PROJECT REPORT

Of
LED BULB UNIT
PURPOSE OF THE DOCUMENT

This particular pre-feasibility is regarding LED Bulb Unit. The objective of the
pre-feasibility report is primarily to facilitate potential entrepreneurs in project
identification for investment and in order to serve his objective; the document
covers various aspects of the project concept development, start-up,
marketing, finance and management. [We can modify the project capacity and
project cost as per your requirement. We can also prepare project report on
any subject as per your requirement.]
 CONTENTS

1. INTRODUCTION
2. CHARACTERISTICS
3. METHOD OF OPERATION
4 EFFICIENCY
5. FLOW OF CURRENT
6. APPLICATIONS OF LED BULB
7. ENERGY CONSERVATION
8. DESCRIPTION OF LED BULB
9. LED MARKET ANALYSIS
10. RAW MATERIAL
11. ABOUT RAW MATERIAL
12. LED BULB MANUFACTURING PROCESS
 LED BULB
INTRODUCTION
Light Emitting Diode (LED) is a relatively old technology,
circa 1970, that has advanced from numeric displays and indicator lights to a
range of new applications, including exit signs, accent lights, task lights, traffic
lights, automobile lighting, signage, wall sconces, and outdoor lighting and
downlighting.

LEDs offer benefits such as small size, long lamp life, low heat output, energy
savings and durability. They also allow extraordinary design flexibility in color
changing, dimming and distribution by combining these small units into
desired shapes, colors, sizes and lumen packages.

Characteristics
LEDs are solid state semiconductor devices. LED illumination is achieved
when a semiconductor crystal is excited so that it directly produces visible
light in a desired wavelength range (color). LED units are small, typically 5mm
(T 1-3/4).

Method of Operation
When an LED unit is activated, a power supply converts AC voltage into
sufficient DC voltage, which is applied across the diode semiconductor
crystal. This results in electrons (negative charge carriers [N]) in the diode’s
electron transport layer and holes (positive charge carriers [P]) in the diode’s
hole transport layer combining at the P-N junction and converting their excess
energy into light. The LED is sealed in a clear or diffuse plastic lens that can
provide a range of angular distributions of the light.
Efficency
LEDs are low-voltage, low-current devices and efficient light sources. For red,
amber, yellow, green and blue LEDs, new materials have been developed that
are more efficient than traditional materials, producing efficacies (lumens per
watt) greater than incandescent lamps and rivaling fluorescent lamps. A.
Efficacies as high as 100 LPW have already been achieved in laboratory
conditions. According to Steve Johnson, group leader of lighting research for
the Lawrence Berkeley National Laboratory, “It is not unrealistic to expect the
efficacy of solid-state sources to achieve 150-200 lumens per watt in the
coming decades.”

White Light LEDs

The utilization of indium gallium nitride (InGaN) as a semiconductor
material resulted in the brightest LEDs and enabled development of
white light LEDs.

White light LEDs feature a phosphor added to a blue LED that

converts some of the light emission into yellow, resulting in a bluish-
white light. White light LEDs are therefore a cool light source with a
spectrum of correlated color temperatures of 4,000-11,000K. White
light can also be achieved by color mixing the light produced by red,
blue and green LEDs. -END-

Flow of Current

LED power supply converts the incoming AC voltage to a DC voltage suitable

for powering your LED lighting system. This process involves regulating the
output voltage and current to ensure a stable and consistent power supply,
preventing damage to your LED lights due to voltage fluctuations. LED power
supply also provides protection against overvoltage, overcurrent, and short
circuits, ensuring the safety and longevity of your LED lighting system.

The efficiency of LED power supply is a crucial factor to consider when

selecting the right power supply for your LED lighting system. A high-efficiency
power supply reduces power consumption, generates less heat, and extends
the lifespan of your LEDs. The efficiency rating of LED power supply is
expressed as a percentage and ranges from 70% to 95%. It's advisable to
choose a power supply with an efficiency rating of at least 80% to ensure
optimal performance and longevity of your LED lighting system.

LED power supply also comes in various types, including constant voltage,
constant current, and dimmable power supplies. Constant voltage power
supply is suitable for powering LED strips and modules, providing a stable
voltage output. Constant current power supply is ideal for powering LED
drivers and high-power LEDs, providing a constant current output. Dimmable
power supply allows you to control the brightness of your LED lighting system,
making it suitable for applications that require adjustable lighting levels.

