
Address: No. 13, Ranka House,
Kale Marg, Bail Bazar Road,
Mumbai, Maharashtra - 400 070, India
Phone: +(91)-(22)-25141266
Fax: +(91)-(22)-32569042
Mobile / Cell Phone: +(91)-9324258495/9825804585
Maruti Alluminium Private LimitedAddress: Plot No.- 380,
Raod No.- 9, G.I.D.C. Kathwada,
Opposite Odhav Octroi Naka,
Odhav, Ahmedabad, Gujarat - 382 430, India
Phone: +(91)-(79)-22901347/22901330
Fax: +(91)-(79)-22901347
Mobile / Cell Phone: +(91)-9909030758
Manaksia Limited
Address: 8/1, Lal Bazar Street,
Kolkata, West Bengal - 700 001, India
Phone: +(91)-(33)-22210051
Mobile / Cell Phone: +(91)-9830790059/9830052173
Gold Star Alloys
Address: Plot No.276, Sector No. 7,
Opposite Sahani Gas Industrial PCNDTA,
Bhosari, Pune, Maharashtra - 411 026, India
Mobile / Cell Phone: +(91)-9822401637
Kamala MetachemAddress: No. 3, British Indian Street,
3rd Floor, Room No. 3D,
Beside Great Eastern Hotel,
Kolkata, West Bengal - 700 069, India
Phone: +(91)-(33)-22100681
Fax: +(91)-(33)-22435682
Mobile / Cell Phone: +(91)-9830028623
Vijay Prakash Aeromarine Metals Pvt Ltd
Address: B-101, FF, Plot No. 2,
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R. G. Complex, Motia Khan,D. B. Gupta Road,
New Delhi - 110 055, India
Phone: +(91)-(11)-23544854
Mobile / Cell Phone: +(91)-9899097631
Alloy Tech, Bangalore
Address: Plot No 22 E, 3rd Main,
5th Cross, Athibele Industrial Area,
Anekal, Taluk, Bengaluru, Karnataka - 562 107, India
Phone: +(91)-(80)-27820540/25729183
Fax: +(91)-(80)-25729859/30616039Mobile / Cell Phone: +(91)-9886788183/8105011880
M. G. Metallinkers Private Limited
Address: E-6, Government Industrial Area,
Bahadurgarh, Haryana - 124 507, India
Phone: +(91)-(1276)-242389/23544451
Fax: +(91)-(1276)-242445
Mobile / Cell Phone: +(91)-9315877241/9996465657
Krishna Metals And Alloys Industries
Address: No. B-34, Krisna Gopal Estate,
Opposite S.B.I. Bank Memco,
Char Rasta, Naroda Road,
Ahmedabad, Gujarat - 380 001, India
Phone: +(91)-(79)-22201882
Fax: +(91)-(79)-22201882
Mobile / Cell Phone: +(91)-9879293970/9327029128
Kiran Aluminium India Private Limited
Address: 229-A, 2nd Floor,
Kewal Industrial Estate,Next To Big Bazaar,
Senapati Bapat Marg,
Lower Parel West, Mumbai,
Maharashtra - 400 013, India
Phone: +(91)-(22)-30406700/30406701
Fax: +(91)-(22)-30406703
Mobile / Cell Phone: +(91)-9869021174/9869021174
Krum Alloys Industries Private Limited
Address: W-46 M I D C.Shiroli,
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Kolhapur, Maharashtra - 416 212, IndiaPhone: +(91)-(230)-2469331
Fax: +(91)-(230)-2469331
Mobile / Cell Phone: +(91)-9322268661
Metal Cast & Alloys
Address: 39, Industrial Estate,
Phase-1, Yamunanagar,
Haryana - 135001, India
Phone: +(91)-(1732)-251315
Fax: +(91)-(1732)-251515
Mobile / Cell Phone: +(91)-9896351615
Baldev Metals Private Limited
Address: B-22 Phase 1,
Maya Puri Industrial Area.,
New Delhi - 110064, India
Phone: +(91)-(11)-28117476
Mobile / Cell Phone: +(91)-9971400401
Anurag Alloys And Diecast Private Limited
Address: Plot No. 57, Sector- 6,
Faridabad, Haryana - 121 006, India
Phone: +(91)-(129)-2243709
Fax: +(91)-(129)-4061446
Mobile / Cell Phone: +(91)-9811665709/9873146519
Thalco
Address: Bileshwar Estate,
Kathwada G.I.D.C.,
Ahmedabad, Gujarat, India
Mobile / Cell Phone: +(91)-9913369920/9924377804
G.K.Founders.Private LimitedAddress: Survey No. 331/2,
Plot 5/B, Tipco Road,
Masat, Dnh,, Silvassa,
Dadra And Nagar Haveli - 396230, India
Phone: +(91)-(260)-3290990
Fax: +(91)-(260)-2631812
Strategic Metals Private Limited
Address: 106, Commerce Centre,
Vishveshwar Nagar Off Aarey Road,
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Gujarat Indl Compound, Mumbai,Maharashtra - 400 063, India
Phone: +(91)-(22)-28739670/28739671
Fax: +(91)-(22)-28739673
Mobile / Cell Phone: +(91)-9820033076
Srg Aluminium Private Limited
Address: 31 Industrial Estate,
Gwalior, Madhya Pradesh - 474004, India
Phone: +(91)-(751)-4040120
Mobile / Cell Phone: +(91)-9893904567/9993032222
Navkar Metal
Address: 94/100, Fanaswadi,
Runghta Bhawan Room No.30,
2nd Floor, Mumbai,
Maharashtra - 400 002, India
Phone: +(91)-(22)-66518883/66595328
Mobile / Cell Phone: +(91)-9324001100
Manju Metals
Address: No. 118,
Konnur High Road,
Ayanavaram, Chennai,
Tamil Nadu - 600 023, India
Phone: +(91)-(44)-26744009
Fax: +(91)-(44)-26744009
Mobile / Cell Phone: +(91)-9380733884
Prism Metals (P) Ltd.
