Вы находитесь на странице: 1из 45

9/13/2017

BABA
BAIDYANATH DETAILED PROJECT REPORT
ENTERPRISES

FLY ASH BRICK & PAVER BLOCK MANUFACTURING UNIT | Neeraj Singh
BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

Table of Contents
EXECUTIVE SUMMARY ............................................................................................................................ 2
BACKGROUND ......................................................................................................................................... 4
LAND /SHED DETAILS & LOGISTICS ......................................................................................................... 9
PROCUREMENT STRATEGY OF RAW MATERIAL & OTHER INPUTS ....................................................... 10
TECHNO-COMMERCIAL VIABILITY ASSESSMENT .................................................................................. 14
PROCESS FLOW DIAGRAM .................................................................................................................... 18
INFRASTRUCTURE SOURCE ................................................................................................................... 21
MARKETING STRATEGY ......................................................................................................................... 22
SWOT ANALYSIS .................................................................................................................................... 23
FINANCIAL ANALYSIS ............................................................................................................................. 24

Neeraj Singh – 9929137131 Page 1 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

EXECUTIVE SUMMARY

1. Executive Summary
a) COMPANY NAME M/S BABA BAIDYANATH ENTERPRISES
b) CONSTITUTION PARTNERSHIP
c) YEAR OF INCORPORATION 2017
d) REGISTERED OFFICE C/O SS SINGH, SINGH VILLA, GROUND FLOOR, B
N JHA PATH, POKHNA TILLA, DEOGHAR,
JHARKHAND, 814112
e) PARTNERS PRIYA LATH W/O ASHISH KUMAR DALMIYAN

C/O SS SINGH, SINGH VILLA,


GROUND FLOOR, B N JHA PATH,
POKHNA TILLA, DEOGHAR,
JHARKHAND, 814112

+91-94315-54049

ASHISH S/O SH ARUN KUMAR DALMIYAN


KUMAR
C/O S S SINGH, SINGH VILLA,
DALMIYAN
GROUND FLOOR, B N JHA PATH,
POKHNA TILLA, DEOGHAR,
JHARKHAND, 814112

+91-93347-55852

f) SHARE HOLDING PRIYA LATH 60%

ASHISH 40%
KUMAR
DALMIYAN

g) WORKS LAND APPLIED


h) REGISTRATION NO./ CIN REGISTRATION UNDER PROCESS

Neeraj Singh – 9929137131 Page 2 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

i) LICENSES/APPROVALS/REGISTRATIONS i. PAN CARD NO – TBO


AND THEIR VALIDITY ii. GSTIN REG. – TBO
O – OBTAINED iii. FACTORY LICENCE – TBO
TBO – TO BE OBTAINED iv. NSIC REGISTRATION – TBO
NA – NOT APPLICABLE
j) PRODUCTS & SERVICES FLY ASH BRICKS AND CONCRETE PAVER BLOCKS
k) EFFLUENTS NONE
l) OPERATIONAL HAZARDS EXPOSURE TO DUST
m) CAPACITY 2,400 GREEN BRICKS PER HOUR +
125 CONCRETE BLOCKS PER HOUR
n) EXPECTED DATE OF PRODUCTION 1 APRIL 2018
o) BANKER PUNJAB NATIONAL BANK, DEOGHAR
p) DEVELOPMENT OBJECTIVES THE OBJECTIVES OF THE PROPOSED
DEVELOPMENT ARE TO:
 PROVIDE A RANGE OF BRICKS AND PAVER
BLOCKS FOR THE CONSTRUCTION
INDUSTRY IN VICINITY OF DEOGHAR;
 SUPPORT LOCAL EMPLOYMENT IN
OPERATIONS.
q) BANK TBO

r) PROJECT FINANCIALS ₹ 83,13,286


CAPITAL INVESTMENT

₹ 2,00,000
CONTINGENCY FUND

₹ 35,28,887
WORKING CAPITAL LESS MARGIN
FOR WORKING CAPITAL

TOTAL ₹ 1,20,42,173

Neeraj Singh – 9929137131 Page 3 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

