ELECTRICAL PANEL BOARD AND ROOF TRUSSES ... - smallB

ELECTRICAL PANEL BOARD AND ROOF TRUSSES
Introduction:
Control panels are used to regulate functioning of electrical equipment. Electrical panels fitted
with necessary relays are also used to protect electrical equipment from being damaged due to
short circuit and over-loading. Light roof trusses are required for construction of ware-houses,
community hall and light Industrial Sheds. These two fabricated items are widely used in
engineering and construction industry.
Market Potential:
The control panels are enclosures fabricated out of sheet metal which can be open, semienclosed
or totally enclosed type. They direct and control electric power to equipment and
appliances. Provision for indicating the parameters like voltage, current, frequency & PF will be
available on the face of the panel. Regulation of the power supply is also possible with the help of
switches/circuit breakers. Panel boards are mainly purchased by the Electricity Boards and large
corporations like NEEPCO, Public Health Engineering Department as well as large factories. The
purchases of the electricity boards are substantial, for instance, the electrical department of the
State PWD in Arunachal Pradesh purchases LT panel boards to the tune of about Rs. 5.2 lakhs
per month. Similarly, the Assam Electricity Board also requires panel boards worth Rs 10 lakhs
per month. Panel boards required for high voltage applications are manufactured by leading
companies like L&T, English Electric and Bharat Heavy Electricals Ltd. LT panel boards can be
manufactured in tiny/small scale units. Such units basically procure the instruments and
assemble the panel boards in their factories. In Guwahati, which is the premier city in the northeast,
there are only 3 or 4 panel board manufacturers. Substantial portion of demand for LT panel
Boards is being met from other states. The demand for panel boards in the north-east is placed at
around Rs 450 lakhs per annum. Based on an average price of Rs 42,000 per panel board, and a
capacity to produce 60 panels per annum, there is scope for more than 15 units to come up in the
region.
For a typical light industrial shed of size 100’ x 30’ the requirement of roof trusses is estimated at
6000 kg. Assuming the total construction volume of 3 lakhs sq.m. per year of light industrial
sheds, the demand for light roof trusses is estimated at about 6000 MT. On this basis, there is
scope for 100 units with a capacity to fabricate 60 tonne of trusses. There are about 30 small
units fabricating light roof trusses in Assam, and 1 or 2 units in other States of the north-east.
Assuming a safety factor of 75%, there is scope for another 15 units to be set up for fabrication of
light trusses. Hence, there exists scope for 10 composite units manufacturing both panel boards
and roof trusses.
The panel boards and trusses are usually demanded together by the buyers like Electricity
Boards and SIDCs. Hence, unit with capabilities to fabricate both thick and thin sections is being
suggested.
Target Production:
The annual production of typical unit is envisaged as follows:
No.of Electrical panel boards : 60
(Control panels, power distribution
Units, motor control centres, D.G. Set
Panel, AMF panel etc.)
Roof trusses : 60
Raw Materials:
The major raw materials required are:
Cold rolled steel sheets of 2mm to 3mm thickness
M.S. angles and flats
Aluminium/copper bus bars, fittings etc.
Door hinges, nuts and bolts, handles,
Electrical instruments
M.S. Tubes/pipes
The annual requirement of materials for manufacturing each units are as under:
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A. For Panel Boards
a) Materials Quantity
C.R. Sheets
2.00 MT
(2mm to 3mm thickness)
b) Angles, flats etc. 0.50 MT
(Mild steel)
(assorted size like
25mm x 25mm x 3mm and
35mm x 35mm x 4mm sizes etc.)
(Considering 2% process loss)
Fittings etc.
60 sets.Aluminium/copper bus
bars,
c) Misc. electrical fittings and
Metering etc. as per order
and specifications like –
- 0-500 V Volmeter 60 Nos
- 0-500 Amps Ammeter 60 Nos.
