Project Profile

Product : Corrugated iron Sheets

Product Code ( ASICC ) : 71241

Plant Capacity per annum : 13,50,000 Mtr.

Value ( Rs. ) per annum : 35,10,00,000

Month & Year of Preparation : March, 2012

: Prepared By : -
Micro Small and Medium Enterprises Development Institute,
Government of India
Ministry of Micro Small and Medium Enterprises
Bais Godam, Jaipur 302 006 (Raj.)
Ph. 0141-2212098, 2213099, Fax. 2210553
e mail- dcdi-jaipur@dcmsme.gov.in
web- dcmsme.gov.in

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 CORRUGATED IRON SHEETS

1. INTRODUCTION : The profile envisage to set up Automatic Roll Forming

Line to manufacturer Corrugated Sheet , Corrugated sheets are roll formed by
roll forming machines, the thickness and color can be different, these panels are
featured with easy installation, high strength, more economic , (low lost ). They
are widely use as the wall or roof of factory, warehouse, garage, exhibition center,
cinema etc.Other products such as Floor Decking Steel Sheet, C & Z Purlin are
also roll formed by roll forming machine,

Corrugated sheet in different models:

Direct overlaped model,screw hidden model,self-locked model or as you
want.Don't you consider choosing favorite one?

Floor Decking Steel Sheet , C & Z Purlin , is roll formed by roll forming machine,
mainly uing galvanized steel, at thickness 0.8 - 1.2mm. Simple shape with high rib and
high strength. Put the panel above the welded wire net, fill cement between them. This
panel is usually used as the floor of high buildings, it can save steel mound and can also
save the weight, in the same loading capacity, use this panel, and save the steel quantity,
and thus save cost.

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C & Z Purlin is roll formed by roll forming machine, mainly use hot roll steel and
galvanized steel at thickness 1.5mm C 3.0mm. it is featured with better anti bending and
straightness, these products are used as the main supporting bars on steel structure for
warehouse, garage, exhibition etc.

2.0 MARKET POTENTIAL : PPGI and PPGL/ NCGI/ GI Sheets have

excellent corrosion resistance, these Sheets have become the most preferred
material for various construction purposes, particularly roofing and walling.
Coated Steel Sheet is a unique building material that combines the strength of
steel with excellent corrosion protection of zinc or zinc/aluminium alloy coatings.
It can be punched, pressed, roll formed and joined into a countless number of
structural and decorative building, PPGL Sheets are available in various colours -
sky blue, royal blue, azurite blue, terra cotta red, off white and mist green.&
architects are use these iron sheets as a sign of prestige and also for security
against fire . They are widely use as the wall or roof of factory, warehouse,
garage, exhibition center, cinema etc. This trend is increasing every year . Such as
demand for corrugated iron sheet has increased greatly.

3.0 RAW MATERIALS : PPGI and PPGL/ NCGI/ GI Sheets

Specifications -PPGI: Al Zn Alloy Coated Steel combination - 55% aluminium;
43.4%zinc & 1.6% silicon

PPGL: Pre-painted Al Zn Alloy Coated Steel

PPGI: Colour Coated Galvanised Steel

Features

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 Good design & secure fastening system ensure the security and weather tight
performance of Coated Steel Roofing during extreme weather conditions.
Coated Steel Sheet is fire resistant.
Excellent thermal properties to keep your building cooler in summer and in
warmer in winter. Galvanised
Steel Sheets which are widely used in construction , These Galvalume and GI
Sheets are available in brick red, chrome green and sky blue colour.

Technical Specification:

Coil input Width : 1220 mm

Covered Width : 1000 mm
Supply Width : 1100 10
Pitch : 200 mm
Crest Height : 28mm

4. MANUFACTURING PROCESS : In the corrugation process sheet metal is

pulled off huge rolls and through rolling dies that form the corrugation. After the sheet
metal passes through the rollers it is automatically sheared off at a desired length. The
standard shape of corrugated material is the round wavy style, but can be easily modified
to a variety of shapes and sizes by simply changing the dies.