BACKGROUND
2. Background
2.1. Sector Background —
The construction industry contributes to about 10 % of the Gross Domestic
Product (GDP), registering an annual growth of about 9 %. Clay fired bricks form
the backbone of the construction industry which is valued at approximately US$
70.8 billion. The brick sector in India, although unorganised, is tremendous in size
and spread. India is the second largest brick producer (China dominates with 54
% share) in the world. It is continuously expanding on account of a rapid increase
in demand for bricks in infrastructure and housing industries. In order to meet
this demand, over 150,000 brick units provide direct employment to more than 8
million workers. During the Ninth Five-year Plan period (1997-2002), the annual
demand of 170 billion bricks per year was estimated to be generating revenues
of over US$ 4.8 billion.
Construction sector is a crucial component of India's development path. It
contributed to 8.2% of the Gross Domestic Product (GDP), in 2011-12 .
Clay fired bricks form the backbone of the construction industry. India is
estimated to have over 1,50,000 brick kilns producing the annual
demand 200 billion bricks per year . It is the second largest producer in the world
after China. The production is slated to increase in the future due to increasing
urbanization, housing shortage and reconstruction due to climatic events.
Brick production in India takes place using century old production methods,
involving manual and inefficient methods of clay preparation, hand moulding and
firing. About 70% of brick production takes place in the Indo-Gangetic plains
using Fixed Chimney Bull’s Trench Kiln (FC-BTK) technology. In peninsular India,
the majority of brick production is through clamp kilns and BTKs. The main fuel
used is coal and biomass.
Fertile top soil is used for the production of bricks. It is estimated that the brick
industry consumes around 350 million tonnes of good quality soil every year.
Increased urbanisation leading to an excessive exploitation of top soil for

Neeraj Singh – 9929137131 Page 4 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

construction purposes has lead to an increased mining activity of raw materials


for brick production. As a result the productivity of land decreases.
Fly ash collected from electrostatic precipitators (ESP) or silos of thermal power
plants in dry state can be used as raw material for brick production. A typical fly
ash unit has a daily production capacity of 8000-15000 bricks per shift of 8 hours.
This technology is economical and
environment friendly as it does
not utilise any fertile top soil.
Because soil has been replaced by
fly ash which was accounted as
wastes once but it comes in use of
brick making and act as an asset.
There is no emission of
greenhouse gases during production. The use of fly ash bricks in construction has
been successfully demonstrated in the country.
The enabling policies of the government have provided crucial support for
development of the Fly Ash Bricks
As environmental consciousness at all levels of society increases, pollution
caused by the brick industry is under the scrutiny of environmentalists and the
government. The Government has taken action by issuing notifications for siting
criteria of kilns, banning polluting moving chimney BTKs, emissions standards for
Fixed Chimney Kilns (FCKs) and Verticle Shaft Brick Kilns (VBSKs), banning top soil
use, promoting utilisation of industrial wastes, etc. Currently all brick production
technologies falls under the “red category” of the State Pollution Control Board.
It is mandatory to get Pollution No-Objection-Certificate (NOC) and renew after
every one year.
The industry enabling guidelines issued vide the The Gazette notification of
MINISTRY OF ENVIRONMENT AND FORESTS, New Delhi, the 14th September,
1999 directs as below;
1. Use of fly ash, bottom ash or pond ash in the manufacture of bricks and other
construction activities.-

Neeraj Singh – 9929137131 Page 5 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

(1) No person shall within a radius of fifty kilometers from coal or lignite
based thermal power plants, manufacture clay bricks or tiles or blocks for
use in construction activities without mixing at least 25 per cent of ash
(fly ash, bottom ash or pond ash) with soil on weight to weight basis.
2. Specifications for use of ash-based products.-
(1) Manufacture of ash-based products such as cement, concrete blocks,
bricks, panels or any other material or the use of ash in construction
activity such as in road laying, embankments or use as landfill to reclaim
low lying areas including back filling in abandoned mines or pitheads or
for any other use shall be carried out in accordance with specifications
and guidelines laid down by the Bureau of Indian Standards, Indian
Bureau of Mines, Indian Road Congress, Central Building Research
institute, Roorkee, Central Road Research Institute, New Delhi, Building
Materials and Technology Promotion Council, New Delhi, Central Public
Works Department, State Public Works Departments and other Central
and State Government agencies.
(2) The Central Public Works Department, Public Works Departments in e
State/Union Territory Governments, Development Authorities, Housing
Boards, National Highway Authority of India and other construction
agencies including those in the private sector shall also prescribe the use
of ash and ash-based products in their respective schedules of
specifications and construction applications, including appropriate
standards and codes of practice, within a period of four months from the
publication of this notification.
(3) All local authorities shall specify in their respective building bye-laws and
regulations the use of ash and ash-based products and construction
techniques in building materials, roads, embankments or for any other
use within a period of four months from the date of publication of this
notification. [F. No. 16-2/95-HSMD]

V RAJAGOPALAN, Jt.. Secy.