Address: B-28, Mayapuri Industrial Area,
Phase- I, New Delhi - 110064, India
Phone: +(91)-(11)-66130300Fax: +(91)-(11)-45082434
International Business Combines
Address: The Industrial Square,
No. 17-9/2, Begampur,
Industrial Area, Sector-35,
39th KM Stone, NH-8, Gurgaon,
Haryana - 122 001, India
Phone: +(91)-(124)-2210981/26143895
Fax: +(91)-(11)-46039660
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Mobile / Cell Phone: +(91)-9811889059
Padmavati Metals
Address: No. 902/290, Street No. 9,
Shalimar Industrial Area,
New Delhi - 110 088, India
Phone: +(91)-(11)-27494609
Mobile / Cell Phone: +(91)-9868748304
Century Metal Recycling Private Limited
Address: Village Tatarpur,
Teh. Palwal, Faridabad,Haryana - 121 102, India
Mobile / Cell Phone: +(91)-9873666455
N. F. Casting India
Address: No. 1567, Shiv Shanker Nagar,
Near Hindu Girls College, Jagadhri,
Yamunanagar, Haryana - 135 003, India
Phone: +(91)-(1732)-222315
Fax: +(91)-(1732)-222315
Mobile / Cell Phone: +(91)-9416022315/9355306130
Bharath Aluminium Company Limited
Address: Welfare Building, Plant I,
Commercial Deptartment Balco Nagar,
Korba, Chattisgarh - 495 684, India
Phone: +(91)-(7759)-240383/242052
Fax: +(91)-(7759)-240626
Mobile / Cell Phone: +(91)-9981144330
Sainath Industries
Address: 34, Rungta Bhavan,
94/100, Fanaswadi, Mumbai,Maharashtra - 400002, India
Phone: +(91)-(22)-56394493
Fax: +(91)-(22)-56548412
Univenture Corporation
Address: No. 4, Sial Layout,
Nelson Square, Nagpur,
Maharashtra - 440 013, India
Phone: +(91)-(712)-2594567
Fax: +(91)-(712)-6629645
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Kundan Traders, Kolkata
Address: 57/6 B.T.Road,
Kolkata, West Bengal - 700 002, India
Phone: +(91)-(33)-25573131
Pankaj Metals Corporation
Address: S/15, Vikram Chambers Ashram Road,
Ahmedabad, Gujarat - 380009, India
Phone: +(91)-(79)-27546252/27546964/32951521
Fax: +(91)-(79)-66611515
Maken AlloysAddress: Logate More, Kathua,
Jammu & Kashmir - 184102, India
Phone: +(91)-(1922)-203241/203242
Fax: +(91)-(1922)-237794/236114
Mobile / Cell Phone: +(91)-9906022324/9906022317
J. S. B. Aluminium
Address: Phase 1, Lane No. 7,
S.I.D.C.O., I.G.C.,
Samba, Jammu & Kashmir - 184 121, India
Phone: +(91)-(1923)-246385/28525421
Fax: +(91)-(11)-28525421
Mobile / Cell Phone: +(91)-9711288899/9811160663
Maruti Alluminium Private Limited
Address: Plot No: 380,
Road No: 9, Gidc Kathwada,
Kathwada,, Ahmedabad, Gujarat - 382430, India
Phone: +(91)-(79)-22901330/22901347
Harsh InternationalAddress: 634, G.I.D.C.,
Phase-Ii Dared, Jamnagar,
Gujarat - 361004, India
Phone: +(91)-(288)-2730417/2730125
Fax: +(91)-(0288)-2730517
Mobile / Cell Phone: +(91)-9978308080
Monarch Overseas
Address: 315, G.I.D.C.,
Phase Ii, Dared Jamnagar,
Jamnagar, Gujarat - 361004, India
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Phone: +(91)-(288)-2730217Fax: +(91)-(288)-2730339
N. H. Engineering Industries
Address: Plot No. 15, Phase No. 2,
G.I.D.C., Vithal Udyognagar
Post Karamsad, Anand, Gujarat - 388 120, India
Phone: +(91)-(2692)-237226
Fax: +(91)-(2692)-230346
Mobile / Cell Phone: +(91)-9879795380
Sagar International Private Limited
Address: 5, Hanuman Road,Delhi - 110 005, India
Phone: +(91)-(11)-23658876
Sri Venkateshwara Non Ferrous Foundry
Address: 19/5, Industrial Area,
Azamabad, Hyderabad,
Andhra Pradesh - 500 020, India
Phone: +(91)-(40)-27603829
Fax: +(91)-(40)-27656218
Perfect Aluminium Alloys
Address: 578 N. H. Road, Marakadai,
Near To Bangalore Hotel, Coimbatore,
Tamil Nadu - 641 001, India
Phone: +(91)-(422)-2391671
Samsung Overseas Limited
Address: 104, Adishwar Apartments,
Firozshah Road, New Delhi - 110 016, India
Phone: +(91)-(11)-45727272
Fax: +(91)-(11)-45727272Mobile / Cell Phone: +(91)-9811067809
Bhawani Wire & Cable
Address: Lane No.3, Phase-I,
SIDCO Industrial Complex,
Bari Brahmana, Jammu,
Jammu & Kashmir - 181 133, India
Phone: +(91)-(1923)-220878
Mobile / Cell Phone: +(91)-9419197099
Shri Ganesh Metal Rolling Mill & Engineering Works
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Address: Unit-Ii, Block No. 271/1-C/1 Gokul,Hubli, Karnataka - 580 026, India
Phone: +(91)-(836)-2210674/2310434