-Voltmeter rotary switch
60 Nos.
-Ammeter rotary switch
60 Nos.
-Electric starter
60 Nos.
-Single phase preventor
60 Nos.
-Isolator
60 Nos.
-Starter push button
120 Nos.
-Energy meter
60 Nos.
-Current transformer and potential
Transformer
120 Nos.
-Relay (thermal overload, high
Voltage, high current)
60 Nos.
d) MCCB (Moulded Case Circuit Breaker) 60 Sets.
e) Indicating lamps, Kit kat and other
minor parts, wiring and equipments
like triple pole fuse base with fuses etc. 60 sets
f) Other misc. spare parts and equipment 60 sets
B. For Roof Trusses and other Tubular Structures:
Process:
a) Black steel pipe (dia 30mm to 50mm) 30 MT
b) Plates, flats, angles, channels etc. 33 MT
(of assorted sizes)
(Considering 5% process loss)
c) Other misc. fittings like nuts and bolts
and consumables like electrodes, paint,
oxygen and acetylene gasses etc.
The main process steps in fabrication of steel items are –
1. Measuring or marking as per specifications.
2. Cutting, drilling, pressing, bending as per specification.
3. Welding
4. Assembling the parts, testing and finishing.
5. Painting
6. Fittings of accessories as per specifications
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7. Machinery:
The major equipment required are –
Particulars
Quantity
i) Arc welding set complete with all accessories
330/440 volts 350 Amp (7KW) 1 set
ii) Gas welding set with all accessories 1 set
iii) Gas cylinder rebits (spare) 2 Nos.
iv) Piller drill machine
(25mm size) complete with 1 HP motor, pulley
V-belt etc.
1 No.
v) Power hacksaw
(150mm size) with 1 HP motor, starter and main
Switch extra.
1 each
vi) Hand drill (12mm size) 100 watts 1 No.
vii) Sheering machine
(300mm size) manual
1 No.
viii) Chain pulley block 2 tonne capacity 1 set
ix) Hydraulic pipe bending machine
(50mm capacity) with die
1 No.
Particulars
Quantity
x) Table vice (No.6) 1 No.
xi) Sheet bending machine (7 size) manual 1 No.
xii) Spray painting equipment with compressor and
spray gun and other misc. equipment with 1 HP
motor.
1 No.
xiii) Misc. hand tools (set) 2 sets
Infrastructure:
Land (with shed)
Power
3500 sq.ft.
20 KW
Location:
The market for the products is mainly the construction and engineering industry. Units located to
areas where industrial projects are likely to come up would be appropriate. Accordingly, the
following locations are suggested:
Assam : Guwahati, Jorhat, Tezpur
Meghalaya : Shillong, Jowai
Arunachal Pradesh : Pasighat, Itanagar
Manipur : Imphal, Thoubal
Tripura : Dharmanagar, Agartala
Nagaland : Dimapur, Kohima
Mizoram : Aizawl, Kolasib.
Total Capital Requirement:
The total capital requirement, including fixed capital and working capital, is estimated at Rs 18.01
lakhs as follows. Of this, the project cost comprising fixed capital and margin money on working
capital is Rs 11.62 lakhs.
A. Fixed Capital (Rs lakhs)
Land & Building (3500 sq. ft)
On rent
Plant & Machinery 6.50
Misc. fixed Assets 1.50
Preliminary & Pre-operative expenses 1.00
9.00
350

B
Note:
Working Capital:
Raw materials & Consumables 1 month 2.48
Finished goods 10 days 1.79
Working expenses 1 month 0.49
Receivables 1 month 4.25
Total (B) 9.01
Grand Total (A+B)
18.01 lakh
Working capital may be finance as –
Bank Finance
Margin Money
6.39 lakh
2.62 lakh
9.01 lakh
MEANS OF FINANCE:
Promoter’s contribution (35%)
Bank Loan(65%)
OPERATING EXPENSES:
4.07 lakh
7.55 lakh
11.62 lakh
The annual operating expenses are estimated at Rs 47.42 lakhs as given below:
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(Rs. in lakhs)
Raw materials (Refer annexure) 29.75
Consumable (Gas, electrodes etc.) 4.00
Utilities 1.50
Wages & salaries 4.25
Rent 1.35
Other overheads 1.50
Selling expenses @ 5% on sales 2.55
Interest on Term Loan @ 12% 0.91
Interest on Bank Finance for Working Capital 0.96
@ 15%
Depreciation @ 10% 0.65
Rs. 47.42 lakh
Sales Realization/ Turnover:
Taking average ex-factory price of Rs 50,000 control panel and Rs 35,000 per tonne of trusses,
the annual sales realization works out to Rs 51.00 lakh as under
Item Quantity Sales Price Rs. lakh
Control panel 60 Nos. Rs 50,000 30.00
Trusses 60 MT Rs 35,000 21.00
51.00
Profitability:
Based on the sales realization and the operating expenses, the profit (pre-tax) at the targeted
annual production would be Rs 3.58 lakhs per year. This works out to a return on investment of
20%. The plant would break-even at about 51% of the annual production envisaged.
