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AUTOCLAVED AREATED CONCRETE BLOCKS PROJECT EXECUTION SUMMERY All figures in Rs. Lakhs
50000 CM/Annum AAC Plant 100000 CM/Annum AAC Plant 150000 CM/Annum AAC Plant
Working Capital Rs. Lakhs 50000 CM/Annum AAC Plant 44.37 100000 CM/Annum AAC Plant 88.75 150000 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 150 KW ball mill and a block separator Extra. Even we may need 2 more autoclaves to reach max production of 1,5 Lakhs CM as the steam curing period is at least 25% more
Assumptions for Sample Project Profile As land costs vary widely, this has been excluded Customs duties considered as per rates applicable during 2010-11 10% depreciations of Land & Buildings considered & 15% on machinery USD exchange rate taken as Rs. 45/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 @ 5% 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
A
1 2 3 4 5
widthe Mt
16.50 16.50 16.50 8.00
total Sft
3960 990 2970 1280 9200
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 60% of Autoclave waiting Bay area 4. Blocks Storage area workshed is also optional.
Installation Schedule
Installation Schedule for 150000 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 4 4 3 Side Pallets 50 50 50 4 Steam Traullies 25 25 25
D
1 2 3 4 5 6 7 8 9 10 11 12
E
Details of Machinary From (Both India and China ) Installation in a 3 Phase Split Item
Items imported from ChinaFOB price ( Fully Automatic Module ) Containers needed Avg Sea frieght + Insurance CIF price Customs + CVD + Surcharge, and other taxes Landing Price Landing price in INR Clearing and liasoning charges per B/L Destuffing and road frieght charges on trawler basis 45 25.13% 1500
Rate
Unit
US$ nos US$ US$ US$ US$ Rs.
Phase-1
613,556 12 18,000 631,556 158,710 790,265 35,561,943
Phase-2
89,018 2 3,000 92,018 23,124 115,142 5,181,396
Phase-3
89,018 2 3,000 92,018 23,124 115,142 5,181,396
Rs.
12,000
12,000
12,000
30000
Rs.
360,000
60,000
60,000
Rs.
35,933,943
5,253,396
5,253,396
USD
364,896
164,960
164,960
Total Indian Parts prices in INR * Grand total Machinary Installation & commissioning including civil works Total Machinary commissioned charges at site Total Machinary commissioned costs in Lakhs INR
45
Rs.
16,420,320
7,423,200
7,423,200
Rs. 5% Rs.
52,354,263 2,617,713
12,676,596 633,830
12,676,596 633,830
Rs.
54,971,976
13,310,425
13,310,425
Lakhs Rs.
549.72
133.10
133.10
* India Side Procurement includes Boiler, Autoclaves, Surrry Tank Body, Loader, Forklift, and Other unfabricated MS items
F
Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Bank Loan
0.00 7.50 96.32 5.60 10.50 3.00 37.50 1.50 412.29 99.83 99.83 3.00 9.00 3.00 788.87
G
1 a b c d e f g h i j k L
Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs.
CM
3333.33
4,071,141.67
2 a b c d 3 a b c d 5 6 7 8 9 a b c d 10 11 12 * i ii iii
Nos 5 5 10
Tot sal/day Rs. 30,000.00 Rs. 25,000.00 Rs. 40,000.00 Rs. 95,000.00 Tot sal/day Rs. 20,000.00 Rs. 32,000.00 Rs. 24,000.00 Rs. 76,000.00 Rs. Rs. Rs. 20,182.99 91,619.96 83,333.33
Rs.