2.2. Project Background

Neeraj Singh – 9929137131 Page 6 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

Deogarh district is located in the western portion of Santhal paraganas. It is


bounded by Bhagalpur district in north, Dumka in south and east and Giridhi in
west. The district extends from 24029’ N 86042' E to 24048’ N 86070’ E. and
comprises 2481 sq. km area. Deoghar was earlier part of Dumka District, but now
itself a district & district town also. The Deoghar district is composed of 7
community development blocks namely Deogarh, Madhupur, Mohanpur,
Sarwan, Palolori, Sarath and Karon. Deoghar is the main city of the Deoghar in
the state of Jharkhand, India. It is an important Hindu pilgrimage centre with the
Baidyanath Temple being one of the twelve Shiva Jyothirlingas in India and one
of the 51 Shakti Peethas in India.
According to a report submitted by a Technical Committee of the Ministry of
Housing and Urban Poverty Alleviation (MHUPA), Jharkhand urban housing
shortage is estimated nearly 0.63 million households in 2012. Around 96 % of the
shortage constitute of Economically Weaker Section (EWS) and Low Income
Group (LIG) of the society.
All dwellings are to be provided with “Basic Urban Services / Municipal Services”
like services of drinking water supply and sanitation, drainage, sewerage, solid
waste disposal and street lighting. The external and internal developments shall
include;
A) External development: External development shall include road connectivity,
street lighting, water supply, sewerage connection, solid waste management
facility and public transport service.
B) Internal development: Internal development works shall include all internal
roads, footpaths, complete water supply including overhead or surface water
reservoir/ distributions lines. Electric distributions lines/ 11 KV line/ transformers
etc. (if required), internal sewer lines/ drainage lines/ Nullahas (wherever
required), gated compound/ street light/ parks/ adequate and proper tree
plantation in parks and in front of buildings. Rainwater harvesting structures,
Solar system & sewerage treatment plant shall be mandatory as per
requirement.
A highway project worth Rs. 1,955 crore for construction of a road link between
Sahibganj in Jharkhand to Manihari in Bihar, including a bridge on the Ganges,

Neeraj Singh – 9929137131 Page 7 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

received cabinet clearance on 13th October 2016. The foundation stone of the
bridge was laid by the Prime Minister of India on 06th April 2017.
The project, will help expedite improvement of infrastructure in Bihar and
Jharkhand and also reduce the time and cost of travel in these states. The
development of this stretch will also be expected to help uplift socio-economic
conditions of people of Santhal Pargana region of the State.
Development of AIIMS like institute at Deoghar.
Proposed Airport at Deoghar.
Proposed Adani Mega Power Project at Godda.
All round development like above provide ample opportunities for the Fly ash
Brick manufacturing unit at Deoghar that presents stable industry development
environs.
2.3. Promoter's Background
Ashish Kumar Dalmiya has worked as Manager at MP Mining & Energy Ltd for 4
years at Jasidih Industrial Area. He has been an asset in market development &
production at MP Mining. He brings sharp marketing acumen and association
with various business promoters in Deoghar and strong financial support base
from family and inheritance.
Priya Lath is a commerce graduate and she has been undertaking account
management and financial resource development since 2013. She brings her
sharp management skills to the partnership.
The Husband – Wife team jointly proposes to develop the business for their
common interests and future.

Neeraj Singh – 9929137131 Page 8 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

LAND /SHED DETAILS & LOGISTICS

3. Land /Shed Details & Logistics


3.1. Nature of the Land
Any plane land is suitable for setting up of the project.
3.2. Requirement of Land Area
35,000 sq ft 250*140
3.3. Ownership of the Land
Leased from SPIADA
3.4. Present Status of Land
Applied for
3.5. Location of Land

Point Latitude Longitude


A 24.5238479 86.6309079
B 24.5242472 86.6310956
C 24.5239832 86.6318120
D 24.5235800 86.6316344

C
A

Neeraj Singh – 9929137131 Page 9 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