Fax: +(91)-(836)-2310385
Mobile / Cell Phone: +(91)-9448342370/9686081663
Lila Aluminium Industries Private Limited
Address: Gut No. 16, Naigaon Khandewadi,
Paithan Taluka, Aurangabad,
Maharashtra - 431 107, India
Phone: +(91)-(240)-2694533
Mobile / Cell Phone: +(91)-9922442388
Maken Alloys
Address: Logate More,
Near Railway Crossing Kathua,
Kathua, Jammu & Kashmir - 184102, India
Phone: +(91)-(1922)-203241
Mobile / Cell Phone: +(91)-9906022298/9906022317
Utlak Aluco Limited
Address: F-140, Delta-i,
Greater Noida, Noida,
Uttar Pradesh - 201 305, India
Phone: +(91)-(120)-2572245
Mobile / Cell Phone: +(91)-9871460653
We or Our Organization are not concerned with any of the contacts provided above. We
do not bear any responsibility or guarantee Quality of their product. We do not know
them neither do they.
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MANUFACTURING PROCESS
When aluminium is to be fabricated it is important to start with
Ingots/billets or slabs as free from segregation and blow holes as
possible.
MANUFACTURING OF INGOT FROM SCRAPE
A methods is being used where by molten aluminium is fed to a
water cooled mold with a moveable bottoms. The rate of flow of metal
is synchronised with the rate of solidification and the bottom of the
mold is lowered at the calculated rate. The solidified metal shrinks
away from the wall of the mold and allows the resulting Ingots to drop
with a moveable bottom and a solid uniform casting of any desired
length is thus obtained.
The furnace contain molten aluminium which flows through the
discharge spout. Two ingots can be simultaneously cast with the flow
each adjusted by valve.
MELTING & TREATMENT OF SECONDARY ALUMINIUM :-
The treatment of aluminium scrap has become complicated by the
increasing number of aluminium alloys which have come on the market in
recent year.
Some degree of sorting is possible based on the uses to which the
object composing the scrap have been put. Bending test are also used
and in some plants the spectrograph /spectrometer is employed. The men
engaged in sorting have in many cases become highly skillful by
experience.
The furnace usually oil or gas fired are used for melting and theatmosphere in regulated to minimize oxidation. It is desirable when
possible to immerse thin scrap below the surface of the bath to
inhibit oxidation during melting. A furnace is in used for melting
aluminium scrap in which a portion of the hearth is external but
contiguous with the interior portion. This scrap is submersed in the
exterior portion of the bath and subjected to slow agitation to
promote rapid melting. The agitation together with the rather high
heat conductivity of the bath promotes heat exchange with the heated
interior and prevents the exterior portion from solidifying.
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FLUXING AND FLUSHING
Fluxing and flusing of aluminium melts is practiced mainly for
two reasons.
A)To provide more effective separation of metal and dross.B)To remove dissolved hydrogen and entrapped dross.Gaseous fluxes used to flush or purge the melt include nitrogen,
helium, argon and chlorine. The gases are slowly bubbled through the
melt for hydrogen removal. Hydrogen dissolved in the aluminium
diffuses into the gas bubbled and is carried away. Dross separation is
probably a mechanical action of the inert gas bubbles carrying oxides
to the surface. Flushing is carried out by skimming off surface dross
and then bubbling the dry gas through the melt.
Fluxing with solid fluxes is a simpler procedure, flux to the
extent of about 0.10lb per 100lb i.e of metal is added to the melt by
forcing it to the bottom of the bath in a perforated container.Aluminium and Zinc chloride, as well as a number of proprietary
composition containing these compounds, are used as solid fluxes.
MANUFACTURING OF SHEET & FOIL
There are two methods of producing Aluminum Sheet/Foil. One from
using Caster where molten metal is directly used to manufacture sheet
and foil and the other is from ingot. The method of producing using
Caste i.e. directly from molten metal is relatively new and is costly.
