Ref. No : GOK/AE/001 Date : 15.06.

2017

Annexure 1
Industrial Shed & Electrical
Total Power Requirement = 400 KW
if we calculate Power Factor 0.92 than 434.78 kVA
Deposit Amount = 15 Lakh
Transformer = 5 Lakh
Power Factor = 3 Lakh
Servo = 5 Lakh
Main Electrical Panel with Air Cicuit Braker,RCCB &
contractor = 3.5 Lakh
cable = 1.5 lakh
Installation Cost = 1 Lakh
Total Infrastructure Cost including Boundary Wall,
Industrial Shed and Staff quarter = 75 Lakh
Total investment = 109 Lakh

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

 Integrated aluminium Extrusion Plant Proposal
Anexure 2
Aluminium Melting & Recycling Plant
PROCESS FLOW CHART
Receipt of imported
virgin material

container wise scrap

stored in Bins

Sorting, segregating &

removal the material

Other impurities (if any),

to be stored seprately

Other impurities (if any),

to be stored separately

Through Spectro analysis

of segregated material

weightment

Melting of material with fluxing & Removal of Fe content In progress spectro analysis at Addition of
combination of Aluminium Drawsing from the bottom various stages alloy Elements

In Process Sample
analysis

Degassing , Refining &

Fluxing

Filtration

Casting Ingots

Final Spectro Analysis

Punching the heat nos.

on the Ingots

Removing Flashes
(Blunding/Stacking)

Weightment

Warehousing

Invoicing

Dispatch

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

UBC (used beverage cans) Recycling system are designed to clean the aluminium by separating it from
magnetic and stainless steel as well as organic material. By downsizing the material and thereby increasing
the density of the material transporting costs will be reduced. As an alternative to virging aluminium
production, the recycling of aluminium is as profitable business.

Aluminium items are eminently suited to recycle. It can be recycled infinitely without losing quality, and it
is much more energy efficient to produce aluminium through recycling than making it from raw bauxite
(save up to 95% energy). The energy saved from recycling one aluminium Coca Cola can will run a TV for
three hours. If not recycled, it takes 80-100 years for an aluminium can to break down in a landfill. As an
alternative to virgin aluminium production, the recycling of aluminium is a profitable business.

Why Aluminium should be Recycled: Aluminium is 100% recyclable and experiences no loss of
properties or quality during the recycling process. Recycling aluminium also uses only 5% of the energy
used to create new Aluminium and emits only 5% of the greenhouse gases. It is for these reasons that
approximately 75% of the aluminium ever produced is still in use today by recycling method.

Recycling Method: Aluminium recycling is the process by which scrap aluminium can be reused in
products after its initial production. The process involves simply re-melting the metal, which is far less
expensive and energy intensive than creating new Aluminium from its Bauxite Ore.

Success of Aluminium Recycling: Aluminum production has been ongoing for over a century and is still
going strong. One of the key factors in the success of aluminum is its recyclability. In fact, recycling has
proven so valuable—both economically and ecologically—that recovery and recycling has become its own
industry, and a highly successful one.

While UBC (Used Beverages Can) are the most visible part of the aluminum recycling story, they are far
from the whole story. In fact, UBC recycling typically amounts to less than 30 percent of the tonnage of
aluminum consumer products that are recycled.
The growth of the market for recycled aluminium is due in large measure to economics.
Today, “Aluminium Recycling” is cheaper, faster, and more energy efficient & it achieves higher
recovery rate of aluminum than ever before. In addition, to achieve a given output of ingot, recycled
aluminum requires only about 10 percent of the capital equipment compared with primary aluminum.

Importance of Recycling Aluminum (UBC) Cans:

Saving Energy & Achieving Carbon Credit
According to the Aluminum Association, an industry trade group, recycling just one can saves the amount
of energy it takes to watch the Super bowl — in other words, the amount of energy needed to power a
television for three hours.(See Reference 4)

Reducing Greenhouse Gas Emissions

In the Hall process, current passes through graphite electrodes submerged in molten alumina, or Al2O3.
The carbon in the graphite electrodes reacts with the oxygen in the molten alumina to yield carbon dioxide.
Although pure aluminum is isolated in the process, the amount of carbon dioxide released is considerable
— more than 1 ton of carbon dioxide for every ton of aluminum produced (see References 1). According
to Waste Online, recycling aluminum releases only 5 percent of the CO2 required to refine fresh aluminum
from bauxite. This way you will get carbon Credit by adopting recycling process.