Automatic Roll Forming Line consists following parts , while the coil stock is passing
through succession contoured rolls the material bends to its desired shape, after final
shape is achieved profile straighter gives straightness to out going profile
1) De Coiler ( 5 Ton)
2) Loop System
3) Entry gauge and Roll Forming machine
4) Cutting unite
5) Run out table
6) Integrated Hydraulic power Pack system
7) P L C control system

DECOILER :Decoiler is provided to load Raw material coil on it's arms & Hold the coil and also
generates Drag tension in process.

LOOP SYSTEM : Loop System is incorporated in between 2 line equipments to syncronise line
speed or some time to eliminate tension, stretch, on passing material.

ROLL FORMING LINE : Roll forming consists pairs of contoured roll tools. While the coil
stock is passing through succession contoured rolls the material bends to its desired shape, after final shape
is achieved profile straighter gives straightness to out going profile.
CUTTING SYSTEM : Cutting as Stop Forming line Cuts length +/- 4 mm and very hay line speed
cuts the blank or profile single word. Press is designed to accept type die or tropping die without slug while
cutting.

Integrated hydraulic Power pack system : To Supply pressurized fluid to all hyd.
actuators at Desired pressure and quantity.

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P.L.C. & CONTROL PANELS : For Electrical controlling of line equipments.
4.1 QUALITY SYSTEM : Bureau of Indian Standard Laid down following
Specifications :

IS 14491 -1999 -low Carbon high strength cold rolled steel sheets & coil for cold
forming
IS 811~Cold Formed Light Gauge Structural Steel Sections

IS 12093~Code of practice for laying and fixing of sloped roof coverings

using plain and corrugated galvanized steel sheets

IS 1254~Corrugated aluminium sheet

IS 12583~corrugated bitumen roofing sheets

IS 14871~Products in Fibre Reinforced Cement - Long Corrugated or

Asymmetrical Section Sheets and Fittings for Roofing and Cladding

IS 12093~Code of practice for laying and fixing of sloped roof coverings

using plain and corrugated galvanized steel sheets

IS 277~Galvanized Steel Sheets (Plain and Corrugated )

IS 1367 : Part 14 : Sec 3~Technical Supply Conditions for Threaded Steel

Fasteners - Part 14 : Mechanical Properties of Corrosion-resistant Stainless-
steel Fasteners - Section 3 : Set Screws and Similar Fasteners not Under
Tensile Stress

5.0 BASIS OF PROJECT SELECTION : Architects are using these iron

sheets as a sign of prestige and also for security against fire . They are widely use
as the wall or roof of factory, warehouse, garage, exhibition center, cinema etc.
This trend is increasing every year . Such as demand for corrugated iron sheet has
increased greatly.

6.0 PRESUMPTIONS: -
The profile has been prepared on single shift basis of 8 hour per day and 300
working days per annum , Presuming the bottlenecks in the heat treatment &
coating operation.

Labour wages has been taken as per market rate. It is likely to vary depending upon the
location of the project .

Rate of interest has been taken 12% on an average on fixed and working capital. It is
likely to vary due to financial outlay and the location of the unit.

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The operative period of the project is estimated to be about 8 years considering
technology obsolescence

Value of machinery & equipment is estimated on the basis Quotations received &
prevailing cost of the local mkt/ Reports.

As the cost of raw Material is major part of working Capital and is very high and as
per the mrket trend the working capital is being taken for 1.5 months only.
7.0 PRODUCTION CAPACITY :
The proposed Automatic Roll forming Line have 18 No.of stations & have
production capacity ( variable line speed 0 to 15 mitr.per minute ). In
keeping view plant capacity and presumptions made over capacity calculated
as under :
Plant Capacity per annum : 15 Mtrs /minute
900 mtr./hours (4.5 kg. in 1 Mtr.)
4500 mtr./day or
20000 kg/day (.5 thickness)
13,50,000 Mtr.per annum
Value (@ Rs.275 per mtr.) :Rs. 37,12,50,000
8.0 UTILITY REQUIREMENTS : 30 Kw
9.0 IMPLEMENTATION SCHEDULE:
S.No. Activities Period in
Months
1 Preparation of project report and selection of site 1
2 Registration 1
3 Application for Electricity Connection 1
4 Civil work & Availability of finance& Procurement of 6
machinery
6 Electrification & installation 2
7 Recruitment of staff 1
8 Trial run 1
Total 13