Also, for manufacturing sheet/foil from scrap, it is less suitable as,
it is difficult to maintain the composition of molten metal due to
unknown composition of scrape. Thus, currently for Indian market,
manufacturing using Aluminum Ingot is more suitable, as the
composition of Ingots can be easily maintained and fresh aluminum
Ingots can be used whenever necessary.
The ingot is usually cooled after casting to room temperature and
then re-heated to around 500 C prior to successive passes through a
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hot rolling mill where it is reduced in thickness to about 4 - 6 mm.The temperature of pre-heat of the ingot and the time held at that
temperature is important for some alloys since a process of
homogenization takes place which renders the material in the best
condition for rolling and the achievement of subsequent properties.
The strip from the hot rolling mill is coiled for transport to
the cold mill which might be on the same site or elsewhere. Cold
mills, in a wide range of types and sizes are available; some are
single stand, others 3 stand and some 5 stand. Cold rolling speeds vary
but modern mills operate at exit speeds as high as 3000 m per minute.
The foil of uniform gauge and desired tolerance is made by subjecting
this foil-stock through a series of cold rolling passes, on one or anumber of rolling mills The minimum thickness to which the foil is
cold rolled, is 0.006 mm, achieved through pack rolling, i.e., rolling
of two foils together.
At the end of cold rolling operations, the foil is annealed
in order to fully soften it and impart the characteristics like
dead fold and easy Work ability. Annealing also burns off the oil
left on the foil surface. Annealing thus makes the foil free from oil
and fully sterile.
The annealed foil, is then subjected to the various treatments as
per requirements:
a) Separation of pack rolled foils,
b) Slitting to desired widths, including edge trimming,
c) Embossing,
d) Sheet making and cutting to length,
e) Application of adhesives, wax, lacquer etc.,
f) Lamination with paper, paper board, LDPE,
g) Single or multi colour printing,
h) Slitting of laminated composite,
i) Packing in desired lengths or weights
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A modern complex including melting furnaces, asting facilities,
pre-heat furnaces, hot mill, cold mill and annealing furnaces involves
a very large capital investment which can only be fully justified on
financial grounds if a big market is assured. Obviously, if such
facilities are not fully utilized the economic viability is
threatened. As indicated above, however, hot mill coil can be obtained
for further reduction in cold mills of lower capacity/speed/complexity.
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PROCESS FLOW SHEET(Ingot to Scrape)
Flow sheet of Aluminum Sheet/Foil manufacturing is same as that
given in 3D graphics in Process description.
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PRINCIPLES OF PLANT LAYOUT
Some of the guiding principles for detailed plant layout will be
discussed for the benefit of those making layout decisions for the
first time.
Storage Layout: Storage facilities for raw materials and intermediate
and finished products may be located in isolated areas or in adjoining
areas. Hazardous materials become a decided menace to life andproperty when stored in large quantities and should consequently be
isolated. Storage in adjoining areas to reduce materials handling may
introduce an obstacle toward future expansion of the plant. Arranging
storage of materials so as to facilitate or simplify handling is also
a point to be considered to design. Where it is possible to pump a
single material to an elevation so that subsequent handling can be
accomplished by gravity into intermediate reaction and storage units,
costs may be reduced. Liquids can be stored in small containers,
barrels, horizontal or vertical tanks and vats, either indoors or out
of doors.
Equipment Layout: In making a layout, ample space should be assigned
to each piece of equipment; accessibility is an important factor for
maintenance.
It is extremely poor economy to fit the equipment layout too
closely into a building. A slightly larger building appears necessary
will cost little more than one that is / that crowded. The extra cost
will indeed be small in comparison with the penalties that will be
extracted if, in order to iron out the kines, the building must be
expanded.
The operations that constitute a process are essentially a series
of unit operations that may be carried on simultaneously. These
include filtration, evaporation, crystallization, separation, and
drying. Since these operations are repeated several times in the flow
of materials, it should be possible to arrange the necessary equipment
into groups of the same kinds. This sort of layout will make possible
a division of operation labor so that one or two operators can be
detailed to tend all equipment of a like nature.
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The relative levels of the several pieces of equipment and theiraccessories determine their placement. Although gravity flow is
usually preferable, it is not altogether necessary because liquids can
be transported by blowing or by pumping, and solids can be moved by
mechanical means. Gravity flow may be said to cost nothing to operate,
whereas the various mechanical means of transportation involve the
first cost of the necessary equipment and the cost of operation and
maintenance. But material must be elevated to a level where gravity
flow must start. However, gravity flow usually means a multistory
layout, whereas the factors favoring a single-story plant may largely,
if not entirely, compensate for the cost of mechanical transportation.
Access for initial construction and maintenance is a necessary
part of planning. For example, overhead equipment must have space for
lowering into place, and heat-exchange equipment should be located
near access areas where trucks or hoist can be placed for pulling and
replacing tube bundles. Thus, space should be provided for repair and
replacement equipment, such as cranes and forked trucks, as well as
access way around doors and underground hatches.
