Professional Documents
Culture Documents
LED Lights
Contents
Project Concept
Market Potential
Growth Drivers
Project Information
10
- Location/ Size
- Infrastructure Availability/ Connectivity
- Raw Material/ Manpower
Project Financials
16
18
19
Page 2
Project Concept
LED Lights Overview
LED lamp is a light-emitting diode (LED) product which is assembled into a lamp (or light bulb)
for use in lighting fixtures.
LED lights pass an electrical current through a semiconducting material to illuminate the lightemitting diodes that give the bulb its name.
The lights have been proven to be more energy efficient, economically viable and long-lasting
than their conventional counterparts.
While an LED bulb last for 50,000 hrs, it consumes 10W electricity and emits 80-100
lumens/watt, an incandescent bulb last for just 1,500 hrs, consume 60W and emits only 13
lumens/watt.
LED lamps are best suited for signs and indicators, night lights, flashlights, undercabinet
fixtures, and some recessed light/downlight applications.
For residential purpose, LED bulbs usually comes in the energy efficient range of 4W, 6W, 10W,
13W, 18W , 25W and 30W. (W = watts)
~70% of
total LED
production
cost
Thermal
interference
Driver
PCB
~30% of
total LED
production
cost
Page 3
Residential
LED housing
LED lighting
system - EMS
Optics
Lens
Diffuser
Downstream
LED lighting
system - OEM
LED chip
Assemblers
Government
Commercial and
Industrial (C&I)
Project Concept
LED Lights Classification
LED
CFL
Incandescent
bulb
50,000
10,000
1,500
14
60
0.006
0.014
0.06
0.036
0.084
0.36
1,800
4,200
18,000
33
400
120
10
400
600
330
2,200
4,800
18,330
Lowest cost
Page 4
CFL is ~2.2x
ICL is ~8.3x
more expensive more expensive
than a LED bulb than a LED bulb
If calculated over the life cycle of the LED bulb
Project Concept
Key components of LED Lamp
An LED lamp comprises following
major sub units/parts:
Conformal coating/white
reflection: The conformal
coating helps in moisture
control and solvent protection.
Thermal interface/ Pottants : It helps in controlling the high temperature of the LED by
providing proper insulation.
Adhesives for environment seals: Adhesives and sealants play a crucial role in the
structural integrity of LED lamps and luminaires, shielding electronics from environmental
stress and moisture. These products ensure components, such as module lids and base
plates, provide a secure structure base for subcomponents and larger assemblies.
Page 5
Market Potential
LED Lighting Industry Global Scenario
CAGR:
13.5%
42.7
19.9
2014
2020F
186.7
192.8
Primarily driven by
government's decision to
switch to LED for all street
lamps and public space
lighting.
216.3
152.8
104.6
75.6
2015E
2016F
2017F
2018F
2019F
2020F
Source: ELCOMA*
*Note:*ELCOMA is the apex body of lighting manufacturers in India which liaisons with govt agencies & supports lighting industry in
India.
As per the official estimates, Use of LEDs in households and public lighting could reduce energy
consumption by 50% to 90%.
It is expected that if 770 million incandescent bulbs sold in Indian households were switched to
LEDs, the country could save 25 billion KWh (units) of energy per year.
Prime Minister Narendra Modi launched LED household and street lighting program, Prakash
Path (way to light) on Jan. 5, 2015 which has led to adoption of LED efficient lighting systems.
Page 6
Growth Drivers
Demand-side drivers
Energy efficient
Government Schemes
Government schemes like Ujala scheme,
Domestic Efficient Lighting Programme
(DELP) and Street Light National
Programme (SLNP) are strongly supporting
the cause by distributing subsidized LEDs.
The cost has been reduced to INR250-300.
Supply-side drivers
Preferential Market Access The GoI launched PMA policy in 2013 to focus on giving preference to
(PMA)
locally manufactured electronic products in Government procurement.
Electronic Development
Fund (EDF)
Page 7
Growth Drivers
Other Government initiatives
Subsidy halt on CFL to
encourage LED-based solar
lights
In Dec 2015, Ministry of
New and Renewable
Energy stopped providing
central financial assistance
to CFL-based solar lighting
system
The increased
compliance norms will
arrest the dumping of
Chinese sub-standard
LEDs and will promote
uptake of locally
manufactured products
*Note: The STAR rating system would be mandatory from 1 Jan 2017 and needs to be adhered before 31 Dec 2018
Page 8
Gujarat - Competitive
Advantage
Ease of doing
business/ Policy
support
Established
infrastructure
Flourishing
economy
Gujarat contributes
around 19.1% to Indias
total exports of goods in
2014-15.
