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The document discusses setting up an aluminum foil manufacturing plant in India. It provides details on the aluminum foil industry in India such as key applications being pharmaceuticals and beverages. It also outlines the total project costs, means of finance, manufacturing process involved, and profitability projections to assess the viability of investing in an aluminum foil production business.

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0% found this document useful (1 vote)

134 views71 pages

Pdfanddoc 29120

Uploaded by

Abhishek Agrawal

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Aluminium Foil

Food Packaging Foil

Manufacturing Plant, Detailed Project Report, Profile, Business Plan,
Industry Trends, Market Research, Survey, Manufacturing Process,
Machinery, Raw Materials, Feasibility Study, Investment
Opportunities, Cost and Revenue, Plant Economics, Production
Schedule, Working Capital Requirement, Plant Layout, Process Flow
Sheet, Cost of Project, Projected Balance Sheets, Profitability
Ratios, Break Even Analysis
Introduction

Aluminium plays a major role in the modern world through

its innumerable forms of applications- from kitchen ware
to electric conductors and from railway wagon to Appollo
spacecraft. Because of its intrinsic and versatile
properties of lightness, strength to weight ratio,
corrosion resistance, electrical and thermal conductivity,
non toxicity etc., a wide range of uses has opened up for
this metal. Aluminium as a packaging material is
unmatched owing to its light weight, hygienic and non-
contamination which eventually results in longer shelf-life
of end products.

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Aluminium foil is a thin sheet of metal. As such it can be
an absolute barrier to moisture, gases, odors, bacteria
and moulds. The high reflectivity of aluminium ensures
good protection against radiant heat, whilst its opacity is
important in preventing deterioration of a very large
range of foods and drinks which are affected by light. It
is used for packaging and non packaging uses. The
growth of this industry has been in the recent past,
owing to the growing application of foil in a variety of
products. India is one of the key producers of aluminium
foil in the region. Over 70% of aluminium foil used in
India is for packaging applications.

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Pharmaceuticals followed by beverages, personal care
and a wide range of food and non-food products, semi
rigid containers and house foil are the principal
applications of aluminium foil in India in the packaging
sector. Indai is the biggest aluminium foil manufacturer in
the country. Other major manufacturers include India
Foils, Emco, PG Foils and Flex Art. Holding on to the
emerging indicators and the future prospects, Hindalco
has plans to increase its aluminum smelting capacity
three-fold to 1.8 mn tonne and alumina refining capacity
four-fold to 6 mn tonne annually. As a whole it is a good
project for new entrepreneurs to invest.

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India's share in world aluminium market is estimated at around 3%. India ranks
fifth in bauxite production after Australia (62 mntonnes), Guinea (17.50
mntonnes), Brazil (16.20 mntonnes) and China (10.75 mntonnes). With a total
output of 9.25 mntonnes, the country contributes about 6% of the world's
total production of 159 mntonnes, India holds the fifth position in reserves
base and is ahead of China with 2300 mntonnes. India ranked seventh in
alumina production with a total output of 3 mntonnes, a share of nearly 5% of
the global production of 61 mntonnes.

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The per capita consumption of aluminium in India continues to remain
abysmally low at under 1 kg as against nearly 25 to 30 kg in the US and
Europe, 15 kg in Japan, 10 kg in Taiwan and 3 kg in China.

The total aluminium foil production in India is placed at around 35,000

tonne, of which Indal and India Foils account for a little over 50%. Indal is the
biggest aluminium foil manufacturer in the country. Other major
manufacturers include India Foils, Emco, PG Foils and Flex Art. Hindalco also
forayed into the segment and managed to capture a sizable share of the
market.

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Its new Silvassa plant in Gujarat has a large capacity of 200,000 tpa. India Foils,
now of the Sterlite group, had prepared a five-pronged strategy to bring back
the heavily losing company on rails. Hindalco made a bid to acquire India Foils
as Sterlite was intending to sell off India Foils.

Aluminium foil industry is growing annually at around 7%. In the near future,
with the phenomenal rise in disposable incomes, the foil industry is expected to
receive a boost. Working couples, for instance, increasingly pack their food in
aluminium foils. The growth in demand is expected to follow the increasing
demand noticed in China.