Safety: A great deal of planning is governed by local and national
safety and fire code requirements. Fire protection consisting of
reservoirs, mains, hydrant, hose houses, fire pumps, reservoirs,
sprinklers in building, explosion barriers and directional routing of
explosion forces to clear areas, and dikes for combustible-product
storage tanks must be incorporated to protect costly plant investment
and reduce insurance rates.
Plant Expansion: Expansion must always be kept in mind. The question
of multiplying the number of units or increasing the size of the
prevailing unit merits must be studied. Suffice it to say that one
must exercise engineering judgment; that as a penalty for bad
judgment, scrapping of present serviceable equipment constitutes butone phase, for shutdown due to remodeling may involve a greater loss
of money than that due to rejected equipment. Nevertheless, the cost
of change must sometimes be borne, for the economies of larger units
may, in the end, make replacement imperative.
Floor Space: Floor space may or may not be a major factor in the
design of a particular plant. The value of land may be a considerable
item. The engineers however, follow the rule of practicing economy of
floor space, consistent with good housekeeping in the plant land with
proper consideration given to line flow of materials, access to
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equipment, space to permit working on parts of equipment that needfrequent servicing, and safety and comfort of the operators. Utilities
Servicing: The distribution of gas, air, water, steam, power, and
electricity is not always a major item, in as much as the flexibility
of distribution of these services permits designing to meet almost any
condition. But a little regard for the proper placement of each of
these services, practicing good design, aids in of operation,
orderliness, and reduction in costs of maintenance. No pipes should be
laid on the floor or between the floor and the 7-ft. level, where the
operator must pass or work. Chaotic arrangement of piping invites
chaotic operation of the plant. The flexibility of standard pipe
fittings and power-transmission mechanisms renders this problem one ofminor difficulty.
Building: After a complete study of quantitative factors, the
selection of the building or buildings must be considered. Standard
factory buildings are to be desired, but, if none can be found
satisfactory to handle the space and process requirements of the
chemical engineer, then a competent architect should be consulted to
design a building around the process - not a beautiful structure into
which a process must fit. It is fundamental in chemical engineering
industries that the buildings should be built around the process,
instead of the process being made to fit building of conventional
design.
In many cases only the control area requires housing, with the
process equipment erected outdoors. This is known as outdoor
construction and such layouts should be considered for many types of
plants. What consideration must be given to buildings depends upon
conditions. If the designer must adapt his design to fit an old
building or building space already erected, his problem is cut out for
him and he has limiting conditions. However, the selection of the
design of a new building to meet the requirements of the process ismore scientific. In this case, one finds before him practically all
types of standard building, built in units, interlocking or otherwise,
ready for shipment and erection.
Throughout chemical industry, much thought must be given to the
disposal of waste liquors, fumes, dusts, and gases. Ventilation, fume
elimination, and drainage may require the installation of extra
equipment. This may involve the design of the individual pieces of
operating equipment, or it may require the installation of isolated
equipment. If the latter be the case, the location of such equipment
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where it will not interfere with the flow of materials in processshould be practiced. The selection of the proper piece of equipment
for doing this service is also an important point; the less attention
the ventilating, fume, or waste-elimination systems require, the
better service they may render. Sometimes air conditioning of the
plant is called for and may require an elaborate setup. But the
installation of such equipment, when needed, pays in better service
from operators, less discomfort, greater production, and a better
morale than when such conditions are left to nature.
It must be recognized that there is not only one solution to the
problem of layout of the equipment. There are many rational designs.Which plant to adopt must be decided upon after exercise of
engineering judgement and after striking a balance between the
advantages and disadvantages of each possible choice.
Material-handling Equipment: Consideration of equipment for materials
handling is only a minor factor in most cases of arrangement, because
of the multiplicity of available materials handling devices. But where
this operation is paramount in a process, serious thought must be
given to it. Again it should be said that engineering judgement must
be exercised. Whenever possible, one should take advantage of the
topography of the site location, and the process involved.
Railroads and Roads: Existing or possible future railroads and
highways adjacent to the plant must be known in order to plan rail
siding and access roads within the plant. Railroad spurs and roadways
of the correct capacity and at the right location should be provided
for in a traffic study and over-all master track and road plan of the
plant area. Some of the factors in rail-track planning are:
1. Existing and future off-site main rail facilities
2. Permissible radius of curvature for spurs - consult local railauthorities.
3. Provision for traffic handling - arrangement of spurs and ladder
track and switching.
4. Adequate spur facilities
a. Loading and unloading facilities for initial plant
construction and subsequent operations.
b. Rack stations for liquid handling
c. Storage space for full and empty cars
d. Space for cleaning and car repairs.
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Major provisions in road planning for multipurpose service are:1)A means of interplant movement for road traffic, both
pedestrian and vehicular
2)Heavier and wider roads for large-scale traffic.3)Routing of heavy traffic outside the operational areas4)Roadways for access to initial construction, maintenance, and
repair points.
5)Roadways to isolated points, storage tanks, and safety equipment,such as fire hydrants.
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PLANT LOCATION FACTORS
Factors which generally apply to the economic and operability
aspect of plant site location are classified into two major groups.
The primary factors listed apply to choice of a region, whereas the
specific factors looked at in choosing an exact site location within
the region. All factors are important in making a site location
selection.