Installing LED power supply is simple and straightforward, with various

options for mounting, including surface mount and panel mount. LED power
supply is also available in various sizes and capacities, allowing you to choose
the best option that suits your specific LED lighting requirements.

In conclusion, LED power supply is an essential component of any LED lighting

system, providing the necessary electrical power, regulating the voltage and
current, and protecting your LEDs from damage. Choosing a reliable and
efficient LED power supply ensures optimal performance and longevity of your
LED lighting system. With various types, sizes, and capacities available, LED
power supply offers a solution that suits any LED lighting requirement, making
it a crucial backbone of your LED lighting system.

Application of LED Bulb

LED Bulb are used for both general and special-purpose lighting. Where
coloured light is needed, LEDs that inherently emit light of a single colour
require no energy-absorbing filters. White-light LED bulb have longer life
expectancy and higher efficiency (more light for the same electricity) than
most other lighting when used at the proper temperature. LED sources are
compact, which gives flexibility in designing lighting fixtures and good control
over the distribution of light with small reflectors or lenses. Because of the
small size of LEDs, control of the sp atial distribution of illumination is
extremely flexible, and the light output and spatial distribution of an LED array
can be controlled with no efficiency loss. LEDs using the colour-mixing
principle can emit a wide range of colours by changing the proportions of light
generated in each primary colour. This allows full colour mixing in lamps with
LEDs of differ.

Energy conservation

With the growing energy needs and shortage coupled with rising energy cost, a
greater thrust in energy efficiency in industrial sector has been given by Govt.
of India since 1980s. The energy Conservation Act 2001 has been enacted on
18th August 2001which provides for efficient use of energy its conservation
and capacity building of Bureau of Energy Efficiency created under the act. The
following steps may be help for conservation of Electrical Energy: i) Adoption
of energy conserving technology, production aids and testing facilities. ii)
Efficient management of process/manufacturing machineries and systems,
QC and testing equipment’s for yielding maximum energy conservation. iii)
Optimum use of electrical energy for heating during soldering process can be
obtained by using efficient temperature controlled soldering and DE soldering
stations. iv) Periodical maintenance of motors compressors etc. v) Use of
power factor correction capacitors, proper selection and layout of lighting
systems timely switching on/off of the lights, use of Compact Fluorescent
Lamps wherever possible.

Description of LED Bulb

Machine Machinery for LED Bulb Unit includes the following :

> Tikki Making Machine

> Punching Machine

> Cutter

> Iron

> Solder

> Nuts

> Heat sinkPaste

TIKKI MACHINE

This Machine assist you to suit MCPCB into housing Body(lodging) at

quicker speed with more precision. Our LED Tikki Fitting Machine is
extremely low cost in value and high in quality, as we put very low
margin to form a relationship with clients and encourage them to begin
their own business with smaller investment.

The most effective method to Use Tikki Fitting Machine:

Tawang Tikki Fitting Machine will assist you to press the aluminium
plate ( heat sink ) to the degree of your lodging (housing) diffuser. LED
Bulb Tikki Fitting Machine used for lodging ( housing ) like Philips type
(180 degree) and Syska type (270 degree). Other Name of Tikki Fitting
Machine is LED Bulb Heat Sink Pressing Machine or Tikki Pressing
Machine.

LED Tikki Fitting Machine comes with 5 components

• (1). Press Machine

• (2). Small Size lodging (housing) 45 MM To 57 MM
• (3). Big Size Bulb lodging (housing) holder 58 MM To 95 MM
• (4). Pressure Die For Small Size Heat Sink Plate
• (5). Pressure Die For Big Size Heat Sink Plate
• (6). Fit and adjust the tiny size heat sink pressure die within the
Nozzle of power Press Machine and place the small size Bulb
lodging (housing) holder before the Press Machine nozzle fitted
 with small size pressure die. Now, place the LED Bulb B22 part of
housing in the middle of housing holder and place the heat sink on
the upper part of housing and press the nozzle down side.
currently you will see your housing is fitted with the heat sink plate.
Benefits of Tawang Tikki Fitting Machine/ LED Heat Sink Fitting

Machine

PUNCHING MACHINE
Stamping is the process of forcing a steel punch through a workpiece to
quickly generate holes of different shapes. Simply put, the punching process
is to cut a shape of waste material from the finished product. The diameter
of the punch determines the size of the hole formed on the workpiece.
Observing the LED light fixtures around us can actually reveal that there are
some lighting components on the base or shell of some LED light fixtures.
These components are usually embedded in the base or housing of LED
batten lights. So it will be necessary to use punching processing technology
to punch a hole on the base or shell of the LED lamp, so that the component
module can be embedded in the base or shell.