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Reducing Waste & Mining Impacts
According to the EPA, Americans threw out 3.4 million tons of aluminum in 2009 — roughly 1.4 percent
of the total waste stream. Moreover, the more aluminum recycled, the less manufacturers need to produce.
Production of aluminum necessitates extraction of bauxite ore, and mining also has environmental
impacts. Typically bauxite is strip-mined, meaning the soil atop the deposit is removed; in the process, the
vegetation at the site is destroyed. (See References 3,4)

Economic Value of Recycled Aluminum

Recycled aluminum is a valuable commodity, so most recycling centers will accept your used cans.
Moreover, aluminum can be recycled indefinitely — with no limit on the number of times the metal can be
reused. According to the Aluminum Association, this property of aluminum gives it an extraordinarily high
value as scrap (see References). According to Waste Online, aluminum is more cost-effective to recycle
than any other metal (see References 2). The EPA notes that aluminum is easy to recycle, so there’s a wide
market for the recycled product.

Aluminium Recycling Process

The aluminum recycling process is fairly straightforward in its major steps. Aluminum cans (UBC)
recycling, for example, is a closed-loop process, which means the new product at the end of the recycling
process is the same as the source product. It goes like this:

• The consumer throws aluminium beverage cans and foil into a recycle bin.
• All UBC (Used Beverage Cans) are baled and formed in compact shape and size for ease of
logistics.
• In the treatment plant the aluminium is sorted and cleaned ready for reprocessing
• The cans are shredded into small pieces and fed into a Decoater Dryer Machine to remove
paint coating available on surface area of the UBC metal shreds.
• It then goes through a re-melt process and turns into molten Aluminium Metal.
• The molten metal from the furnace is molded and cooled into rectangular or in other type of
ingots.
• The ingots are sent to other process or flattened into thin sheets, which are then used to make
new cans.

How the process works

1.) The Loading Conveyor:

Aluminium UBC arrives at the recycling plant in large blocks, or bales. These bales are loaded onto
a conveyor, which takes them to the shredder.

2.) The Shredder:

The shredder chops the cans into small pieces. The pieces are about the size of a 50p coin. This is so
that it is easier to remove all the paint and coatings used to decorate and protect the can. It also makes the
metal melt faster in the furnace.

3.) The Magnetic Separator:

Shredded pieces of UBC are passed under a very powerful magnet which removes any traces of steel
or the magnetic impurities. Steel or iron impurities are magnetic hence they can be separated from the
aluminium using this powerful magnet.

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

4.) Rotary Decoater:
The aluminium shreds move along the conveyor into the Decoater. Here the paint decoration is
removed from the shredded cans. The decoater blows hot air through the shreds and the paint and
coatings vaporise. The decoating process also warms the shreds up, so that they melt faster when they
reach the furnace. The hot gases are removed and cleaned by passing into the after burn chamber. It saves
95% of the greenhouse gas emissions compared to the primary, or smelting, process.

5.) Side well Melting Furnace:

The decoated shreds are fed into the furnace. The furnace is heated to 800°C – this is a low melting
point for a metal. These furnaces are the latest ones with capacities ranging from 10 to 100 T. The
charging of the light scrap is done in the side well, while fuel-fired burners give the heat input in the main
well. The metal pump circulates the hot metal from main well to side well & also allows gas injection.
Vortex Generator: This new technology. Vortex generator or elctro-magnetic pump further improves the
melting rate, reduce melt loss, improves alloy dissolution rate, reduce inclusion & gas contamination. Light
scrap in the form of chips can be charged through a conveyor continuously in the vortex created.

Holding Furnace: The molten aluminium is transferred to another furnace. This ‘Holding furnace’
is where the metal waits to be cast into ingots. You can add various metals like Magnesium, Silicon,
Copper etc. to prepare desired grades of alloy in various series like, LM 0 to LM 31 series .The holding
furnace tilts gradually to pour the hot, molten Aluminium Metal.