Primary Factors
1. Raw-material supply:a. Availability from existing or future suppliers
b. Use of substitute materials
c. Distance
2. Markets:
a. Demand versus distance
b. Growth or decline
c. Inventory storage requirements
d. Competition - present and future.
3. Power and fuel supply:a. Availability of electricity and various type of fuel
b. Future reserves
c. Costs
4. Water supply:
a. Quality - temperature, mineral content, bacteriological
content
b. Quantity
c. Dependability - may involve reservoir construction
d. Costs.
5. Climate:
a. Investment required for construction
b. Humidity and temperature conditions
c. Hurricane, a tornado, and earthquake history
Specific Factors
6. Transportation:
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a. Availability of various services and projected rates1. Rail - dependable for light and heavy shipping over all
distances
2. Highways - regularly used for short distance and
generally small quantities
3. Water - cheaper, but may be slow and irregular
4. Pipeline - for gases and liquids, particularly for
petroleum products
5. Air - for business transportation of personnel
7. Waste disposal:
a. Regulations lawsb. Stream carry-off possibilities
c. Air-pollution possibilities
8. Labor:
1. Availability of skills
2. Labor relations - history and stability in area
3. Stability of labor rates
9. Regulatory laws:
a. Building codes
b. Zoning ordinances
c. Highway restrictions
d. Waste-disposal codes
10. Taxes:
a. State and local taxes
1. Income
2. Unemployment insurance
3. Franchise
4. Use
5. Propertyb. Low assessment or limited term exemptions to attract industry.
11. Site characteristics:
a. Contour of site
b. Soil structure
c. Access to rail, highway, and water
d. Room for expansion
e. Cost of site
f. Site and facilities available for expansion on present
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company-owned property
12. Community factors:
a. Rural or Urban
b. Housing costs
C. Cultural aspects - churches, libraries, theatres
d. School system
e. Recreation facilities
f. Medical facilities - hospitals, doctors
13. Vulnerability to wartime attack:
a. Distance important facilitiesb. General industry concentration
14. Flood and fire control:
a. Fire hazards in surrounding area
b. Floor history and control
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EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
This represents reduction in the utility and value of a capital
asset because of wear and tear, lapse of time, obsolescence etc. The
use of an asset helps in the generation of revenue for the business. A
part of the cost of the asset, estimated to be equal to the reduction
in the utility and economic life of the asset, because of its use, is
charged off by way of depreciation charge against such revenue to
arrive at the true profits.
2. FIXED ASSETS:
Represent those assets which remain permanently (till their
useful lives) with the business and are not meant for resale. These
assets are acquired for use in the operation of business and help in
the generation of revenue for the business. These include land and
building, plant and machinery etc.
3. WORKING CAPITAL:
This represents the total expenses on Raw materials, utilities &
overheads, and salaries & wages, for a specified period of time.
4. BREAK-EVEN POINT:
This represents the level of output and sales at which the firm
is able to recover all its expenses-both fixed and variable. In other
words it indicates the level of output and sales at which the firm is
neither making profit nor incurring any loss. Level of output more
than the Break-Even Level generates profit for the firm.
5. OTHER FIXED EXPENSES:
These represent expenses which remain fixed irrespective of
changes in level of output. In other words these are the expenses
which the firm has to incur whether there is production or not. These
include expenses such as preliminary and Preoperative expenses,
Insurance and Freight, Technical Know-how and Consultancy, Erection &
Commissioning etc. building, insurance, etc.
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6. MARGIN MONEY:
This represents that part of the cost of project which the
promoter has to meet from his own resources. This is the contribution
which the promoter must make to the equity of the project for becoming
eligible for assistance from financial institutions/Banks.
7. TERM LOANS:
Represent Loans which are repayable over a long period of time.
These loans are meant for meeting capital expenditure of the project.
8. TOTAL LOAD:
It is the ratio of the maximum power consumed in KWH in a
particular period of time to the number of operating hours of the unit
in that particular period.
9. LAND AREA/MAN POWER RATIO:
It is the ratio of manpower utilised per unit area of land
required for operating the unit.
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SUPPLIERS OF PLANT & MACHINERIES
FURNACE
HIGH TEMP FURRNACES LTD.
