[www.kalifashions.com] [AAC BLOCK MAKING MACHINE] SKF IMPEX Ankur Shopping Center-3,11,Building No-2, Opp Sardar Bridge,Near Gujarat Gas Circle, Adajan, Surat Office Number: 261-2122Mobile Number: 91-11631 Email:info@kalifashions.com [www.kalifashions.com]
AUTOCLAVED AREATED CONCRETE BLOCKS PROJECT EXECUTION SUMMERY All figures in Rs. Lakhs Items (Fly ash Based AAC lines) Phase-1 (First executions- Gestation period-6 Months min) Phase-2 (2nd executions- Gestation period-2 Months min) Phase-1 (3rd executions- Gestation period-2 Months min) Semi Auto Total Project Fixed costs Auto Module AddONlanding Automatic Module Project Fixed Costs CM/Annum AAC Plant 1 CM/Annum AAC Plant 1.2 32.92. 133.1.. 1.2 66.2 6. 6..2 926.2 1 CM/Annum AAC Plant.32 133.1 133.1 113.3 6. 13.3 Working Capital Rs. Lakhs CM/Annum AAC Plant 1 CM/Annum AAC Plant.3. 1 CM/Annum AAC Plant 133.12 Please see the fixed inner sheets for details If we need sand base AAC add on, we need to add a 1 KW ball mill and a block separator Extra. Even we may need 2 more autoclaves to reach max production of 1, Lakhs CM as the steam curing period is at least 2% more Assumptions for Sample Project Profile As land costs vary widely, this has been excluded Customs duties considered as per rates applicable during 21-11 1% depreciations of Land & Buildings considered & 1% on machinery USD exchange rate taken as Rs. /- Sea Fare, Truck charges, C/F charges as per the prevailing charges is considered The shed area and office area for guidelines only. Clients can have their own luxury as per the needs. The work shed and office space and fabrication charges considered as CPWD averages. The Machinary Commissioning and Civil charges are considered @ % of its landing price For clarity Phase 2 expansion is considered in Year 2 and Phase 3 expansion in Year-3 The raw material rates pertains to a specific place and may vary from place to place Block sale price indicated in this Project is exfactory. All taxes and transport extra as applicable Intrest and oppurtunity cost is considered at 13% as per the Prevailing rates Disclaimer This Project Profile is supplied free of cost to all prospective AAC clients This FULL document can be distributed free of cost to any one, without any sort of permission This Document cannot be sold to anyone for any purpose( neither soft copy nor hard copy) This Project Profile is A GENERALISED profile and do not represent any one unit in particular. This is for guiding prospective client, and helping them to understand the project well This can also serve a basis for Clients Chartered Account for making a DPR for them This template with a little variation can be used to get the DIC EM-1, Pollution control NOC, and other Docs This document do not in any way bind, restrict or force any data on Dongyue Company or N.G.Reddy The AAC project being Modular, there can be client specific needs, which may not be mentioned herein. As the raw materials vary widely, so also does the mix designs we suggest. So final costing may vary. The Price basics for China Machinery, and Indian side machinery is just for reference purpose. Even the quantity of items is approximate, and can vary from case to case basis The civil costs can vary depending location, and the clients rapport and grasp on the field The fabrication costs can depend a lot on clients ability to handle the things on his own, and Steel Prices The speed of execution of project totally depends on Clients skills to Coordinate the Indian suppliers We can take up the client specific Project profile on a Nominal Payment basis We are attempting to get the AAC units bundled in a group for CDM benefit to earn Carbon Credits Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in
