Detailed Project Report on MANUFACTURING OF HOUSE WIRE & CABLES (COPPER) & AERIAL BUNCHED CABLE (CAP: 75

The market for wire and cables is divided into different segments in terms of product variation. The basic division is between cables and conductors. Cables are either power cables or control cables. Power cables supply energy at voltages up to 230 KV. Control cables are low voltage cables (up to 0.6 KV) used to transmit control signals in switch boards. The conducting material can be copper or aluminum with insulating material, PVC, XLPE, elastomers or paper. The cable market is segmented by the combination of material used to form the conductor, the insulator, sheathing and armoring.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



MANUFACTURING OF HOUSE WIRE & CABLES
(COPPER) & AERIAL BUNCHED CABLE (CAP: 75
TON/DAY) [EIRI/EDPR/4722] J.C.: 2942US$

The market for wire and cables is divided into different segments in terms of
product variation. The basic division is between cables and conductors. Cables are
either power cables or control cables. Power cables supply energy at voltages up to
230 KV. Control cables are low voltage cables (up to 0.6 KV) used to transmit
control signals in switch boards. The conducting material can be copper or
aluminum with insulating material, PVC, XLPE, elastomers or paper. The cable
market is segmented by the combination of material used to form the conductor,
the insulator, sheathing and armoring.

An ABC Cable, also known as Aerial Bundled Cable, is an overhead power line.
This cable consists of numerous insulated conductors, bundled and
wrappedtogether tightly. It also comes along with a bare neutral conductor. The
use of insulation is the ABC cable is in contrast with the traditional transmission
cables that were uninsulated. Additionally, these cables can transmit power in low
voltages.

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CONTENTS


INTRODUCTION
OBJECTIVE OF THE PROJECT
THE SOCIO-ECONOMIC SIGNIFICANCE OF THE PROJECT
EMPLOYMENT OPPORTUNI TY
SAVE THE COUNTRY FOREIGN EXCHANGE
BENEFIT FOR THE LOCAL COMMUNITY
STIMULATE THE LOCAL ECONOMY
TECHNOLOGY TRANSFER
PRODUCT DESCRIPTION
TYPES OF ABC CABLES:
LOW VOLTAGE AERIAL BUNDLE CABLES:
MEDIUM VOLTAGE AERIAL BUNDLE CABLES:
DUPLEX/TRIPLEX SERVI CE DROP WIRE:
AERIAL BUNCHED CABLES
CONSTRUCTION OF ABC
MATERIALS
APPLICATION
AERIAL BUNCHED CABLES CAN BE CONVENIENTLY USED:
ADVANTAGES/APPLICATI ONS
ADVANTAGES OF USING ABC CABLES:
• INCREASED SAFETY:
• LOW MAINTENANCE COSTS:
• WIDE AREA COVERAGE:
• SECURE FROM SHORT CIRCUITS:
• AFFORDABLE PRICES:
EASY DETECTION OF FAULTS:
• EASY INSTALLATION:
B.I.S. SPECIFICATIONOF PRODUCTS
INDUSTRY/MARKET OVERVIEW
ECONOMIC OUTLOOK

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GLOBAL ECONOMY
TABLE 1: GLOBAL GROWTH OUTLOOK PROJECTIONS (IN%)
1.1 INDIAN ECONOMY
1.1.1 INDEX OF INDUSTRIAL PRODUCTION
1.1.2 SECTORAL PERFORMANCE
1.1.3 CONSUMPTION AND INVESTMENT
1.1.1 CAPITAL MARKET PERFORMANC E
1.1.2 IMPACT OF THE RUSSIA INVASION ON ECONOMY
1.1.3 OUTLOOK
OVERVIEW OF WIRE AND CABLE INDUSTRY
GLOBAL WIRE AND CABLE MARKET HISTORIC TRENDS
GLOBAL WIRE AND CABLE MARKET FORECAST GROWTH
INDIAN WIRE AND CABLE INDUSTRY MARKET
C & W MARKET IN REVENUE TERMS
GROWING SHARE OF ORGANIZED PLAYERS
COVID IMPACT ON WIRE AND CABLE INDUSTRY
GROWTH & DEMAND DRIVERS OF WIRE AND CABLE INDUSTRY
CABLES AND WIRES DEMAND DRIVERS
SUPERIOR QUALITY PRODUCT IN HOUSING WIRES LED TO HIGHER MARG INS
FOR ORGANIZED PLAYERS
HOUSING SECTOR:
TIER II AND III CITIES TO DRIVE HOUSING CONSTRUCTION GROWTH
NHB INDIA HOUSING PRICE INDEX*
HOUSING DEMAND -SUPPLY UNITS IN TOP 8 CITIES 2016-2020
INFRASTRUCTURE:
PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES
POWER
INDUSTRIAL EXPANSION AND STRONG GDP GROWTH DRIVING POWER
DEMAND
RAILWAYS:
1. GROWING DEMAND
2. POLICY SUPPORT
 RISING INCOME AND URBANISATION DRIVING PASSENGER TRAFFIC
GROWTH
 INFRASTRUCTURE DEV ELOPMENT
1. TELECOMMUNICATION
 SECOND -LARGEST SUBSCRIBER BASE