10. FINANCIAL ASPECTS:

A . Land & Building

Land : The 2000 Sq 3500 Rs.70,00,000.00

requirement of land for .m
the proposed unit
would be 1950 sq m @
Rs3500 Sq m

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 Building/Civil Construction
Factory Shed 5000 Sq. Rs.450 per Sq feet Rs. 2250000.00
Ft.

Office 600 Sq. Ft. Rs.800 per Sq Feet Rs. 480000.00

Labour Quarters 450 Sq. Ft. Rs.700 per Sq.feet Rs. 315000.00

Boundary Wall Rs. 190 Running Rs. 760000.00

Mtr.
Roads LS Rs. 780000.00
Others(Electric & LS Rs.200000.00
Sanitary fittings)
TOTAL Rs. 4785000.00
Total ( Land & Building ) Rs.1,17,85000.00

B) PLANT & MACHINERY

S.No. Description of machine Qty. Price Amount ( Rs. )
1 Automatic Roll Forming Line 23,000,00.00
1 SET
(De Coiler ( 5 Ton), Loop System,
Entry gauge and Roll Forming
machine, Cutting unit, Run out table,
Integrated Hydraulic power Pack
system, P L C control system) have
production capacity 15mtr per Minute ,
total power required 25 KW , its
General pecification are as under ax.
width of coil : 1380 mm Min width of
Coil : 500 mm Max. Thickness of Coil :
0.8mm Min. hickness of Coil : 0.2mm
Max. weight of Coil : 30 ton Variable
Speed : 0 to 15 mtr./min.
Misc. Tool S, Dies & Spares 3,40,000.00
Taxes & Transportation 2,30,000.00.00
Installation & Electrification @ 10% 2,30,000.00
TOTAL 31,00,000.00
Office Equipment (Furniture & LS 5,00,000.00.00
fixture, Fire Fighting Equipments,
Computers & Printers, Air
conditioners, Other Office
Equipments )
Total Investment In Plant & machinery 36,00,000.00
Pre Operative Expenses 200000.00
Total 38,00.000.00
C. Total Investment In fixed assets 1,55,85,000.00

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D. WORKING CAPITAL
i Personnel ( Per month )
S.NO. DESIGNATION No. Salary Total (Rs.)
1 Workshop in charge 1 30000 30000
2 Accountant/Store 1 20,000 20,000
incharge

3 Supervisor 2 15,000 30,000

4 Skilled Worker 2 12,000 24,000
5 Semi skilled worker/ 2 8000 16,000
Helper
6 Peon / Watchman 3 5000 15,000
Total 1,35,000
Additional Perquisites (
Included )
Total Expenditure in 135000
Salary & Wages

ii Raw Material ( Per Month )

S.No. Particular (Indigenous) Qty Rate Value (Rs.)

1 PPGL/ PPGI/ NCGI/ GI 500 tonne Rs.55000 (Average) 2,75,00,000.00
Coils per tonne
TOTAL 2,75,00,000.00

iii Utilities ( Per Month ) Value (Rs.)

1 Power ( 150 units per day 3750 units Rs. 5.50 20,625
)
2 Water & Compressed Air LS 1,375
TOTAL 22,000.00
iv Other Contingent Expenses
1 Postage and stationary 3500
2 Office Consumable stores 3500
3 Transport charges 10000
4 Telephone charges 5000
5 Publicity Expenses 5000
6 Traveling expenses 15000
7 Repair & Maint. 10000
8 Miscellaneous expenses 7500
9 Insurance 2500
TOTAL 62,000.00

v Total Recurring Expenditure ( Per Month )

S.No. Description Cost
1 Personnel 135000.00
2 Raw material 2,75,00,000.00
3 Utilities 22,000.00
4 Other Contingent Expenses 62,000.00
TOTAL 2,77,19,000.00