SOLDERING IRON
Solder is a conductive material that melts around 400 degree Fahrenheit
and allows two pieces of metal to connect in a circuit. A standard ‘point-
to-point’ connection is two leads, lets say the cathode of an LED and the
anode of a second LED twisted and soldered together; this is more
efficient than simply just twisting leads together. Another common type
of solder connection is found on PCBs and MCPCBs, where there are
conductive traces in a board that lead to components where a solder
connection is made. Most of the soldering we encounter is with LEDs on
MCPCB, which you can see on the right

HEAT SINK PASTE

A heat sink is a part with a large surface area consisting of thermally
conductive metal. This heat sink is typically attached to printed circuit board
components, including power transistors and switching devices. The
purpose of this part is to absorb and dissipate heat.
PCB heat sinks work through the principle of conduction. In this principle,
heat transfers from areas of high thermal resistance to areas of low thermal
resistance, and areas of high heat to areas of low heat. Because heat sinks
are made of aluminum or copper, which both have excellent thermal
conductivity and low thermal resistance, the heat will naturally move from
PCB components to the heat sink.
LED MARKET ANALYSIS

The LED Lighting Market size is estimated at 46.54 billion USD in 2024, and
is expected to reach 65.13 billion USD by 2030, growing at a CAGR of
5.76% during the forecast period (2024-2030).
RAW MATERIALS
> MCPCB
> DRIVER
> B22 NICKLE RIVIT
> BODY OF BULS
> HOUSING OF BULBS
> SCREWS

MCPCB
Metal-Core Printed Circuit Boards (MCPCBs) are designed to provide high-
power output in a compact package. Each LED package consists of a single
LED that has been soldered to an MCPCB.
DOB MCPCB
A DOB lighting system uses only solid state driver components which are
available in surface-mount packages capable of being assembled on circuit
boards with a single-sided copper construction. This makes it possible to
mount driver components a metal-core printed circuit board (MCPCB) where
LEDs are mounted. Typically, the driver is designed as a linear power supply.
Since there is no high frequency switching, electromagnetic interference
(EMI) is practically absent in linear power supplies. The complete absence of
EMI radiation allows linear power supplies to be designed with a
significantly reduced parts count. The small circuit parts count and small
form factor of circuit components contribute a small footprint of the driver,
which introduces minimal impact on the LED assembly when it comes to
photometric performance. The drive current is regulated by small driver ICs
without using electrolytic capacitors. The weakest component with the
shortest life expectancy determines the life of the driver. The removal of
electrolytic capacitors translates to significantly improved driver reliability.
LED DRIVER
An LED driver is a self contained power supply which regulates the power
required for an LED or array of LEDs. The light emitting diodes are low
energy, lighting devices with a long lifespan and low energy consumption,
hence the requirement for specialized power supplies.
• Provides low voltage
Individual LED bulbs operate at voltages ranging from about 1.5 to 3.5
volts and currents of up to a maximum of 30mA. The domestic bulbs
may consist of several bulbs, in series and parallel combinations and
which requires a total voltage of between 12 and 24 V DC. The LED
driver rectifies the AC and lowers the level to suit the requirements.
This means converting the high AC mains voltage which ranges from
120 Volts to 277Volts, to the required low DC voltage.

• Provides protection to the LED bulbs

The LED drivers provide protection to the LED bulbs against current
and voltage fluctuations. The drivers ensure that the voltage and
current to the LED bulbs remains within the operating range of the
LEDs regardless of fluctuations in the mains supply. The protection
avoids providing too much voltage and current that would degrade the
LEDs or too low current that would reduce the light output.
 SEMI DOB DRIVER
AC DOB (Driver-On-Board) LED chips are a pivotal innovation in
lighting technology, designed to operate directly from alternating
current (AC) without the need for a separate driver. This category of
LED chips is prevalent in various lighting applications due to their
integrated design and ease of use

AC DOB LED lights are efficient and long lasting for up to 50,000 hours
which means you do not incur the cost of replacement. In total, a user
can save about 3 times the regular amount by switching to AC DOB.