6.) Ingot caster machine:

Different sizes of Ingots or billets can be casted in this process. The metal flows into moulds, the moulds
are fitted over a conveyor. As it enters the mould it is cooled by a spraying the fine mist of water on the
moulds. As the aluminium cools it hardens and becomes heavier. This makes the base of the mould lower
into the pit so that more aluminium flows into the mold. Gradually an ingot is formed.

7.) The ingots:

The ingots are bundled and handled. By an overhead crane They are loaded onto a truck and
dispatched to the rolling mill or for further process. The ingots are either used directly in the production of
industrial products such as alloy gear boxes and engine blocks (auto components) or converted into
aluminium sheets. Sheet aluminium is then used to produce new aluminium cans, house siding, roof,
guttering or even aircraft skins.
At the rolling mill the ingots are rolled into a very, very thin sheet which is used by the can making
company to make new Beverages drink cans. And the whole process starts all over again!

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Aluminium UBC (Used Bevarage Can), Chip & Scrap Recycling machinery Detail

Sl. No. No. Of type of machinery

1. Scrap Shredding Machine.

2. Shredded Scrap Charging Hopper With Flow Control Lever.

3. Slat Conveyor Motorized Belt With VFD Drive

4. Centrifuge Unit Machine (optional) For Chip Recycling Only

5. Magnetic Separator Machine

6. Decoating Dryer Machine

7. After Burn Chamber Heat

8. Vibrator Feeder Machine

9. Electric Resistance Furnace

10. Vortex pump/Scrap eater machine

11 2ND Tilting Furnace for making various Aluminium alloys Connected

through launder with side wall Furnace

12 Launder system to carry the molten Metal

13 Caster machine for manufacturing Ingot with VFD Drive

14 Water Cooling system for Billtes

15 Weighing balance

16. Forklift & overhead crane suitable capcity (Customer SCOPE)

17 Pollution Control water Slabber

18 Hydrogen analyser

19. Dross Recovery system

20 Spectrometer

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Total Power requirement
Tolal investment
Input material Cost
Processing cost
Output Finished Billet Cost
(Billets are homogenised)
Profit margin Per kg
Per Month Production
in Kg
Profit Per Month = 300000 X 12 :
Thirty Six Lakhs Profit Per month
Anual Profit
(Four Crore thirty Two lakh Only)
Equipment Depreciation Value
working capital
Bank EMI & Interest
Annual
Net Profit
Research & development
After Tax 30%
Net Profit after Tax
Employee bonus
Miscellaneous
Net Profit After All Deduction
Net Profit Per Month
: 350 kVA
: 1.65 Crore
: 132 Rs./Kg incl of all taxes
: 15 Rs./Kg Incl of all taxes
: 165 Rs./Kg Incl of all taxes
: 12 Rs./Kg Incl of all taxes
: 300 TON
: 300 X 1000 = 300000 Kg
3600000 Rs.
: 3600000 X 12 = 4,32,000,00.00
: @15% = 24,75,000.00
: 1,50,00,000.00
: 4,50,000.00 Per Month
: 54,00.000.00 Per Annum.
: 4,32,000,00.00 - 78,75,000.00
: 3,53,25000.00 Annual
: 30,00,000.00 Per Annum
: 3,23,25,000.00 - 96,97,500.00
: 2,26,27,500.00
: 5,00,000.00 Distributed among 20
employee 25,000.00 Rs each
: 5,00.000.00
: 2,16,27,500.00 Rs Per Annum
: 18,02,292.00 Rs. Per Month.
Annexure - 3

Aluminium Extrusion Plant

List of plant & Machineries
➢ Aluminium extrusion Press
➢ HOT TOP Casting table

➢ Hot Log Shear Billet Heater

➢ Aging Oven

➢ Aluminium Profile Handling table

➢ Puller System
➢ graphite Lining Quenching Table

➢ Air Cooling System

➢ Rough Cutter

➢ Stretcher (Hydraulic)
➢ Stop gauge Stacker

➢ Scrap Handling System

➢ Cooling Tower

➢ Compressor (oil Cooled air Compressor with Dryer)