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APPLICATIONS

The foil is used for packaging of many products, some of which

are given below:
— Pharmaceutical tablets

— Bulk & unitized packing of tea and coffee

— Prepared meals — Bakery products

— Frozen meat, fish

— Milk bottle caps

— Wine

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— Lube Oil, greases

— Powdered milk

— Confectionery

— Biscuits

— Photographic film

— Gift wraps

— Household wraps

— Butter, margarine, Cigarettes

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PROPERTIES OF ALUMINIUM FOIL

Aluminium foil has significant properties as given

below:
i) Good thermal and electrical conductivity,
ii) good formability,
iii) impermeability and non-absorptivity to water, grease, oil &light;
odourless and tasteless

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i) good adhesion to a variety of compounds,
ii) excellent printability,
iii)resistance to oxidation and chemical attacks

Owing to these properties, aluminium foil is preferred to

other packaging materials as flexible materials cannot match
these characteristics of aluminium foil

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Reasons for buying the report:

• This report helps you to identify a profitable project for investing

or diversifying into by throwing light to crucial areas like industry

size, market potential of the product and reasons for investing in the

product

• This report provides vital information on the product like it’s

characteristics and segmentation

• This report helps you market and place the product correctly by

identifying the target customer group of the product

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• This report helps you understand the viability of the project by

disclosing details like machinery required, project costs and

snapshot of other project financials

• The report provides a glimpse of government regulations

applicable on the industry

• The report provides forecasts of key parameters which helps to

anticipate the industry performance and make sound business

decisions

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Our Approach:

• Our research reports broadly cover Indian markets, present analysis,

outlook and forecast for a period of five years.

• The market forecasts are developed on the basis of secondary

research and are cross-validated through interactions with the

industry players

• We use reliable sources of information and databases. And

information from such sources is processed by us and included in the

report

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Scope of the Report

The report titled “Market Survey cum Detailed Techno Economic

Feasibility Report on Aluminium Foil” provides an insight into the
Aluminium Foil market in India with focus on uses and applications,
Manufacturing Process, Process Flow Sheets, Plant Layout and Project
Financials of Aluminium Foil project. The report assesses the market
sizing and growth of the Indian Aluminium Foil Industry. While
expanding a current business or while venturing into new business,
entrepreneurs are often faced with the dilemma of zeroing in on a
suitable product/line. And before diversifying/venturing into any
product, they wish to study the following aspects of the identified
product:

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• Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period

We at NPCS, through our reliable expertise in the project consultancy

and market research field, have demystified the situation by putting
forward the emerging business opportunity in the Aluminium Foil
sector in India along with its business prospects. Through this report
we have identified Aluminium Foil project as a lucrative investment
avenue.

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Project at a Glance

COST OF PROJECT MEANS OF FINANCE

Particulars Existing Proposed Total Particulars Existing Proposed Total
Land & Site Development
Exp. 0.00 72.50 72.50 Capital 0.00 77.96 77.96
Buildings 0.00 77.00 77.00 Share Premium 0.00 0.00 0.00
Plant & Machineries 0.00 57.89 57.89 Other Type Share Capital 0.00 0.00 0.00
Motor Vehicles 0.00 8.00 8.00 Reserves & Surplus 0.00 0.00 0.00
Office Automation
Equipments 0.00 25.00 25.00 Cash Subsidy 0.00 0.00 0.00
Technical Knowhow Fees &
Exp. 0.00 7.50 7.50 Internal Cash Accruals 0.00 0.00 0.00
Long/Medium Term
Franchise & Other Deposits 0.00 0.00 0.00 Borrowings 0.00 233.89 233.89
Preliminary& Pre-operative
Exp 0.00 3.50 3.50 Debentures / Bonds 0.00 0.00 0.00
Unsecured
Provision for Contingencies 0.00 5.00 5.00 Loans/Deposits 0.00 0.00 0.00
Margin Money - Working
Capital 0.00 55.46 55.46

TOTAL 0.00 311.85 311.85 TOTAL 0.00 311.85 311.85

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Project at a Glance

Year Annualised Book Debt Divide Retained Payou Probabl P/E Yield Price/
Value nd Earnings t e Ratio Book Value
Market
Price
No.of
Per
Times
EPS CEPS Per Share Share Per Share
` ` ` ` ` % ` % ` %