INVETER DRIVER
Inverter LED Bulb Driver, AC DC LED Bulb MCPCB, Rechargeable LED
Bulb Housing and Battery. We give you the most effective and high-quality
variety of ACDC Rechargeable / Inverter LED Bulb Raw Material at well-
timed delivery.

Our presented drivers are perfect for making LED Rechargeable Inverter
Lights for their unique quality and high performance.The bulbs emit
soothing light and are energy efficient. They use both direct current and
alternating current for conveying their ideal working.

B22 NICKLE RIVIT

B22 is a type of lamp cap. A B22 lamp means a lamp with the B22 cap - 22mm dia
with 2 pins to hold the lamp in the lamp socket. Also known as Bayonet cap. In
normal Indian term we call it a 2pin cap. Most of our household lamp holders are
B22. The numbers after B indicate the diameter of the lamp cap.
LED Bulb Manufacturing Process
> Take Body & diffuser of Bulb separately.
> Adjust in the tikki machine.
> Now soldering the PCB with diffuses wire.
> Cut the extra wire in the PCB unit.
> Put B22 cap on the PCB.
> Now press it with punching machine.
> Packaging
Machinery & Equipment’s required
NAME COST

MACHINE 11670 RS
G.S.T @ 16% 1780 RS
TOTAL 13450 RS

> Cost of the machine is exclusive of GST & value of the machine
varies with the change in batch size.

Labour Requirement:
4-7 Manpower is required for the LED Bulb unit.

Includes:

2 skilled Labour

4 Unskilled Labour

Raw Material Requirement of Chalk

> Housing (body, Diffuser, tikky)

> DOB (PCB)

 > B22 cap with wire

Preamium bulbs

Raw materials Cost per unit

Housing 11.0 RS
M.C.P.C.B and Driver 26.5 RS
B22 Nickle rivit 2.5 RS
Packing and Leaser print 3 RS
Total cost 43 RS

Gold bulbs
Raw materials Cost per unit
Housing 11.00 RS
M.C.P.C.B and Driver 19.00 RS
B22 Nickle rivit 2.50 RS
Packing and Leaser print 3.00 RS
Total cost 35.5 RS

Silver bulbs
Raw materials Cost per unit
Housing 11.00 RS
M.C.P.C.B 5.5 RS
B22 nickle rivit 2.5 RS
Packing and Leaser print 3.00RS
Total cost 22.00 RS

Inverter bulbs
Raw materials Cost per unit
Housing 22.00RS
M.C.P.C.B and Driver 76.00RS[ battery= 75]
B22 nickle rivit 2.5 RS
Packing and leaser 6.00 RS
Total cost 181.5 RS

LED Bulb License & registration

For Proprietor:
> Obtain the GST registration.
> Fire/ Pollution Registration as required.
> Choice of a Brand Name of the product and secure the name
with Trademark if required.
Implementation Schedule

S. N Activity Time Required (in

Months)
1 Acquisition Of premises 1
2 Construction (if Applicable) 1-2 Months
3 Procurement & installation of Plant 1
& Machinery
4 Arrangement of Finance 1
5 Requirement of required Manpower 1
Total time Required (some activities 2-3 Months
shall run concurrently)
Conclusion:
After completion of manufacturing process, product is ready to sell
in the market. This machine can be installed with low investment &
one can earn a good Margin of profit by doing this business.

COMPUTATION OF PRODUCTION OF LED BULB

COMPUTATION OF PRODUCTION OF LED

BULB

Items to be Manufactured
LED BULB
Machine capacity 300BULB FOR
DAY
Machine capacity per annum 90000 PIECE

Production of LED Bulb

PRODUCTION CAPACITY BULB
1st YEAR 70% 63,000
2 YEAR 75% 67,500
3 YEAR 80% 72,000
4 YEAR 85% 76,500
5 YEAR 90% 81,000

Raw Material
year CAPACITY RATE PER AMOUNT
UTILISATION BULB [ RS .IN LAKH]
1ST YEAR 70% 43 RS 27.09 LAKH
2 YEAR 75% 43.50 29.02 LAKH
3 YEAR 80% 43.70 30.96 LAKH
4 YEAR 85% 43.80 32.89 LAKH
5 YEAR 90% 43.90 34.83 LAKH

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