PROCUREMENT STRATEGY OF RAW MATERIAL & OTHER INPUTS

4. Procurement Strategy of Raw Material & Other Inputs


Fly ash-lime bricks are generally manufactured by inter-grinding or blending various raw
materials which are then moulded into bricks and subjected to curing cycles at different
temperatures and pressures. On occasions, as and when required, crushed bottom ash
or sand is also used in the composition of the raw material. Crushed bottom ash or sand
is used in the composition as a coarser material to control water absorption in the final
product. Fly ash reacts with lime in presence of moisture to form a calcium silicate
hydrate which is the binder material. Thus fly ash-lime brick is a chemically bonded
brick.
The main raw materials are as below;
(A) FLYASH:
The left out after burning of coal is generally available in Thermal power stations.
Paper mills or where steam boilers burning coal are used. The fly ash available in
these industries is good quality and normally free of cost. The FAL-G brick making
units can be put up in a radius of 150-250Kms. from the fly ash source. As per NTPC,
brick/block plants use dry fly ash collected from 1st or 2nd fields of ESP’s. Generally
fly ash collected from 1st & 2nd field of ESP’s meet the requirement of Grade 2 of IS:
3812. As per the information collected, the minor variations in quality of dry ash &
pond ash does not affect the quality of the brick significantly.
(B) LIME:
The lime used in this process is hydrated lime powder, which will be available locally.
Low cost and high quality lime will be available in Oxygen, Acetylene, and paper
manufacturing Plants. The lime is a waste in these industries and can be very well
used in making Fal-G-bricks. Hydrated lime proposed to be used during the week
should be tested for Calcium Oxide contents as per Clause-9 (Determination of
available lime as CaO) of IS-1514.
(C) GYPSUM:
The calcined gypsum is available at the rate of 300-400 Rs. / Ton. (Freight extra). The
locally available gypsum can be fired in a kiln to get calcined gypsum. Based on the

Neeraj Singh – 9929137131 Page 10 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

tied back from sites the following recommendations are made for use of Gypsum in
ash brick making.
1. Gypsum should be free of lumps. Lumps, if any, should be screened and remainder
over the screen should be crushed and re-screened before use.
2. Gypsum should be tested for its purity as per IS 1288- 1f82. Its purity should be
above 80%. However, in case of variation in purity, percentage of Gypsum in the mix
should be adjusted to obtain desired quality of finished bricks.
(D) SAND:
Sand is used as an economizer and to increase the strength of brick to some extent.
Any locally available cheap sand can be used in making the bricks. Any coloring
material can be added to give desired color but the cost will be high and it can be
stored as a premium brick.
(E) CEMENT: Many Pilot plants faced difficulty in regular supply of consistent quality
sludge lime. Some NTPC projects have switched over to cement as the binding
material in place of sludge lime. When cement is used, used of gypsum can be
avoided. Ordinary Portland cement conforming to IS-269, IS-8112 or IS-12269 (latest
revision) should be used.
(F) Water requirement is about 500 – 1000 m3 per million of bricks in case of using
FaL-G unit. In most of the cases, the source is ground water. The magnitude of the
impact depends on the water balance on the region
4.1. Raw Material Availability –
Generally, dry fly ash available from power plants meets the properties specified
in IS: 3812 and is suitable for manufacture of Fly Ash – lime bricks in accordance
with the requirements of IS: 12894.
Soluble salts or organic matter in water should not exceed 0.25%. Water is an
essential but temporary constituent of fly ash bricks. If is needed to form them
but is subsequently eliminated during drying.
Fly Ash Production & Utilisation Report of GoI 2014-15 states and we quote
herewith as below;

Neeraj Singh – 9929137131 Page 11 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

