Project Profile

Product

Product Code ( ASICC )

71241

Plant Capacity per annum

13,50,000 Mtr.

Value ( Rs. )

35,10,00,000

March, 2012

per annum

Month & Year of Preparation

Corrugated iron Sheets

: 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.

RAW MATERIALS : PPGI and PPGL/ NCGI/ GI Sheets

3.0

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)
2)
3)
4)
5)
6)
7)

De Coiler ( 5 Ton)
Loop System
Entry gauge and Roll Forming machine
Cutting unite
Run out table
Integrated Hydraulic power Pack system
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 Stainlesssteel 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

9.0 IMPLEMENTATION SCHEDULE:
S.No.
1
2
3
4
6
7
8

30 Kw

Activities
Preparation of project report and selection of site
Registration
Application for Electricity Connection
Civil work & Availability of finance& Procurement of
machinery
Electrification & installation
Recruitment of staff
Trial run
Total

Period in
Months
1
1
1
6
2
1
1
13

10. FINANCIAL ASPECTS:

A . Land & Building
Land : The
requirement of land for
the proposed unit
would be 1950 sq m @
Rs3500 Sq m

2000 Sq
.m

3500

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Rs.70,00,000.00

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

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

Rs. 190 Running

Mtr.

Rs. 760000.00

Boundary Wall
Roads
Others(Electric &
Sanitary fittings)

LS Rs. 780000.00
LS Rs.200000.00
Rs. 4785000.00
Rs.1,17,85000.00

TOTAL
Total ( Land & Building )
B) PLANT & MACHINERY
S.No.

Description of machine

Qty.

Price

Amount ( Rs. )

23,000,00.00

1 Automatic Roll Forming Line

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

Taxes & Transportation
Installation & Electrification @ 10%

TOTAL
Office Equipment (Furniture &
fixture, Fire Fighting Equipments,
Computers & Printers, Air
conditioners, Other Office
Equipments )
Total Investment In Plant & machinery
Pre Operative Expenses

Total
C. Total Investment In fixed assets

LS

3,40,000.00
2,30,000.00.00
2,30,000.00
31,00,000.00
5,00,000.00.00

36,00,000.00
200000.00

38,00.000.00
1,55,85,000.00

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D. WORKING CAPITAL
i
S.NO.

Personnel ( Per month )

DESIGNATION

No.

Salary

Total (Rs.)

Workshop in charge

30000

30000

Accountant/Store
incharge

20,000

20,000

Supervisor

15,000

30,000

4
5

Skilled Worker
Semi skilled worker/
Helper
Peon / Watchman

2
2

12,000
8000

24,000
16,000

5000

15,000

Total

1,35,000

Additional Perquisites (
Included )
Total Expenditure in
Salary & Wages
ii
S.No.
1

iii
1
2
iv
1
2
3
4
5
6
7
8
9

v
S.No.
1
2
3
4

135000

Raw Material ( Per Month )

Particular (Indigenous)
PPGL/ PPGI/ NCGI/ GI
Coils

Utilities ( Per Month )

Power ( 150 units per day
)
Water & Compressed Air

Qty
500 tonne

3750 units

Rate
Rs.55000 (Average)
per tonne
TOTAL

Rs. 5.50

LS
TOTAL
Other Contingent Expenses
Postage and stationary
Office Consumable stores
Transport charges
Telephone charges
Publicity Expenses
Traveling expenses
Repair & Maint.
Miscellaneous expenses
Insurance
TOTAL

Value (Rs.)
2,75,00,000.00
2,75,00,000.00
Value (Rs.)
20,625
1,375
22,000.00
3500
3500
10000
5000
5000
15000
10000
7500
2500
62,000.00

Total Recurring Expenditure ( Per Month )

Description
Personnel
Raw material
Utilities
Other Contingent Expenses
TOTAL

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Cost

135000.00
2,75,00,000.00
22,000.00
62,000.00
2,77,19,000.00

vi

Total working capital for 1.5 Month :

Rs.

4,15,78,500.00

Total Capital Investment :

i
ii

Fixed Capital
Working Capital for 1.5 Months
Total Capital Investment :

1,55,85,000

Total Capital Investment

Say

5,72,000,00

Finance Detail

4,15,78,500
5,71,63,500

Self Contribution

%
Contribution
25

iii

Banks Contribution

75

1,43,00,000
4,29,00,000

FINANCIAL ANALYSIS
1
i
ii
iii
iv
v

Cost of Production (Per Year) :

Total recurring cost :
Depreciation of machinery and equipment @ 10%
Interest on total Capital investment @ 12%
Depreciation of tools and office equipment / furniture
@ 20%
Depreciation of Building @ 5%
Total :
Total Sales (Per annum)
Products

Qty.

PPGL/ PPGI/ NCGI/ GI

Corrugated Sheet

33,26,28,000
3,10,000
68,64.,000
1,00,000
2,39,250
34,01,41,250

Rate
Rs.275Rs/mtr.
Rs.

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

Net profit ratio :

Net profit 100
Turn Over

Rate of return :
Net profit 100
Total Investment

37,12,50,000

13,50,000 Mtr.
TOTAL

Value (Rs.)

37,12,50,000

3,11.08,750.00
37,12,50,000.00

x100 =

8.38%

3,11.08,750.00

x100 =

54.38 %

5,72,00,000.00

BREAK-EVEN POINT;
FIXED COST ;
1 40% salary & wages
2 Depreciation on machinery &
Equipments @ 10%
3 Depreciation of tools and office

6,48,000.00
3,10,000.00
75,000.00

equipment @ 15%

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4 Depreciation of Building @ 5%
5 Interest on capital investment
@ 12%
6 40% of other contingent
expenses& Insurance
TOTAL
Net Profit (Per yr.) (Before tax)

2,39,250 .00
68,64.,000.00

2,97,600.00
84,33850
3,11.08,750

BEP :
Fixed Cost 100
Fixed Cost + Profit

=( 84,33850 / 84,33850 + 3,11.08,750.00)x100 =

= 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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