95,000.00
Nos 2 4 4
Insuraance per Month ( at 0.3% per annum ) Maintainance per Month ( at 2% per annum ) Office Overheads(Post+phone+Net+travel+stanry) @ Rs. 25/CM Total Expences per Month Working Capital for 1 Cycle Curing Line 2 days Cerdit Period 14 days Stock holding 14 days Total = 30 Days Working Capital for 1 Cycle (30 days=1 month)- 1st year Working Capital for 1 Cycle (30 days=1 month)- 2nd year Working Capital for 1 Cycle (30 days=1 month)- 3nd year Note Installed Capacity in phase-1 (1st Year ) is 50000 CM/annum capacity adition in phase-2 (2nd Year ) is 50000 CM/annum capacity adition in phase-3 (3rd Year ) is 50000 CM/annum
H
1 2 3 4 1 2 3 4
DEPREATIATION
Item
Block Land & Building Added Land & Buildi ngs Depreaciation on building/shed and other constructions except land Year end Block Block Machinary Block Added in the Year Depreaciation on machinary & equipments Year end Block 15% 1st Yr 165.60 0.00 10% 16.56 149.04 601.72 0.00 90.26 511.46 2nd year 149.04 0.00 14.90 134.14 511.46 133.10 76.72 567.85 3rd Year 134.14 0.00 13.41 120.72 567.85 133.10 85.18 615.77 4th Year 120.72 0.00 12.07 108.65 615.77 0.00 92.37 523.41 5th Year 108.65 0.00 10.87 97.79 523.41 0.00 78.51 444.90 Remarks
I
1 2 3 4 5 6 7
33%
D.S.C.R
4.06
2.51
3.75
4.37
5.08
9 Average DSCR
3.95
Note D.S.C.R = ( Profit After Tax + Depreciation + Intrest on Trrm Loan ) / (Intrest on Term Loan + Term Loan Repayment )
Project Cost
Total Fixed Capital Total Working Capital Project Cost Machinary Utilisation assumed/production Cost of production per year Working capital for 12 months Depreaciation on building/shed and other constructions except land equipments Intrest and Oppurtunity Cost Total cost of production (30 days)
1st Yr 2nd year 3rd Year 4th Year 5th Year 807.32 940.42 1073.53 1073.53 1073.53 44.37 88.75 133.12 144.21 155.30 851.69 1029.17 1206.65 1217.74 1228.83 CM/ 140000 year
J2 E 1 2 3 4 5
40000
80000
120000
130000
532.47 10 percent 15 percent 13 percent 16.56 90.26 110.72 750.01 1000.00 2808.00 5000.00 25.88
J3 Sales per year @ Rs. 2500/CM Note : Sales inclusive of VAT & Excise Expected CER Generated J4 Note : Carbon Credit Revenue (Apprx) CERs @8 CM=1 CER, 50000 CM=6666 CER @ 11.5 Euros@60 INR Analisis J5 J6 J7 J8 J9 1 2 3 4 5 6 7 Total Revenue Net Profit/year Net Profit Ratio Rate of return on investment Fixed cost (Per annum) Depreatiation (Full) Insurance (0.3% on Fixed costs) Intrest on investment (Full) 25% Power 30% of wages &50% salary Other Overheads (Full) Total fixed cost
25% of CERs deducted as transactional and operational costs. CER revenues for Guidelines only. Not computed in Profitability of this report
1000.00 249.99 25.00 29.35 106.82 2.42 110.72 5.40 7.98 10.00 243.34 49.33
2000.00 709.64 35.48 68.95 91.62 2.82 133.79 10.80 15.96 20.00 275.00 31.66
3000.00 1147.13 38.24 95.07 98.59 3.22 156.86 16.20 23.94 30.00 328.82 22.28
3250.00 1256.72 38.67 103.20 104.44 3.22 158.31 17.55 25.94 32.50 341.95 21.01
3500.00 1387.22 39.63 % 112.89 % 89.38 3.22 159.75 18.90 27.93 35.00 334.18 19.41 %
Note :
1 2 3 Net Profit Ratio = (Net Profit / Net Sales) x100 Rate of Return on Investment = (Net Profit / Project Cost) x 100 Break Even Point ( B.O.P )= (Fixed Cost / (Fixed Cost + Net Profit)) x 100