NAME OF POWER STATE DIST. FROM INSTALLED FLY ASH % AGE OF IN MAKING OF
THERMAL POWER UTILITY DEOGHAR CAPCITY GENERATION UTILISATION FLY ASH BASED
STATION BRICKS/
BLOCKS/ TILES
ETC.
KMS MW MILLION TON % AGE MILLION TON
BARH SUPER NTPC BIHAR 192 1320 0.274 3.65% 0.002
THERMAL POWER
STATION
KAHALGAON NTPC BIHAR 145 2340 5.648 29.87% 0.242
MUZAFFARPUR KBUNL BIHAR 273 220 0.290 18.99% -
TPS
BARAUNI BSPGCL BIHAR 175 220 - 0.00% -
BOKARO 'B' DVC JHARKHAND 175 630 0.663 65.15% -
CHANDRAPURA DVC JHARKHAND 160 890 1.671 86.09% 0.007
JOJOBERA TPCO JHARKHAND 275 547.5 1.194 99.03% 0.001
KODARMA DVC JHARKHAND 145 1000 0.667 96.18% 0.017
MAITHON RBTPP MPL JHARKHAND 115 1050 1.649 161.01% 0.019
PATRATU JUUNL JHARKHAND 255 770 0.282 10.24% 0.007
TENUGHAT TVNL JHARKHAND 182 420 0.748 95.80% -
BUDGE BUDGE CESC W BENGAL 352 750 1.377 100.00% 0.032
GENERATING
STATION
BAKRESWAR WBPDCL W BENGAL 146 1050 2.277 67.03% 0.051
BANDEL WBPDCL W BENGAL 297 450 0.327 171.64% 0.002
CHINAKURI DPSCL W BENGAL 115 30 - 0.00% -
DISHERGARH DPSCL W BENGAL 115 12 0.031 100.00% -
POWER STATION
DURGAPUR DVC W BENGAL 147 350 0.512 89.81% -
DURGAPUR DPL W BENGAL 150 891 0.456 88.50% 0.003
PROJECTS POWER
STAION
DURGAPUR STEEL DVC W BENGAL 150 1000 1.281 62.55% 0.018
FARAKKA NTPC W BENGAL 180 2100 3.618 27.83% 0.015
HALDIA ENERGY HALDIA W BENGAL 435 600 0.070 100.00% -
LIMITTED (W.B) ENERGY
LIMITTED
KOLAGHAT WBPDCL W BENGAL 373 1260 2.485 90.01% 0.093
MEJIA DVC W BENGAL 156 2340 3.825 118.30% 0.024
NEW COSSIPORE CESC W BENGAL 323 160 0.022 100.00% -
SOUTHERN CESC W BENGAL 336 135 0.272 100.00% 0.010
GENERATING
STATION
SAGARDIGHI WBPDCL W BENGAL 179 600 1.015 62.68% 0.071
SANTALDIH WBPDCL W BENGAL 160 500 1.099 40.67% 0.008
TITAGARH CESC W BENGAL 327 240 0.422 100.00% 0.082
GENERATING
STATION

As can be inferred ample quantity of un-utilised Fly Ash is available at close by


Thermal Power Stations.

Neeraj Singh – 9929137131 Page 12 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

Durgapur, Asansol, Giridih & Jamshedpur being major producing cities of Steel
are big consumers of Lime. Hence, the availability of lime is abundant and can be
obtained from any trader or may even be bought from Katni which is a famous
lime producing region.
Other raw materials are locally available.
4.2. Sources of Procurement
4.2.1. N K Enterprises
Chowk Bazar, Jugsalai, Jamshedpur, Jharkhand, 831006, India
Key Personnel : Mr. Alok Lodha (Proprietor)
Mobile : +919431139541
4.2.2. Ravindra Lime Works
Madan Mohan Choubey Ward, Bhatta Mohalla , Katni , MP
Surendra Sharma, +91-94254-65803, +91-7387208252, +91-
9039385601, surendralime@gmail.comM/s.
4.2.3. Hindustan Chemical & Lime Industries
Ram Manohar Lohiya Ward, NH7, Nadipar,, Katni, Madhya Pradesh
483501 +91- 94243 94844
4.3. Process of Procurement
The procurement shall be done on long term quantity contract basis whereby the
prevailing market rates shall be applicable.

Neeraj Singh – 9929137131 Page 13 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

TECHNO-COMMERCIAL VIABILITY ASSESSMENT

5. Techno-Commercial Viability Assessment


5.1. Technology to be Used
The Main ingredient in Fly Ash Bricks is “FLY ASH”. 50 to 60 % of Fly Ash is used in
manufacturing of Fly Ash Bricks. Pulverized fuel ash commonly known as Fly Ash
is
a

by-product from Thermal Power Stations. Fly ash is being accumulated as waste
material in large quantities near thermal power plants. Energy requirements for
the developing countries in particular are met from coal-based thermal power
plants. The disposal of the increasing amounts of solid waste from coal-fired
thermal power plants is becoming a serious concern to the environmentalists.
Coal ash, 80% of which is very fine in nature and is thus known as fly ash is
collected by electrostatic precipitators in stacks. In India, nearly 175 million
tonnes (as per data from NV centre on Fly Ash) of fly ash is generated per annum
at present and is largely responsible for environmental pollution. As the power
requirements of the country goes up, the amount of waste produced will also
increase enormously creating problems for its safe disposal due to lack of
adequate disposal facilities. Its use in manufacture of bricks will be helpful in its
disposal and also help in controlling pollution. To overcome this huge
environment loss the concept of making Fly Ash Bricks, Blocks, Pavers and other
Construction materials has developed.
The Fly ash brick making plant has been designed to manufacture fly ash with
FAL-G Technology. The plant consists of the following equipment
a) It is a hydraulically operated, automatic and controlled by electronic circuits.
The electronic circuit is self-diagnosing. It has an optional alpha-numeric