1C, PHASE-II,
PEENYA IND. AREA,
BANGALORE - 560 058
KARNATAKA,
PH: 91-80-28395917, 28394076
D. N. Reddy, MDA P MOTRONIX PVT LTD
3-18-3, Pragathi Nagar, Ramanthapur
Hyderabad-500013, Andhra Pradesh
Phone: 040-27038560/27031929
Email: [email protected]
Mr. Manwani
ADOR TECHNOLOGIES LTD
Plot No.53, 54 & 55,
F-II Block, MIDC, Pimpri
Pune-411018, MaharashtraPhone: 020-7470225/7476009
Email: [email protected]
Mg. Director
ADVANCE HEATING SYSTEMS
207, Vardhman Complex 8,
Facility Centre,
Mayapuri Industrial Area-II
New Delhi-110064
Phone:011-25139315, 25403798, (r) 25613649
Email: [email protected]
Mg. Director
AJANTA SCIENTIFIC INDUSTRIES
Science Market,
Near Hargotal Dharmashala
Ambala Cantt.-133001, Haryana
Phone:0171-2642428, 2630814 (O), (R) 2650316
Email: [email protected]
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Mg. DirectorAMBICA ENGINEERING WORKS
# 16/A, 1st Main,
Modi Hospital Road,
West Of Chord Road, 2nd Stage
Bangalore, Karnataka
Phone:080-3495370
V. S. Prasanna, Marketing Mgr
APNA SCIENTIFIC SUPPLIES PVT LTD
M-2, Industrial Estate, Guindy
Chennai-600032, Tamil NaduPhone: +91 44 22340963, 22340630
Mr. Kapahi
ASSOCIATED INDUSTRIAL FURNACES PVT LTD
F-9, Sector-Xl
Noida-201301, Uttar Pradesh
Phone: 0120-2529187, 2529169
Email: [email protected];[email protected]
COOLING TOWER
Lalit Narang, Proprietor
A TO Z ENGINEERS & CONSULTANTS
915, Vishal Towers,
10, District Centre,
Janakpuri, New Delhi-110058
Phone: +91 11 25619462, 25551832
Email: [email protected]
Yogesh Pujari, Export Mgr
ADVANCE REINFORCED PLASTICS PVT LTD
405/406, Span Centre,
R K Mission Marg, Santacruz (W)
Mumbai-400054, Maharashtra
Phone: 022-26001067, 26001068
Email: [email protected]
Mr. Kailash Magolra
ALBATRON FINE CHEM LTD
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40, Dlf Industrial Area,Alishan Building, Kirti Nagar
New Delhi-110015
Phone: 011-25161151/25114789/25100768
Mr. Ravinder
B D T LTD
Sri Madurakripa Towers,
2nd Floor, New No. 51,
North Boag Road, T. Nagar
Chennai-600017, Tamil Nadu
Phone: 044-28235971/28235977
Email: [email protected]
Mr T S Rao
EAST COAST STRUCTURALS
96/3, Sidco Estate, Ambattur
Chennai-600098, Tamil Nadu
Phone: 044-26252850
Davindar Sapru, Sales Mgr
AADI HEAT EXCHANGER PVT LTD
D-83, Hosiery Complex, Phase II Ext.
Noida-201305, Uttar Pradesh
Phone: +91 120 2460073, 2460073
Email: [email protected]
Mr. Ajay
D M POLYMERS
Near, Chungi,, Daultabad Road,
Gurgaon, Haryana
Phone:0124-2469780, 3095483, 9810074583
Email: [email protected]
WATER PUMP
MR. A S THAPAR (CHAIRMAN)
ALLENA AUTO INDUSTRIES LTD
B-68, WAZIRPUR, INDL. AREA
DELHI-110052
Phone: 011-27373704, 27121008
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MR. MANISH PATEL
AMIDHARA INDUSTRIES
L-92, GIDC ESTATE,
BEHIND OLD WATER TANK,
ODHAV AHMEDABAD-382415, GUJARAT
Phone: 079-3870420/2876420
M. Z. BANDUKWALA, MD
ANCO MOTORS
248/250,, ABDUL REHMAN STREET
MUMBAI-400003, MAHARASHTRAPhone: +91 22 3424764 3400605
Email: [email protected]
MRS. MUKHERJEE
B E PUMPS PVT LTD
C/401, CRYSTAL PLAZA,
NEW LINK ROAD, ANDHERI (WEST),
MUMBAI-400053, MAHARASHTRA
Phone:912226733510
Email: [email protected]
MR. BABU KHAN & MR. DISHAD KHAN (DIR)
B K HI-TECH ENGINEERING,
C-334,, SECTOR-10,
NOIDA-201301, UTTAR PRADESH
Phone: 0120-2557355, 9811642485,
MR. A K BEHAR
B S PUMPS PVT LTD
BASAI ROAD
GURGAON-122001, HARYANA
Phone: 0124-2321052, 2329934Email: [email protected];[email protected]
MR. C P DAHRA/MR. SAMIR DAHRA
DAHRA ENGG CO
35 VISHWAKARMA INDL. AREA,
SECTOR 24, NEAR DHARAMKANTA,
MUJESSAR, FARIDABAD-121005, HARYANA
Phone: 0129-2232388, 2232684, 4023153, 9811211965, 2241519
Email: [email protected], [email protected]
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MR. DINESH PATELDEV INDUSTRIES
13, PRAGATI INDUSTRIAL ESTATE,