A Work Shed for different Size AAC Units Mandatory Items sl No Item Descriptions Length Mt widthe Mt total Sft 1 Pre curing Room 2. 16. 396 2 Mould Turning Ares 6. 16. 99 3 Cutting Area 1. 16. 29 Boiler Area 16.. 12 Total Mandatory workshed Areas 92 Optional---Raw Material Area 6 Raw Material Handling Section 12. 16.6 2 Autoclave block waiting Bay.a For CM/annum plant 3.. 2.b For 1 CM/annum plant 3. 1. 2.c For 1 CM/annum plant 3. 2. 6 B Work Shed & Instllation Area Summery Total Area Plant Area Workshed & Plant Area Summery Shed Area (sft) (acers ) (sft) 1. Minimum Area for CM Plant 2. Minimum Area for 1CM Plant 2. 3. 136 1 1 23 3. Minimum Area for 1CM Plant 3. 12 292 Note: 1. The Autoclave out bay shed and Autoclave Area shed is optional 2. Autoclave out bay shed is equal to Autoclave waiting Bay area 3. Autoclave shed area is equal to 6% of Autoclave waiting Bay area. Blocks Storage area workshed is also optional. C Installation Schedule Installation Schedule for 1 CM/Year capacity AAC plant on autoclaves & Major Items Sl. No Items Phase-1 Phase-2 Phase-3 Autoclaves Complete Kit along with 1 Body, Steam Pipes, Cyllinder and 2 2 2 Insulation, safety devices, Rails 2 Moulds 12 3 Side Pallets Steam Traullies 2 2 2 Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
D Indian Total Duty Obligation Calculations 1 CIF Price (=FOB Price+Sea Fright+ Sea Insurance) % value 1. 2 Landing Overheads by Indian Costoms 1% 11. 3 Basic Customs Duty (1).%. sub total-1 1. CVD (Counter Valing Duty) 1% 1.6 6 Deducational cess 3%.33 Sub total-2 119.6 Customs cess on total duty 3%.6 9 sub Total-3 12.32 1 Aditional customs cess %.1 1 Grand Total 12.13 1 EFFECTIVE Percentage of tax on imports over CIF price 2.13% 2 Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
E Details of Machinary From (Both India and China ) Installation in a 3 Phase Split Item Rate Unit Phase-1 Phase-2 Phase-3 Items imported from China FOB price ( Fully Automatic Module ) US$ 613,6 9,1 9,1 Containers needed nos 12 2 2 Avg Sea frieght + Insurance 1 US$ 1, 3, 3, CIF price US$ 631,6 92,1 92,1 Customs + CVD + Surcharge, and other taxes 2.13% US$ 1,1 23,12 23,12 Landing Price US$ 9,26 11,12 11,12 Landing price in INR Rs. 3,61,93,11,396,11,396 Clearing and liasoning charges per B/L Rs. 12, 12, 12, Destuffing and road frieght charges on trawler basis 3 Rs. 36, 6, 6, Total Chinise Machine at site Price Rs. 3,933,93,23,396,23,396 Total Indian Machines FOR Prices (approxmate USD equvalent) Total Indian Parts prices in INR * USD 36,96 16,96 16,96 Rs. 16,2,32,23,2,23,2 Grand total Machinary Rs. 2,3,263 12,66,96 12,66,96 Installation & commissioning including civil works Total Machinary commissioned charges at site % Rs. 2,61,13 633,3 633,3 Rs.,91,96 13,31,2 13,31,2 Total Machinary commissioned costs in Lakhs INR Lakhs Rs 9.2 133.1 133.1 * India Side Procurement includes Boiler, Autoclaves, Surrry Tank Body, Loader, Forklift, and Other unfabricated MS items Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
F Sl No Fixed Cost Calculations Details Fixed Cost Promote r's Margin in % Seed Funding Bank Loan 1 Land Acers @ Rs. Own Land. 1... 2 Land Devolopment @ Rs. 3 Lakhs/Acer 1.... 3 Stores & workshed 12 sft @ Rs./- 13.6 3. 1.2 96.32 office 1 sft. 3. 2..6 sft x 3 floor rcc or MS struct 1. 3.. 1. 6 Mis fixed assets.. 2. 3. Transformer/geneset/Electric Installations & charges. 2. 12. 3. Water Source--Boor Well with Pump 2. 2.. 1. 9 Plant & Machinary(with Installation)- Phase-1 (1st Year) 9.2 2. 13.3 12.29 1 Plant & Machinary(with Installation)- Phase-2 (2nd yr) 133.1 2. 33.2 99.3 11 Plant & Machinary(with Installation)- Phase-3 (3nd yr) 133.1 2. 33.2 99.3 12 Prilimnary exp.. 2. 3. 13 Preoperative 1.. 6. 9. 1 Contingency.. 2. 3. 1 Total 13.3 2.66. Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