Neeraj Singh – 9929137131 Page 14 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

display, computer connection and modem that can be connected to the


computer through telephone lines to detect local faults in advance.
b) Brick making machine develops 120 T of compressive force over the bricks
uniformly to hold pressure for the required time allowing the material to
flow and form.
c) The compressive force can be varied by turn of a knob.
d) The machine structure is designed to take up heavy cyclic loads.
e) The compressive ratio (1:1.6- brick height: filling height) can be varied
infinitely within the limits of the moulds.
f) Different size of moulds can be fitted with maximum size of 230x 110x
75mm as per your requirement.
g) Monogram on the brick can be embossed
h) Efficient water cooling system to ensure the continuous running of the
machine
The Automation in Batching unit and mixer allows for proper mixing of
ingredients for best results in the final product.
Pan Mixer
a) A sturdily constructed machine with heavy rollers to grind and mix material
thoroughly
b) Drive through quality worm reducing gear box
c) Changeable bottom gear plates with scrappers fitted with TC tips
d) Easy bottom loading mechanism with rap pinion door arrangement
Conveyor
a) Frames and intermittent bins are fabricated sturdily
b) The fly ash mix can be regulated according to the speed of the brick making
machine
c) Nylon with rubber top conveyor belts
d) Friction-less idlers
Pallet Trucks
a) Novel and ergonomically designed to handle the bricks with pallets for
effortless and easy transportation of fly ash bricks.
5.2. Possible Source of Equipments / Machine Suppliers

Neeraj Singh – 9929137131 Page 15 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

Karmyog Hi-Tech Machineries


Add:107 GIDC Estate , Bhuj Kutch ,Gujarat ( INDIA )
Mob. 7226002284, 02832-245525
5.3. Capacity & Production
10 Bricks/stroke
4 Stroke/Minute
2400 bricks/per hour
The machine having robust frame structure made up of heavy steel with main
cylinder specially designed by Karmyog Hi-Tech Machineries along with 120 Ton
Pressing Capacity and bottom vibrator attached for
clean outcome. Main hopper with vibrator is attached to store and feed mixed
material to main feeder which is travelling on four steel rollers.
The whole plant is run by Power Pack having 400 Ltrs. Oil Capacity with oil
cooling system which is controlled by fully automatic Control Panel.
5.4. Pollution Control (Please provide the details precisely)
Utilization of fly ash is environment friendly with improved cementitious binder
economics.
 Fly ash utilization reduces the requirement of clay, sand, lime stone in
cement manufacturing and hence conserves natural resources.
 Fly ash utilization reduces the cement requirement and hence carbon-
di-oxide liberation during cement manufacturing is reduced.
 Fly ash utilization reduces the top soil requirement for land filling /
brick manufacturing and saves agricultural land.
 Fly ash utilization achieves increased strength of the finished concrete
product without increasing the cement content
5.4.1. Amount of Generation of Pollution / Wastage
Dust generation within the premises can be well managed good
material handling techniques like using Silos for storing fine fly ash
and cement
5.4.2. Mode of Waste Disposal
No waste generation

Neeraj Singh – 9929137131 Page 16 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

5.4.3. Machines to be installed for adhering to pollution norms


None

Neeraj Singh – 9929137131 Page 17 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

PROCESS FLOW DIAGRAM

6. Process Flow Diagram


6.1. Machine Layout Plan
6.1.1. Shed for Brick Making Unit 70 * 20 ft
6.1.2. Shed for Paver Block Unit 30 * 20 ft
6.1.3. Store for Cement, Lime and other additives 40 * 20 ft
6.1.4. Provision for Silo for Fly Ash Storage and its paraphernalia 20 * 15 ft
6.1.5. Storage of Fly Ash about 100 MT.
6.1.6. Water Curing Tank of Semi Dried Bricks 60 * 60 ft
6.1.7. Water Curing Tank of Semi Dried Paver Blocks 30 * 30 ft
6.1.8. Set Back for thick Green Plantation to prevent blowing of dust 25 ft along the
three sides of boundary.
6.1.9. Road 15 ft wide and about 250 ft long for easy movement of trucks and
stores

Neeraj Singh – 9929137131 Page 18 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