1-2 6.15 8.92 16.15 24.00 0.00 100.00 6.15 0.00 6.15 1.00 0.00

2-3 9.03 11.46 25.18 18.00 0.00 100.00 9.03 0.00 9.03 1.00 0.00

3-4 11.92 14.06 37.10 12.00 0.00 100.00 11.92 0.00 11.92 1.00 0.00
4-
5 14.70 16.59 51.80 6.00 0.00 100.00 14.70 0.00 14.70 1.00 0.00
5-
6 17.34 19.01 69.14 0.00 0.00 100.00 17.34 0.00 17.34 1.00 0.00

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Project at a Glance

Year D. S. C. R. Debt / Equity Total Retur Profitability Ratio Assets Curre

- as- Net n on Turnov nt
Deposi Equity Worth Net er Ratio
ts Worth Ratio
Debt
Individ Cumulat Overa GPM PBT PAT Net P/V
ual ive ll Contri Ratio
bution
(Number of
(Number of times) times) % % % % % %
Initi
al 3.00 3.00

1-2 1.31 1.31 1.49 1.49 4.58 5.41% 2.54% 1.69% 307.19 10.86% 4.06 1.07

2-3 1.63 1.47 0.71 0.71 3.00 5.86% 3.30% 2.13% 358.28 10.85% 4.23 1.15

3-4 2.02 1.64 2.01 0.32 0.32 2.10 6.15% 3.86% 2.46% 409.46 10.85% 4.23 1.24
4-
5 2.48 1.82 0.12 0.12 1.55 6.35% 4.26% 2.70% 460.64 10.85% 4.15 1.35
5-
6 3.02 2.01 0.00 0.00 1.19 6.47% 4.53% 2.87% 511.82 10.85% 4.01 1.57

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Project at a Glance

BEP
BEP - Maximum Utilisation Year 5
Cash BEP (% of Installed Capacity) 55.70%
Total BEP (% of Installed Capacity) 58.23%

IRR, PAYBACK and FACR

Internal Rate of Return .. ( In %age ) 28.13%

Payback Period of the Project is ( In Years ) 2 Years 3 Months

Fixed Assets Coverage Ratio ( No. of times ) 27.141

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Major Queries/Questions Answered in the Report?

1. What is Aluminium Foil industry ?

2. How has the Aluminium Foil industry performed

so far and how will it perform in the coming years ?

3. What is the Project Feasibility of a Aluminium Foil

Plant ?

4. What are the requirements of Working Capital for

setting up a Aluminium Foil plant ?

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5. What is the structure of the Aluminium Foil
Business and who are the key/major players ?

6. What is the total project cost for setting up

Aluminium Foil plant ?

7. What are the operating costs for setting up a

Aluminium Foil plant ?

8. What are the machinery and equipment

requirements for setting up a Aluminium Foil
plant ?

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9. Who are the Suppliers and Manufacturers of
Plant & Machinery for setting up a Aluminium
Foil plant ?

10. What are the requirements of raw material for

setting up a Aluminium Foil plant ?

11. Who are the Suppliers and Manufacturers of Raw

materials for setting up a Aluminium Foil plant ?

12. What is the Manufacturing Process and

Formulations of a Aluminium Foil plant ?

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13. What is the total size of land required for setting
up a Aluminium Foil plant ?
14. What will be the income and expenditures for a
Aluminium Foil plant ?

15. What are the Projected Balance Sheets of a

Aluminium Foil plant ?

16. What are the requirement of utilities and

overheads for setting up a Aluminium Foil plant?
17. What is the Built up Area Requirement and cost
for setting up a Aluminium Foil Business?

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18. What are the Personnel (Manpower)
Requirements for setting up a Aluminium Foil
Business?
19. What are Statistics of Import & Export for
Aluminium Foil ?

20. What is the time required to break-even?

21.What is the Break-Even Analysis of a Aluminium
Foil plant?

22.What are the Project financials of a Aluminium

Foil plant?

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23. What are the Profitability Ratios of a Aluminium
Foil plant?