Highlight:
The major highlights of the project are as follows:
1. The capital requirement : 18.01 lakh
2. Promoter contribution : 4.07 lakh
3. Annual Sales : 51.00 lakh
4. Annual operating expenses : 47.42 lakh
5. Annual Profit (Pre-tax) : 3.58 lakh
6. Pre-tax return on sales : 7%
7. Break Even Point : 51%
8. Number of person employed : 8 Nos.

MACHINERY SUPPLIERS:
1. M/s Ashoka Machine Tools Corporation.
15 –A, Industrial Area
Rewari Lines,
New Delhi – 110 027
2. M/s Davy Ashmore India Ltd.
6-A, Middleton Street,
Kolkata – 700 071
3. M/s Indi Hume Pipe Co. Ltd.
Construction House,
Ballard Estate,
Mumbai – 400 038
4. M/s Industrial Gases Ltd.,
15, Ganesh Chandra Avenue,
Kolkata – 700 020
5. M/s Industrial Machinery & Tools Corporation,
P-14, Mission Row Extension,
Kolkata – 700 001
6. M/s Kanubhai Engineering Pvt. Ltd.,
3, Mango Lane,
Kolkata – 700 001
ANNEXURE-
ESTIMATE OF RAW MATERIAL COST
A. For Panel Boards.
Sl.No. Items Quantity Amount (Rs Lakh)
A For Panel Boards
1 C.R. Short (1.2mm to 3mm 2.0MT @ Rs 40,000/MT 0.80
2. Angles, Flats etc. (M.S.)
0.5 MT @ Rs 29,000/MT 0.15
Assorted sizes like
25mm x 5mm x 3mm
35mm x 35mm x 4mm
3. Aluminium/Copper bus bars & fittings 60 sets @ Rs 500 each 0.30
4. Door hings, bolts, nuts handles etc. 60 sets @ Rs 800 each 0.48
5. Electrical fittings
- Voltemeter (0.500V)
- Ammeters
- Rotary switches
- Single phase preventor L&T make
- Isolator Siemens make
- Starter push bottoms
- Energy meters
- Current transformer & potential
transformer
- Relays (thermal overload, high
Voltage, & high current
- MCCB
- Indicating lamps, kit kat fuses, wiring
& equipment limtriple pole fuse base
with fuse etc.
- other misc. parts
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60 Nos. @ Rs 300 each
60 Nos. @ Rs 300 each
120 Nos. @ Rs 275 each
60 Nos. @ Rs 2000 each
60 Nos. @ Rs 650 each
120 Nos. @ Rs 490 each
300 Nos. @ Rs 500 each
120 Nos. @ Rs 950 each
60 Nos. @ Rs 1050 each
60 Nos.
60 Nos. @ Rs 950 each
0.18
0.18
0.33
1.20
0.39
0.59
1.50
1.14
60 Nos. @ Rs 700 each
0.42
Total of A 9.51
0.63
0.65
0.57

B
For Roof Trusses
Black steel pipe (dia 25mm to 50mm) 30 MT @ Rs 35,000 /MT 10.50
M.S. Plate, Flats Angles (Assorted sizes) 33 MT @ Rs 28,000/MT 9.24
considering 55 wastage
Misc. Fittings like bolts, nuts, screws etc. 1 MT @ Rs 50,000/MT 0.50
Total of B 20.24
GRAND TOTAL 29.75
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