6.1.10. Balance area shall cater to drying of green bricks & blocks and storage of
cured bricks & blocks for dispatch.

Neeraj Singh – 9929137131 Page 19 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

6.2. Process Flow Table

Neeraj Singh – 9929137131 Page 20 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

INFRASTRUCTURE SOURCE

7. Infrastructure Source
7.1. Power
Total Power consumption of the Brick Plant is 42.5 HP, 3 Phase whereas the
power consumption of the Paver Block unit is 10 HP, the lighting requirement will
be another 7 KW. Thus a total power demand shall be demand 50 KW at peak.
The power situation with the supply substation of Industrial Area Jasidih is
sufficient to meet the requirement.
7.2. Water
As discussed the Power requirement shall be about ½ ltr per brick at the least
and at the max it will be about 1 ltr per brick.
7.3. Manpower
Job Description Skilled Semi-Skilled Un-Skilled
Plant Operator 2 0 0
Raw Material Handling 0 1 2
Green Brick Carriage 0 0 2
Semi Dried Bricks to Curing Tank & Retrieval 0 0 2
Paver Plant Operator 1 0 0
Paver Blocks Making 0 0 3
Paver Raw Material Handling 0 0 2
Paver Shifter 0 0 1
3 1 12

Neeraj Singh – 9929137131 Page 21 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

MARKETING STRATEGY

8. Marketing Strategy
8.1. Market Opportunities
Huge development activities in Deoghar including Airport, AIIMS, Stadium &
Sports Complex, Development at the Industrial Area, and Smart City related
development avenues under Public domain opens tremendous opportunities for
a Fly ash Brick making unit in Deoghar.
8.2. Approach
Through Government Tenders & Direct industrial Marketing to the Construction
Agencies.

Neeraj Singh – 9929137131 Page 22 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

SWOT ANALYSIS

9. SWOT Analysis
SWOT ANALYSIS OF THE INDUSTRY
The strengths, weaknesses, opportunities and threats for the Indian Fly Ash Brick
industry have been listed below:
Strengths:
 The location is better placed in terms of logistics, raw material sourcing, and
closeness to demand pockets, manpower availability and social infrastructure
 Availability of unhindered Electric Power
 Low labour wage rates
 Well-qualified and experienced management and technical team.
 Mature production base & technology
 Technology used is contemporary and stabilised which is easy to understand.
Weaknesses:
 Small Scale of operations
 Low productivity
 Low R&D investments
 High cost of debt
 Inadequate infrastructure
Opportunities:
 Nascent market in Santhal
Pargana region & North Bihar
 Growing domestic demand
 Boom in Housing & infrastructure Industry.
 Increasing Governmental spending on urban amenities & telecom.
Threats:
 Blockages in supply of Fly Ash due to government intervention or plant
breakdown.
 Market price fluctuations of raw materials and finished goods

Neeraj Singh – 9929137131 Page 23 of 24


BABA BAIDYANATH ENTERPRISES – DPR – FLY ASH BRICK INDL. AREA, JASIDIH

FINANCIAL ANALYSIS

10. Financial Analysis


10.1. Financial Plan

CAPITAL INVESTMENT GRADING


PROPOSED
1 LAND & SITE DEVELOPMENT 12,84,148
2 BUILDING & CIVIL WORKS 10,80,000
3 PLANT & MACHINERY & ELECTRICAL INSTALLATION 42,22,842
4 PRELIMINARY & PRE-OPERATIVE EXP. 3,50,000
5 MISC. FIXED ASSETS 2,00,000
6 MARGIN FOR WORKING CAPITAL 11,76,296
7 CONTINGENCY FUND 2,00,000
TOTAL 85,13,286

MEANS OF FINANCE
A TOTAL FUND REQUIREMENT
CAPITAL INVESTMENT 83,13,286
CONTINGENCY FUND 2,00,000
WORKING CAPITAL LESS MARGIN FOR WORKING CAPITAL 35,28,887
1,20,42,173

B FINANCE RESOURCING
SHARE CAPITAL 20,42,173
TERM LOAN 64,71,113
CASH CREDIT LIMIT TO MEET WORKING CAPITAL REQUIREMENT 35,28,887
*** TERM LOAN + CC LIMIT = 1 CR 1,20,42,173

10.2. Cost Estimates


Please go to next page.