24. What is the Sensitivity Analysis-Price/Volume of

a Aluminium Foil plant?

25. What are the Projected Pay-Back Period and

IRR of a Aluminium Foil plant?

26. What is the Process Flow Sheet Diagram of a

Aluminium Foil project?

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27. What are the Market Opportunities for setting
up a Aluminium Foil plant?

28. What is the Market Study and Assessment for

setting up a Aluminium Foil plant?

29. What is the Plant Layout for setting up a

Aluminium Foil Business?

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Table of Contents
of the
Project Report

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1. PROJECT LOCATION
1.1. District Profile & Geotechnical Site Characterization
1.1.1. General
1.1.2. Demographics
1.1.3. Geography
1.1.4. Map
1.1.5. Transportation
1.1.6. Economy
1.1.7. Climate
1.1.8. Culture

2. INTRODUCTION

3. USES & APPLICATIONS

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4. PROPERTIES OF ALUMINIUM

5. PROPERTIES OF ALUMINIUM FOIL

5.1.1. Technical Properties

6. BIS SPECIFICATION

6.1. IS 16011 (2012): Aluminium and Aluminium Alloy Foil for

Pharmaceutical Packaging - Specification [MTD 7: Light Metals and their
Alloys]

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7. MARKET SURVEY

7.1.1. Newly Emerging Indicators

7. FINANCIALS & COMPARISON OF MAJOR

PLAYERS/COMPANIES
8.1. About Financial Statements of CMIE Database
8.2. Profits & Appropriations
8.3. Total Liabilities
8.4. Total Assets
8.5. Net Cash Flow from Operating Activities
8.6. Section – I
8.6.1. Name of Company with Contact Details
8.6.2. Name of Director(S)
8.6.3. Plant Capacity

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8.6.4. Location of Plant
8.6.5. Name of Raw Material(S) Consumed with Quantity & Cost
8.7. Section – II
8.8. Assets
8.9. Cash Flow
8.10. Cost as % ge of Sales
8.11. Forex Transaction
8.12. Growth in Assets & Liabilities
8.13. Growth in Income & Expenditure
8.14. Income & Expenditure
8.15. Liabilities
8.16. Liquidity Ratios
8.17. Profitability Ratio
8.18. Profits
8.19. Return Ratios

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8.20. Structure of Assets & Liabilities (%)
8.21. Working Capital & Turnover Ratios

9. PRESENT MANUFACTURERS

10. EXPORT & IMPORT STATISTICS DATA OF INDIA

10.1. Export Statistics Data of Aluminium Foil

10.2. Import Statistics Data of Aluminium Foil

10. 11. SPECIFICATION LIST OF DIFFERENT TYPES OF

FOIL
11.1. Aluminium Pharmaceutical Foil
11.1.1. Specification

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11.1.2. Chemical Compositions
11.1.3. Mechanical Properties
11.2. Aluminium Cigarette Packing Foil (Double Zero Foil)
11.2.1. Specification
11.2.2. Chemical Compositions
11.2.3. Tensile Strength Property
11.3. Aluminium Household Foil
11.3.1. Specification
11.3.2. Chemical Compositions
11.3.3. Tensile Strength Property
11.3.4. Applications
11.4. Aluminium Container Foil
11.4.1. Specification
11.4.2. Thickness Options
11.4.3. Coating/ Lubrication

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11.5. Printed Aluminium Foil/Sheet
11.5.1. Specification
11.5.2. Chemical Compositions
11.5.3. Mechanical Properties
11.6. Aluminium Beer Mark Foil
11.6.1. Specification
11.6.2. Tensile Strength Property
11.6.3. Mechanical Properties

12. MANUFACTURING PROCESS

13. PRINTING/COLORING ON ALUMINUM FOIL

14. PROCESS FLOW DIAGRAM

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15. BUYER’S LIST

15.1. Contact Details of Buyer’s

15.2. Name of Director(S)
15.3. Plant Capacity
15.4. Location of Plant
15.5. Company Wise Consumption Detail of the Raw Materials

16. SUPPLIERS OF PLANT & MACHINERY

17. SUPPLIERS OF RAW MATERIAL

18. 18. PRODUCT, MACHINERY & RAW MATERIAL

PHOTOGRAPHS

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18.1. Product
18.2. Machinery
18.3. Raw Material