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 vi Total working capital for 1.5 Month : Rs. 4,15,78,500.00

E Total Capital Investment :

i Fixed Capital 1,55,85,000
ii Working Capital for 1.5 Months 4,15,78,500
Total Capital Investment : 5,71,63,500
Total Capital Investment 5,72,000,00
Say
Finance Detail %
Contribution
i Self Contribution 25 1,43,00,000
iii Banks Contribution 75 4,29,00,000
F FINANCIAL ANALYSIS
1 Cost of Production (Per Year) :
i Total recurring cost : 33,26,28,000
ii Depreciation of machinery and equipment @ 10% 3,10,000
iii Interest on total Capital investment @ 12% 68,64.,000
iv Depreciation of tools and office equipment / furniture 1,00,000
@ 20%
v Depreciation of Building @ 5% 2,39,250
Total : 34,01,41,250

2 Total Sales (Per annum)

Products Qty. Rate Value (Rs.)

PPGL/ PPGI/ NCGI/ GI Rs.275Rs/mtr. 37,12,50,000

Corrugated Sheet 13,50,000 Mtr.
TOTAL Rs. 37,12,50,000

3 Net Profit (Per yr.) (Before tax)

Total turnover per yr. -cost of production per yr.
(in Rs.) = 37,12,50,000.00 -34,01,41,250.00 = 3,11.08,750.00

4 Net profit ratio :

Net profit 100 = 3,11.08,750.00 x100 = 8.38%
Turn Over 37,12,50,000.00

5 Rate of return :
Net profit 100 = 3,11.08,750.00 x100 = 54.38 %
Total Investment 5,72,00,000.00

6 BREAK-EVEN POINT;
FIXED COST ;
1 40% salary & wages 6,48,000.00
2 Depreciation on machinery & 3,10,000.00
Equipments @ 10%
3 Depreciation of tools and office 75,000.00
equipment @ 15%

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 4 Depreciation of Building @ 5% 2,39,250 .00
5 Interest on capital investment 68,64.,000.00
@ 12%
6 40% of other contingent 2,97,600.00
expenses& Insurance
TOTAL 84,33850
Net Profit (Per yr.) (Before tax) 3,11.08,750

BEP :
Fixed Cost 100 =( 84,33850 / 84,33850 + 3,11.08,750.00)x100 =
Fixed Cost + Profit

= 84,33850 / 31108750)x100= 27.11 %

11. PLANT & RAW MATERIAL SUPPLIER ADDRESS

11.1. Plant & Machinery :
Jupiter Enterprises
Survey No. 267,Plot No. 7, Behind Maruti Petrol Pump
Opp.Captain Polyplast Ltd.
Shapar ( Veravali) Rajkot ( Guj.) Phone
+91-2827-252004 , (M) +91-9276087001,9276087006
www.rollformingjupiter.com
E-mail: jupiterenterprise1@gmail.com

Maneklal and Sons (Exports)

237 / 239 Perin Nariman Street Fort, Mumbai - 400 001, INDIA
Tel: (+91 22) 22618951 / 22618962 Fax: (+91 22) 22618903
e-mail: sales@maneklalexports.com / maneklalexports@gmail.com

11.2 Raw Materials & Consumables

1. Local Market
2. SAIL
3. JSW Steel

12. List of the units set up by using this project Profile :

1.Quality Roofs
16, Ist Street , East Kamakodi Nagar , Valsaravakkam, Channai, Tamilnadu -
600087 ( India )
Ph. 91-44-24860349, Fax: 91-44-24860349
Contact Person : Mr. S.Srini (M) 09841510901
www.qualityroofing.in

2. M.G.Exim Pvt. Ltd.

3rd Floor , Sumeru Centre, Paldi Ahmedabad,
Guj.( India)- 380007
Ph. 91-79-2665 1742 Fax: 91-79-2665 2847
Contact Person : Mr. Gaureen Nagarsheth (CEO )(M) 91-9824062036

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