G Working Capital Calculation 1st Year Capacity Costing Per Month at % production 2 Tons 1 Raw materials/ CM in Rs. in Rs. a particulars Quantity T rate/tonne Amount Fly Ash. 1 Rs. 6. b lime.9 Rs.. c OPC Cement (Tanker load). Rs. 3. d Aluminium power. 23 Rs. 11. e Gypsium. Rs. 2. f RM/CM.62 Rs. 9.2 g Power(KWH) 9. 6 Rs.. h Coal (Kg) 3. Rs. 12. Other Consumables Rs.. i Total Rs. 1,29.2 j add Wastage @ 1% Rs. 12.9 k Raw material per CM Rs. 1,221.3 L Raw Materials per month at % capacity CM 3333.33 Rs.,1,11.6 2 Labour/Month Nos Lab/Month Tot sal/day a Skilled Labour 6 Rs. 3,. b Semi Skilled Labour Rs. 2,. c Un skilled Labour 1 Rs.,. d Total Labour/Month Rs. 9,. Rs. 9,. 3 Officeial staff/month Nos Lab/Month Tot sal/day a Managers & accounts 2 1 Rs. 2,. b Supervisors Rs. 32,. c Other staff 6 Rs. 2,. d Total Labour/Month Rs. 6,. Rs. 6,. Insuraance per Month ( at.3% per annum ) Rs. 2,12.99 Rs. 2,12.99 6 Maintainance per Month ( at 2% per annum ) Rs. 91,619.96 Rs. 91,619.96 Office Overheads(Post+phone+Net+travel+stanry) @ Rs. 2/CM Rs. 3,333.33 Rs. 3,333.33 Total Expences per Month Rs.,3,2.9 9 Working Capital for 1 Cycle a Curing Line 2 days b Cerdit Period 1 days c Stock holding 1 days d Total = 3 Days 1 Working Capital for 1 Cycle (3 days=1 month)- 1st year Rs.,3,2.9 11 Working Capital for 1 Cycle (3 days=1 month)- 2nd year Rs.,,.91 12 Working Capital for 1 Cycle (3 days=1 month)- 3nd year Rs. 13,311,33.6 * Note i Installed Capacity in phase-1 (1st Year ) is CM/annum ii capacity adition in phase-2 (2nd Year ) is CM/annum iii capacity adition in phase-3 (3rd Year ) is CM/annum Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
H DEPREATIATION Item 1st Yr 2nd year 3rd Year th Year th Year Remarks 1 Block Land & Building 16.6 19. 13.1 12.2 1.6 2 Added Land & Buildi ngs..... 3 Depreaciation on building/shed and other constructions except land 1% 16.6 1.9 13.1 12. 1. Year end Block 19. 13.1 12.2 1.6 9.9 1 Block Machinary 61.2 11.6 6. 61. 23.1 2 Block Added in the Year. 133.1 133.1.. 3 Depreaciation on machinary & equipments 1% 9.26 6.2.1 92.3.1 Year end Block 11.6 6. 61. 23.1.9 I Debt Service Coverage Ration ( D.S.C.R ) 1 Bank Loan 69. 69. 616.61.3 22.9 2 Intrest on Bank Loan 9. 9..16. 3.3 3 Repayment. 12.26 12.26 12.26 12.26 Aditional Loan in Year. 99.3... Profits before TAX 29.99 9.6 11.13 126.2 13.22 6 Profits after Tax (33%) 33% 2. 23.1 3. 1.2. Profit After Tax 16.9.6 6. 2. 929. D.S.C.R.6 2.1 3..3. 9 Average DSCR 3.9 Note D.S.C.R = ( Profit After Tax + Depreciation + Intrest on Trrm Loan ) / (Intrest on Term Loan + Term Loan Repayment ) Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)
J J 1 Project Cost, Profitability Calculation & Ratios Project Cost 1st Yr 2nd year 3rd 1 Total Fixed Capital.3 2 Total Working Capital (3 2.3 3 Project Cost days) 1.6 Machinary Utilisation 9 J2 assumed/production E Cost of production per year 1 Working capital for 12 months 32. Depreaciation on building/shed and 2 other constructions except land 1 16. 3 equipments percent 1 69.2 Intrest and Oppurtunity Cost percent 13 11. 6 Total cost of production percent 2. 1 J3 Sales per year @ Rs. 2/CM 1. Sales inclusive of VAT & Excise 2. Note : Expected CER Generated. J Carbon Credit Revenue (Apprx) 2. CERs @ CM=1 CER, CM=6666 CER @ 11. Euros@6 IN Note : Analisis J Total Revenue 1. J6 Net Profit/year 29.9 J Net Profit Ratio 92. J Rate of return on investment 29.3 J9 Fixed cost (Per annum) 1 Depreatiation (Full) 16. 2 Insurance (.3% on Fixed costs) 2 2. 3 Intrest on investment (Full) 11. 2 2% Power 2. 3% of wages &% salary.9 6 Other Overheads (Full) 1. Total fixed cost 23.3 J1 Break Even Point (B.E.P) 9.3 3 9. 2. 129.1 16.9 1.9 6. 133. 2 129.3 9 6 2. Year 13. 3133.1 126.6 2 12 19. 2 13. 1.1 16. 12. 6 3. th Year 13. 31.2 121. 1 13 13. 12. 92.3 1.3 1993.2 1 32. th Year 13. 31.3 122. 3 1 163.6 6 1.. 19. 1 2112. 3. 1. 1. 162. 1. 1..6. 9. 2% of CERs deducted as transactional 3 and operational 9 costs. 6 CER revenues for Guidelines only. Not computed in Profitability of this report 2. 9.6 3. 6.9 91.6 22. 133. 2 91. 1.9 62. 2. 31.6 6 Note : 1 Net Profit Ratio = (Net Profit / Net Sales) x1 2 Rate of Return on Investment = (Net Profit / Project Cost) x 1 3 Break Even Point ( B.O.P )= (Fixed Cost / (Fixed Cost + Net Profit)) x 1 3. 11.1 3 3.2 9. 9. 93.2 16. 2 616.2 23.9 3. 32. 222.2 32. 126. 2 3.6 13.2 1. 3.2 1.3 2 11. 2.9 32. 31.9 21. 1 3. 13.2 2 39.6 3 112. 9 9.3 3.2 19. 2 1.9 2.9 3. 33.1 19. 1 C M/ yea r % % % Prepared by Project Consultant. K.J.Bhojak (Ph-966291, Email: kunal_bhojak2@yahoo.co.in)