19.PLANT LAYOUT

20. QUOTATION OF PLANT, MACHINERY AND

EQUIPMENTS FROM SUPPLIER

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Project Financials
• Project at a Glance Annexure

• Assumptions for Profitability workings ………………………..1

• Plant Economics…………………………………………………..2
• Production Schedule………………………………………………3
• Land & Building……………………………………………….……4
Factory Land & Building
Site Development Expenses

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• Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)

• Other Fixed Assets………………………………………..........….......6

Furniture & Fixtures
Pre-operative and Preliminary Expenses
Technical Knowhow
Provision of Contingencies

• Working Capital Requirement Per Month……………………….…7

Raw Material
Packing Material
Lab & ETP Chemical Cost
Consumable Store

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• Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses

• Salary and Wages …………………………………………....……..9

• Turnover Per Annum ……………………………………….....…10

• Share Capital…………………………………………………….....11
Equity Capital
Preference Share Capital

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• Annexure 1 :: Cost of Project and Means of Finance

• Annexure 2 :: Profitability and Net Cash Accruals

 Revenue/Income/Realisation
 Expenses/Cost of Products/Services/Items
 Gross Profit
 Financial Charges
 Total Cost of Sales
 Net Profit After Taxes
 Net Cash Accruals

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• Annexure 3 :: Assessment of Working Capital
requirements

 Current Assets
 Gross Working Capital
 Current Liabilities
 Net Working Capital
 Working Note for Calculation of Work-in-
process

• Annexure 4 :: Sources and Disposition of Funds

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• Annexure 5 :: Projected Balance Sheets

 ROI (Average of Fixed Assets)

 RONW (Average of Share Capital)
 ROI (Average of Total Assets)

• Annexure 6 :: Profitability Ratios

 D.S.C.R
 Earnings Per Share (EPS)
 Debt Equity Ratio

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• Annexure 7 :: Break-Even Analysis

 Variable Cost & Expenses

 Semi-Variable/Semi-Fixed Expenses
 Profit Volume Ratio (PVR)
 Fixed Expenses / Cost
 B.E.P

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• Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume

 Resultant N.P.B.T
 Resultant D.S.C.R
 Resultant PV Ratio
 Resultant DER
 Resultant ROI
 Resultant BEP

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• Annexure 12 :: Shareholding Pattern and Stake Status
 Equity Capital
 Preference Share Capital
• Annexure 13 :: Quantitative Details-Output/Sales/Stocks
 Determined Capacity P.A of Products/Services
 Achievable Efficiency/Yield % of Products/Services/Items
 Net Usable Load/Capacity of Products/Services/Items
 Expected Sales/ Revenue/ Income of Products/ Services/
Items

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• Annexure 14 :: Product wise Domestic Sales
Realisation

• Annexure 15 :: Total Raw Material Cost

• Annexure 16 :: Raw Material Cost per unit

• Annexure 17 :: Total Lab & ETP Chemical Cost

• Annexure 18 :: Consumables, Store etc.

• Annexure 19 :: Packing Material Cost

• Annexure 20 :: Packing Material Cost Per Unit

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• Annexure 21 :: Employees Expenses

• Annexure 22 :: Fuel Expenses

• Annexure 23 :: Power/Electricity Expenses

• Annexure 24 :: Royalty & Other Charges

• Annexure 25 :: Repairs & Maintenance Expenses

• Annexure 26 :: Other Manufacturing Expenses

• Annexure 27 :: Administration Expenses

• Annexure 28 :: Selling Expenses

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• Annexure 29 :: Depreciation Charges – as per Books
(Total)
• Annexure 30 :: Depreciation Charges – as per Books
(P & M)
• Annexure 31 :: Depreciation Charges - as per IT Act
WDV (Total)
• Annexure 32 :: Depreciation Charges - as per IT Act
WDV (P & M)
• Annexure 33 :: Interest and Repayment - Term Loans
• Annexure 34 :: Tax on Profits
• Annexure 35 :: Projected Pay-Back Period and IRR

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Niir Project Consultancy Services (NPCS)
can provide Detailed Project Report on
Aluminium Foil

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