➢ Power Distribution Panel

➢ Nitriding Oven

➢ Die Heating Oven

➢ Baling Machine

➢ aluminium Profile Finished Cutter

➢ Spectrometer

➢ hardness Tester
➢ Die Cleaning system

➢ Overhead Crane
➢ extrusion Dies

➢ aluminium Profile packing System

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Total Power requirement
Tolal investment
Input material Cost
Processing cost
Output Aluminium extruded Cost
(Billets are homogenised)
Profit margin Per kg
Per Month Production
: 300 kVA
: 2.85 Crore
: 165 Rs./Kg incl of all taxes
: 10 Rs./Kg Incl of all taxes
: 178 Rs./Kg Incl of all taxes
: 10 Rs./Kg Incl of all taxes
: 250 TON

in Kg : 250 X 1000 = 250000 Kg

Profit Per Month = 250000 X 10 : 2500000 Rs.
Twenty Five Lakhs Profit Per month
Anual Profit : 2500000 X 12 = 3,00,000,00.00

(Three Crore Only)

Equipment Depreciation Value : @15% = 42,75,000.00
working capital : 1,50,00,000.00

Bank EMI : 5,92,618.00 Per Month

Annual : 71,11.418.00 Per Annum.
Net Profit : 3,00,000,00.00 - 1,13,86,418.00

: 1,86,13,582.00 Annual
Research & development : 10,00,000.00 Per Annum
After Tax 30% : 1,76,13,582.00 - 52,84,075.00
Net Profit after Tax : 1,23,29,507.00
Employee bonus : 5,00,000.00 Distributed among 20
employee 25,000.00 Rs each

Miscellaneous : 5,00.000.00

Net Profit After All Deduction : 1,13,29,587.00 Rs Per Annum

Net Profit Per Month : 09,44,125.00 Rs. Per Month.

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Annexure - 4

Aluminium Profile Surface Finish line Anodizing, Colour anodizing,

Powder coating, Wooden Finish, Ladder manufacturing, Shot blasting
& fabrication Plant

List Of Plant & Machineries

✓ aluminium Profile Shot blasting system

✓ aluminium Profile buffing System

✓ Aluminium Profile Anodizing & electro Colouring System

✓ Aluminium Profile Bright Finish system

✓ Aluminium Profile Powder Coating System

✓ Aluminium Profile Wooden Finish System

✓ Aluminium Profile ladder making system

✓ Aluminium Profile Grill Making System

✓ Aluminium Profile Fabrication System

✓ quality assurance & Quality Control Unit

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004

Total Power requirement
Tolal investment
Input material Cost
Processing cost
Output Aluminium extruded Cost
(Billets are homogenised)
Profit margin Per kg
Per Month Production
in Kg
Profit Per Month = 200000 X 15
Thirty Lakhs Profit Per month
Anual Profit
(Three Crore Sixty lakh Only)
Equipment Depreciation Value
working capital
Bank EMI
Annual
Net Profit
Research & development
After Tax 30%
Net Profit after Tax
Employee bonus
Miscellaneous
Net Profit After All Deduction
Net Profit Per Month
Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004
: 250 kVA
: 2.15 Crore
: 178 Rs./Kg incl of all taxes
: 12 Rs./Kg Incl of all taxes
: 205 Rs./Kg Incl of all taxes
: 15 Rs./Kg Incl of all taxes
: 200 TON
: 200 X 1000 = 200000 Kg
: 3000000 Rs.
: 3000000 X 12 = 3,60,000,00.00
: @15% = 37,50,000.00
: 65,00,000.00
: 4,25,000.00 Per Month
: 51,00.000.00 Per Annum.
: 3,60,000,00.00 - 88,50,000.00
: 2,71,50000.00 Annual
: 20,00,000.00 Per Annum
: 2,51,25,000.00 - 75,45,500.00
: 1,76,05,000.00
: 5,00,000.00 Distributed among 20
employee 25,000.00 Rs each
: 5,00.000.00
: 1,66,05,000.00 Rs Per Annum
: 14,67,083.00 Rs. Per Month.
CONCLUSION
Total Investment : 9 Crore including All
Infrastructure
Working Capital : 3.65 Crore
Profit Per Month : 43,01,667.00 Rs/Month
Annual Profit : 5,16,20,004.00Rs/Month
Misceleneous investment : 30,00,000.00
Return Of Investment : 30 months.
Total tax Payment Annual to government
2,29,80,500.00

Plot No. 218, Manifit, Kalimati Mouza, Jamshedpur - 831004