Unlimitedprojects.com
INTRODUCTION
The technology providers are manufacturers of Power Conditioning equipment and Instrumentation and Control equipment for energy management. Their products are marketed under their brand name and enjoy market leadership with a market share of over 30 % in Southern and Western India. This position of market leadership has been enabled by providing greater value to the customer through accent on Value engineering resulting in better quality and reliability at a lower cost.
One of the major impact areas of Value engineering is in the use of Aluminium foil wound transformers. As our power conditioning range of products had a high copper content, the possibility of reducing our dependence on copper due to its relative high cost and price instability was considered. This resulted in our using Aluminium foil wound transformers in place of copper wire wound ones.
The Aluminium foil wound transformers so developed have been successfully used in Stabilisers and Isolation transformers and are working on the field since 1992. As this manufacture involves a convenient and efficient method of winding the foil around the core, they designed and developed the Special purpose foil-winding machine. They now offer this Special purpose foil-winding machine to you along with the know-how to design and develop Aluminium foil wound transformers.
A detailed note on the technology, the winding machine and proposal is given below:
ADVANTAGES OF ALUMINIUM FOIL WOUND TRANSFORMERS
COMMERCIAL ADVANTAGESo Reduced material costs
o Stable material costs
o Competitive price
o Higher productivity of transformers handling larger currents
o Savings on freight and packaging
TECHNICAL ADVANTAGES
o Compact size and reduced weight
o Increased thermal stability and higher short-term over load capacity
o Increased thermal stability and higher short-term over load capacity
o Higher surge withstanding capability
o Enhanced ability to withstand short circuit currents
o Reduced impact of harmonics and high frequency on the design of transformers
o Greater insulation reliability
MATERIAL COST COMPARISON
ENAMELLED COPPER WIRE WOUND TRANSFORMER
| 500 VA | 1000 VA | 5000 VA | |
PRIMARY SWG | 19 | 17 | 10 |
| WEIGHT(Grams) | 742 | 1099 | 3958 |
| COST ( Rs per Kg) | Rs.193.07 | Rs.191.97 | Rs.l96.35 |
| SECONDARY SWG | 17 | 14 | 8 |
| WEIGHT ( Grams) | 770 | 1072 | 3982 |
| COST ( Rs per Kg) | Rs.191.97 | Rs.191.43 | Rs.201.82 |
| TOTAL MATERIAL COST | Rs.291.07 | Rs.416.19 | Rs.1,580.78 |
ALUMINIUM FOIL WOUND
| 500 VA | 1000 VA | 5000 VA | |
| PRIMARY THICKNESS ( microns ) | 20 | 40 | 140 |
| WEIGHT ( Grams) | 398 | 566 | 2540 |
| COST ( Rs per Kg) | Rs.209.30 | Rs.200.93 | Rs.178.20 |
| SECONDARY THICKNESS ( microns ) | 40 | 75 | 100/150 |
| WEIGHT ( Grams) | 396 | 528 | 2110 |
| COST ( Rs per Kg) | Rs.200.93 | Rs.l87.25 | Rs.l78.20 |
| INSULATION FILM WEIGHT ( Grams) | 166 | 119 | 231 |
| COST ( Rs per Kg) | Rs.154.07 | Rs.154.07 | Rs.154.07 |
| TOTAL MATERIAL COST | Rs. 188.44 | Rs.230.93 | Rs.864.23 |
| SAVINGS GENERATED | Rs.102.63 | Rs.l85.26 | Rs.716.55 |
| % REDUCTION | 35 | 45 | 45 |
Cost of the project Rs. in Lakhs Cost of Building Rental 1000 Sq.feet 0.00 Indigenous Equipment 6.70 Preliminary & Pre-operative Expenses 0.10 Provision for Contingencies 1.76
Total 8.56 Promoter's equity 3.50 Bank/FI 5.06 Total 8.56 Working Capital requirement from Bank 12.24
Total fund requirement will be Rs 20.80 lacs assuming that all funds will be provided by the promoter. If needed Bank finance can also be obtained to the extent of 75%. PROFITABILITY Installed Capacity 12000 Nos. Utilised 90% 10800 Nos. Selling Price (1000VA) Rs.400/= each (A) 43.2 Lakhs Cost of production Raw Material Rs.250/= per pc 27.0 Lakhs Labour 0.5 " Utilities 7.0 " Rental 1.2 " Depreciation 0.66 " Total Cost of Production (B) 36.36 " Gross profit (A-B) 6.84 Lakhs