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STRONG GROWTH IN BROADBAND DRIVES INTERNET ACCESS REVENUES
CHALLENGES FACED BY THE INDUSTRY
CYCLICAL MARKET
POWER SHIFTS IN THE SUPPLY CHAIN
CONVERSION INDUSTRY AND WORKING CAPITAL
DE-REGULATION LOWERS BARRIERS OF ENTRY
GOVERNMENT INITIATIVES UNDERTAKEN FOR INDUSTRY
1. HOUSING FOR ALL
PROGRESS OF PMAY:
PRADHAN MANTRI AWAS YOJANA-URBAN (PMAY-U)
PRADHAN MANTRI AWAS YOJANA GRAMIN (PRADHAN MANTRI AWAS YOJANA
RURAL)
1. GOVERNMENT’S FOCUS ON IMPROVING ELECT RIFICATION
2. MAKE IN INDIA
3. SMART CITIES MISSION
COMPETITIVE ANALYSIS & KEY INDUSTRY PLAYERS
1. PORTER FIVE FORCES ANALYSIS
• THREATS OF NEW ENT RANTS
• BARGAINING POWER OF SUPPLIERS
• BARGAINING POWER OF BUYERS
• THREATS OF SUBSTIT UTE PRODUCTS OR SERVICES
• RIVALRY AMONG THE EXISTING COMPETITORS
IMPLICATIONS OF PORT ER FIVE FORCES ON WI RE & CABLE COMPANY
1. FINOLEX CABLES LIMITED
3. POLYCAB INDIA LIMITED
4. HAVELLS INDIA LIMITED
5. RR KABEL LIMITED
6. V-GUARD INDUSTRIES LIM ITED
7. PLAZA WIRES LIMITED
OUTLOOK/CONCLUSION
MANUFACTURING PROCESS
TECHNOLOGY
COPPER BONDING WIRE OF 99.999% PURITY
FEATURES
MANUFACTURING PROCESS
ANNEALING
STRANDING
INSULATING

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LAY-UP
SHEATHING
ARMORING
PACKING
MANUFACTURING FLOW CHART
1. SINGLE WIRE
2. MULTIPLE WIRE
3. FLEXIBLE WIRE
4. FLAT TWIN-CORD WIRE
5. POWER CABLE WIRE
6. ARMOUR CABLE
DRAWING
BUNCHING
STRANDING
EXTRUSION
COILING AND PACKING
MANUFACTURING PROCESS
(I) METHOD OF MAKING STRIP
(II) PROCESS OF COVERING
(III) METHOD OF MATERIAL ANNEALING
MACHINERY & EQUIPMENTS REQUIRMENT
A. MACHINERIES
A. ACCESSORY EQUIPMENT’S
B. INSPECTION AND TESTING EQUIPMENT
PROCESS FLOW DIAGRAM
QUALITY CONTROL
KEY REGULATIONS AND POLICIES
A. INDUSTRYRELATED LEGISLATION
1. THE FACTORIES ACT, 1948
1. THE ELECTRICAL WIRES, CABLES, APPLIANCES AND PROTECTION DEVICES
AND ACCESSORIES (QUALITY CONTROL) ORDER, 2003
2. ELECTRICITY ACT, 2003
B. EMPLOYEE AND LABOUR RELATED LEGISLATI ONS:
THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION,
PROHIBITION AND REDRESSAL) ACT, 2013
A. SHOPS AND COMMERCIAL ESTABLISHMENTS LEGISLATION:
B. TAX RELATED LAWS:
1. INCOME-TAX ACT, 1961