OPP. JAGANNATH ESTATE,
GUJARAT BOTTLING ROAD, RAKHIAL
AHMEDABAD-380023, GUJARAT
Phone: 079-2748716/98250-38773
HARGOVIND BATRA, MD
H F H AUTO PUMPS
SURVEY NO. 115, HISSA NO. 6,
GHODBUNDER ROADTHANE-401104, MAHARASHTRA
Phone: +91 22 285 50156,28550158
MR. KAPIL BHATIA (EXP MGR)
HAMMER AUTO INDUSTRIES
374 PUNJA SHARIF, KASHMERE GATE
DELHI-110006
Phone: 011-23975863
Email: [email protected];[email protected]
R. K. BANSAL, PARTNER
HINDUSTAN TRADING CORP
4, LIBERTY HOUSE, MAVDI PLOT
RAJKOT-360004, GUJARAT
Mobile:Phone: +91 281 388 541,388630
Email: [email protected]; [email protected]
MR. KAMAL KAPURIA (DIR)
IAEL PUMPS LTD
C-60-B, KALKAJI
NEW DELHI-110019Phone: 011-26447880, 26473243,
Email: [email protected]
JAYANT DAVE, OWNER
JAYANT ENGINEERING WORKS
46/2/1B, KALA HALAI INDUSTRIAL ESTATE,
PUNE SATARA ROAD
PUNE-411009, MAHARASHTRA
Phone: +91 20 422 0244
Email: [email protected]
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B. LANGETARTELS
K B S PUMPS LTD
MAKER CHAMBERS,
NO. III/126, NARIMAN POINT
MUMBAI-400021, MAHARASHTRA
Phone: 022-22854237/4242/22840614
Email: [email protected]
Mg. Director
KAFILA GROUP OF COMPANIES
32, RAJSTHANI UDYOG NAGAR,G T ROAD, AZADPUR
NEW DELHI-110033
Phone:011-55457319
RAKESH KAD, MD
KAD ENTERPRISES
13-Y, THE MALL
PATIALA-147001, PUNJAB
Phone: +91 175 354 433
Mg. Director
KHADIKAR SALES & SERVICES LTD
1ST FLOOR VRAJ BHOOMI COMPLEX,
C G ROAD, NAVRANGPURA
AHMEDABAD-380009, GUJARAT
Phone: 079-26420318
Email: [email protected]
Mg. Director
KISHOR PUMPS PVT LTD
C-46, BALI NAGAR,NEAR RAJA GARDEN
NEW DELHI-110015
Phone:011-25933920, 25464912
Email: [email protected]
MR. RAKESH KOCHHAR
KOCHHAR BROTHERS
HADIABAD, PHAGWARA, PUNJAB
Phone:01824-62307/(R)2220578
Email: [email protected]
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MR. ANIL MALHOTRA
MOON PAPER & MACHINERY PVT LTD
32, RAJASTHANI UDYOG NAGAR,
G T KARNAL ROAD, DELHI-110033
Phone: 011-27139462, 27243593, 27139463,
Email: [email protected]
MR. MILIND S. WALVEKAR
OM ENTERPRISES
D-113, ANGOL INDL. ESTATE,
BELGAUM, KARNATAKAPhone: 918312441694
Email: [email protected]
MR. ASHISH SHAH
PARAS ENGINEERING COMPANY
ROYAL BUILDING,
OPP MAHALAXMI PETROL PUMP,
KADIAKUI, RELIEF ROAD,
AHMEDABAD-380001, GUJARAT
Phone: 917922131338/55441600
Mg. Director
PENTAFOUR PRODUCTS LTD AUTO DIVN
PENTAFOUR TOWERS,
1ST MAIN ROAD, UNITED COLONY
CHENNAI-600024, TAMIL NADU
Phone: 044-24836934
Email: [email protected]
MR. D. C. POTTADAR
POWER & MACHINERY INDIA PVT LTD3, MANGOE LANE, GROUND FLOOR
KOLKATA-700001, WEST BENGAL
Phone: 033-248-2047
MR. HITESH D. RAMANI
RADHA ENTERPRISES
10/3, BHAKTINAGAR ST. PLOT
RAJKOT-360002, GUJARAT
Phone: 0281-2462206
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MR A V SHANKARANRAPID AUTO COMP PVT LTD
21-B, BALAJI NAGAR, PADI
CHENNAI-600050, TAMIL NADU
Phone: 044-26541819
MR. RAMBHAI PATEL
SAGAR PUMPS(INDIA)LTD
135, BANNER INDIA ESATE OPP,
SOMA TEXTILE, RAKHIAL
AHMEDABAD-380023, GUJARAT
Phone: 079-2743182/2742579
K. SAMPATHKUMAR, MD
SAM TURBO INDUSTRY LTD
BHARATI PARK, CROSS ROAD NO 7,
P B NO 2725, COIMBATORE-641011,
TAMIL NADU
Phone: +91 422 436264, 441155
P. D. JOSHI, MANAGER
SHREE SAINATH INDUSTRIES
S S HOUSE, OPP. SUMIN PARK,
G.D. HIGH SCHOOL ROAD, SAIJPUR BOGHA
AHMEDABAD-382345, GUJARAT
Phone: +91 79 2820363, 2821763
Email: [email protected]
Mg. Director
SUGUNA MACHINE WORKS LTD
707, AVANASHI ROAD
COIMBATORE-641018, TAMIL NADU
Phone: 0422-2215512Email: [email protected]
Mg. Director
WALKAR AUTOMOTIVES PVT LTD
20, SECTOR-4,, BALLABGARH
FARIDABAD, HARYANA
Phone: 0129-2240061,62,
Email: [email protected]
COMPRESSOR
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7/22/2019 ALUMINIUM FOIL & SHEET PROJECT REPORT
56/90
ALUMINIUM FOIL & SHEET [EDPR/0966] (J.C.9601)
Raj Patni, Director