Gujarat Chief Minister Anandiben Patel launched the Central governments Ujala Scheme
according to which domestic consumers will be provided LED bulbs at a subsidised rate
of INR80-85 per piece. Till now 1.07 Cr bulbs has been sold at the subsidize rate in Gujarat.
2,718
Auto
2,202
Chem
2,220
IT
Electronics
Electrical
Computer
Civil
4,857
5,607
9,611
10,224
12,114
Mech
18,028
Gujarat Government enacted the Special investment regions (SIR) act in 2009 with the objective
of creating large size investment regions in the state and develop them as global hubs of
economic activity supported by world class infrastructure.
The state has three SIRs for electronics manufacturing.
SEZ are special duty free enclaves for the purpose of trade. These zones are self-contained and
integrated, having their own infrastructure and support services. Apart from state-of-the-art
infrastructure and access to a large skilled work force, the SEZ also provides enterprises with
attractive incentives.
The state has one electronics SEZ at Gandhinagar and 14 IT/ITeS SEZs - six at Ahmedabad,
four at Gandhinagar, three at Vadodara and one at Valsad.
Ahmedabad
Gandhinagar
Viramgam
Halol-Savli
Vadodara
Electronics SIR
IT/ITeS SEZ
Electronics and IT/ITeS SEZ
Tourist
flow*
Navlakhi
Valsad
Page 10
Project Information
Project location
Vatva industrial estate and adjoining areas in Ahmedabad district are appropriate location to
establish an LED manufacturing plant.
The site is owned and managed by Gujarat Industrial Development Corporation (GIDC) and falls
under Ahmedabad district.
DMIC**
Vatva industrial estate: Key highlights
Area
Land price
527 hectares
INR ~4,780/ square meter
(Apr16)
Focus
sectors
Engineering (including
electrical equipment and
products)
Foundries
Chemicals
Ahmedabad
Vatva GIDC
Vatva is a hub of small local LED manufacturers such as Geco Industries, Interio Lighting,
Farmson Enviro Care and Inovision Electronics.
Vatva along with several adjoining industrial estates in Odhav (11 kms*), Navrangpura (12 kms*),
Saraspura (11 kms) and Naroda (19 kms*) is base to several electric manufacturing facilities. This
indicate the presence of robust supply chain in the region.
*Distance from Vatva GIDC
Compound semiconductor materials (Indium gallium nitride, Aluminium gallium indium phosphide
and Aluminium gallium arsenide), electrical chipsets (capacitor, diode, resistor and IC chip, etc.)
and optical glass are the key raw materials used in the production of LED bulbs/lights.
Industry
Electronic chipsets
Compound semiconductor
materials
Copper
Page 11
Project Information
Infrastructure availability
Road
Air
Port
Utilities
Water
Power
Gas
Page 12
Gujarat State Petroleum Corporation (GSPC) is the gas supplier to the site through a well
established pipeline.
The company needs to directly apply for gas to GSPC.
Project Information
LED Manufacturing List of raw materials
Material
Quantity
Units
Material
Quantity
Units
Acetone
0.472
l/wafer
AuSn solder
11.817
mm3/wafer
Developer
92
ml/wafer
Etchant Ag
24
ml/wafer
Etchant Metal
48
ml/wafer
GaN Etchant
0.154
l/wafer
H2 gas
1.296
m3/wafer
N2 gas
3.536
m3/wafer
NH3 gas
0.358
Kg/wafer
O2 gas
1.6
l/wafer
Photoresist
15.2
ml/wafer
Power
34.06
kWh/wafer
SF6
0.08
l/wafer
SiH4
0.194
g/wafer
Slurry
1.84
l/wafer
Target Ag
0.352
mm3/wafer
Target Al
1.016
mm3/wafer
Target Ni
0.334
mm3/wafer
Target Ti
0.374
mm3/wafer
Target W
2.471
mm3/wafer
TMAl
0.002
g/wafer
TMGa
1.176
g/wafer
TMIn
0.008
g/wafer
UPW
192
l/wafer
12
Packaged
LEDs
Aluminium heat
sink
0.03273
Kg
IC chip
0.003
Kg
Lamp Weight
0.143
Kg
Diode
Pieces
Resistor SMD
23
Pieces
Resistor
Pieces
Transistor
Pieces
Electrolytic Capacitor
Pieces
0.18
Kg
Manufacturing
0.143
Kg
Energy in Use
240
kWh
Manpower requirement
Departments
Executives
Administration (3)
Financing (5)
Marketing (3)
Production (50)
Total - 70
Page 13
Project Information
List of equipment and machinery
5 High Magnification Microscope
1 LED prober
1 Dicing Machine
1 Auto DA/WB
1 Auto DTFS
1 Auto SD
1 Auto tester
1 Compressor
1 Oven
1 Freezer
2 Air Shower