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2. CENTRAL GOODS AND SERVICES TAX ACT, 2017
1. INTEGRATED GOODS AND SERVICES TAX ACT , 2017
2. THE CUSTOMS ACT, 1962 AND THE CUSTOMS TARIFF ACT, 1975
5. PROFESSIONAL TAX
A. INTELLECTUAL PROPERTY LAWS
1. THE TRADEMARKS ACT, 1999
2. THE COPYRIGHT ACT , 1957
B. OTHER APPLICABLE LAWS:
THE COMPANIES ACT, 2013
1. THE CONSUMER PROT ECTION ACT, 1986
1. THE TRANSFER OF PROPERTY ACT, 1882
2. THE SALE OF GOODS ACT, 1930
3. THE REGISTRATION ACT, 1908
4. THE INDIAN CONTRACT ACT, 1872
5. THE SPECIFIC RELIEF ACT, 1963
1. COMPETITION ACT, 2002
2. LEGISLATIONS PERTAINING TO STAMP DUTY
3. LEGAL METROLOGY ACT, 2009
A. ENVIRONMENTAL LAWS
1. THE ENVIRONMENT PROTECTION ACT, 1986 AND ENVIRONMENT
(PROTECTION) RULES, 1986
1. THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (“THE
WATER ACT”)
2. THE AIR (PREVENTION AND CONTROL OF POLLUTI ON)ACT,1981 (THE AIR
ACT)
B. REGULATIONS REGARDING FOREIGN INVESTMENT
FOREIGN EXCHANGE MANAGEMENT ACT, 1999
SUPPLIERS OF MAJOR PLANT & MACHINERY
MACHINERY
MATERIAL HANDLING EQUIPMENTS
LABORATORY TESTING EQUIPMENTS
MIXING PLANT
STEEL WIRES
MIXTURE
SUPPLIERS OF SIEVING MACHINE
SUPPLIERS OF METAL T ESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF PRECISION MEASURING TOOLS

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SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER T RANSFORMERS
SUPPLIERS OF ELECTRI CAL PANEL
SUPPLIERS OF ELECTRI C MOTOR
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENT S
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF JIGS AND FIXTURE
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:

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8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATI ON SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
GENERATION AND MANAGEMENT OF WASTES
SOLID WASTES
LIQUID WASTES
GASEOUS EMISSION
OTHERS
INDUSTRIAL WASTE MANAGEMENT
SEWERAGE SYSTEM
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVI RONMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW
MATERIAL & PRODUCT)
SAFETY DATA SHEETS
ENVIRONMENTAL/SAFETY LIABILITY
PRE-PROJECT ACTIVITIES
PROPOSED IMPLEMENTAT ION SCHEDULE
PLANT LAYOUT
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
SWOT ANALYSIS
SWOT ANALYSIS
1. STRENGTH
2. WEAKNESS
3. OPPORTUNITY
4. THREATS
ORGANIZATION CHART
ORGANIZATIONAL STRUC TURE
1. MANAGER

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2. THE MANUFACTURING DEPARTMENT DUTIES AND RESPONSIBILITIES: -
3. ADMINISTRATION AND FINANCE DEPARTMENT
FINANCE SECTION
DUTIES AND RESPONSIB ILITIES: -
4. MARKETING AND SALES DEPARTMENT
IMPLEMENTATION SCHEDULE
FUTURE DEVELOPMENT
ENVIRONMENTAL IMPACT OF THE PROJECT

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 75 TON/Day

Land & Building (10,000 sq.mt.) US$ 6.79 Lac

Plant & Machinery US$ 4.04 Lac

Working Capital for 2 Months US$ 1.36 Cr

Total Capital Investment US$ 1.48 Cr

Rate of Return 20%

Break Even Point 48%