1 Back-up Generator
Miscellaneous equipment
1 Alarm System
12 Air conditioner
2 Bundy Clock
10 Chair
10 Desk
1 Photocopying Machine
2 Telefax
12 Telephone
Office Supplies
20 Fire Extinguisher
15 Smoke Detector
Page 14
Project Information
Key players in Indian LED market
Company
Product offerings
Philips
Bulbs, Wall Lights, Ceiling Lights, Tube Lights, Spot Lights, Down lights,
Desk/Table Lights, Suspension Lights and Decor Lights
Osram
Havells
Wipro
Bajaj
Bulbs, Down Lights, Spot Lights, Tube Lights, Flexi Strips, Highbay
Luminaires, Street Lights, Landscape Lights, and Flood Lights
Eveready
Bulbs, Spot Lights, Down Lights and Deco Lights, Digi LED Torches, Ultra
LED Torches
SYSKA
Lamps, Tube Lights, Down Lights, Panel Lights, Strip Lights, Multibox Lights,
Track Lights, Moisture Proof Lights, Flood/Beam Lights, Hi-bay, Tunnel Lights,
Industrial Lights, Portable Lights, Corn Lights, Street Lights, Garden Lights
Black/White, Garden / Wall Lights, Parking Lights
Oreva
Lamps, Night Lamps, Down Lights, Panel Lights, Spot Lights, Tube Lights,
and Street Lights
Moser Baer
Bulbs, Panel Lights, High Bay Lights, Street Lights, Down Lights and Tube
Lights
Surya
Lamps, Spot Lights, Battens, Decorative luminaries, Down Lights, Strip Lights,
Street lights, Facade lights, High-bays luminaries and Linear Lamps
Charlston
NTL Lemnis
Page 15
Project Information
Key considerations
Non-standard ratings
Ratings of electrical equipment are not standardised and all utilities follow
their own standard ratings.
Access to Technology
Any abrupt increase in the aluminium price will adversely impact the
profitability of LED manufacturing companies.
Page 16
Project Financials
Estimated project cost
The total project cost of setting up a LED manufacturing unit is INR500 Crore. The facility will
manufacture LED lighting solutions for indoor, outdoor and industrial segments.
Project specifications
Project specifications
Details
50 acre
2.57 Cr
2,000
INR500 Cr
INR300
12.00%
*The land requirement and average cost of setting up of the plant (alongside the employment
generation) has been considered based on the recent proposal of Telangana LED plant.
**The total annual units production has been calculated by dividing the total annual revenue of
lighting segment by average cost of LED bulb.
***The EBITDA margin has been calculated by averaging the top LED manufacturers figures.
771
948.33
1166.44
1434.72
EBITDA/Cash Flow
(INR crore)
92.52
113.79
139.97
172.16
Undiscounted
Cumulative Cash flow
(INR crore)
92.52
206.31
346.29
518.46
INR500 crore
Estimated Payback period: 3.9 years
Page 17
Project Financials
Minimum viable size
Revenue
771.8 Cr
83.8 Cr
Total cost
688.0 Cr
216.1 Cr
Variable cost
471.9 Cr
2.57 Cr
INR183.6
INR300
1.85 Cr
Page 18
Environment clearance
Interest subsidy of 5% up to maximum amount of INR2.5 million (~US$ 37,5001) per annum for
five years on the term loan of machinery and equipment anywhere in the state.
Assistance for technology acquisition from recognized institution for manufacturing products will
be provided by way of 50% of the cost payable subject to a maximum of INR5 million
(~US$75,0001), including royalty payment for first two year.
Assistance for venture capital to raise promoter contribution in the form of equity or loan through
Gujarat Venture Finance Limited (GVFL).
SMEs will be given access to the patent pool and/or part of reimbursement of technology
acquisition costs up to a maximum of INR 2 million (~US$ 30,0001) for the purpose of acquiring
appropriate technologies up to a maximum of 5 years.
A 10% one-time capital subsidy for units practising zero water discharge.
Page 19
http://www.dst.gujarat.gov.in
Gujarat Industrial Development Corporation
www.gidc.gov.in
Office of Industries Commissioner
www.ic.gujarat.gov.in
Industrial Extension Bureau
www.indextb.com
This project profile is based on preliminary study to facilitate prospective entrepreneurs to assess a prima facie scope.
It is, however, advisable to get a detailed feasibility study prepared before taking a final investment decision.