Neeraj Singh – 9929137131 Page 24 of 24


ESTIMATED COST OF PROJECT ON FLY ASH BRICK & CONCRETE BLOCKS
Based on 16 hours per day & 25 days per month
Average Production of 10 KVT M/c
Item Pcs/ Hour Pcs/Day Pcs/Month
Pcs (Average)
FAL-G Brick 1,680 26,880 6,72,000
Concrete Paver Blocks 88 1,400 35,000
7,07,000
Raw Material Required 18,816

Considering rejection/wastage @ 3.00% 21,210


Total production of Bricks & Blocks ready for sale : Pcs 6,85,790

Efficiency
Efficiency
Full Efficiency production 2,525 Pcs/Shift 100%
FAL-G Brick 2,400 Pcs/ Hour
Concrete Paver Blocks 125 Pcs/ Hour
Initial Operational Efficiency 1,768 Ltr/ Shift 70%
FAL-G Brick 1,680 Pcs/ Hour
Concrete Paver Blocks 88 Pcs/ Hour

Depreciation on civil structures 10% p.a. on WDV method for civil structures
Depreciaption on plant and machinery and electricals 10% p.a. on WDV method for plant and machinery and
electricals
Depreciaption on Moulds 25% p.a. on WDV method for Moulds

Depreciation on miscellaneous fixed assets 20% p.a. on WDV method for miscellaneous fixed assets

Interest on Term Loan per Year 12.5%


Interest on CC per Year 12.5%
Important Dates
Loan Disbursement 1Jan18
Commencement of Operatons 1Apr18
Income Tax rate 33.7%
Tenure of bank loan (year) 6 years
Grace period (year ) 1 years

Assumption
PLANT & MACHINERY
1 MACHINERY & EQUIPMENTS : (In Rs.) (In Rs.)
FLYASH BRICKS MAKING MACHINE MODEL 10 KVT [Ex-works Bhuj, Gujarat unpacked] 17,42,152
PAN MIXER 4,83,800
CONVEYOR BELT 1,93,107
GREEN BRCIKS SHIFTING TROLLEY 16,352
2Vibrator table (2.5 HP motor, 11 * 3 feet 1,60,000
Color Drum (2 HP Motor) 50,000
Mixer 1,50,000
Rubber Mould 2000 Nos 3,00,000
Packing & Forwarding charges 1% 30,954.11
Transportation 2 Trucks @ Rs. 50,000/- per truck 1,00,000
Transit Insurance 0.50% 16,131.83
Total cost of RPVC Plant Model KTS-200/200V 32,42,497
2 ANCILLIARY EQUIPMENTS :
a) Hydraulic shifting truck 1 No. 50,000
b) MOULD 1 No. 85,845
1,35,845
3 UTILITIES REQUIRED :
a) Weighing Machine - 75 KG capacity 1 No. 10,000
b) Weighing Machine - 5 KG capacity 1 No. 7,500
c) Water Pump (3 H.P. - 1no.) 1 No. 15,000
32,500
4 ELECTRICAL SECTION:
a) Electrical Cables & Conduits 1 Lot 2,00,000
b) Earthing Materials 1 Lot 50,000
c) H.T. Panel 1 no. 50,000
d) Distribution Board 1 no. 1,25,000
e) Security Deposit for 50 KW load 87,500
f) Deposit for electricity connection 63 KW line 11 KV line 94,500
6,07,000
5 OTHERS:
a) Water distribution system with total water pipe line system 5,000
b) Water Storage Tank (Overhead Tank and under ground hot & cold sump) -
c) Office & Laboratory furnitures 50,000
55,000
6 OTHER CHARGES ON MACHINERY :
a) Transport charges for other machinery 50,000
b) Pre-installation expenses 50,000
c) Foundation & Installation of all equipments 50,000
1,50,000
7 LAND AND BUILDING :
a) Land & Land Development 35,000.00 SqFt 12,84,148
b) Building-70*20+30*20+40*20*2 square ft. @ Rs. 300.00 per Sq Ft. 3,600.00 SqFt 10,80,000
23,64,148

A. TOTAL FIXED EXPENSES 65,86,990


75 % of Fixed Expenses 49,40,242

P&M
SALARY AND WAGES PER MONTH :

Job Description Skilled Semi-Skilled Un-Skilled Total


1 Plant Operator 1 - - 1
2 Raw Material Handling - 1 2 3
3 Green Brick Carriage - - 2 2
4 Semi Dried Bricks to Curing Tank & Retrieval - - 2 2
5 Paver Plant Operator - 1 - 1
6 Paver Blocks Making - - 3 3
7 Paver Raw Material Handling - - 2 2
8 Paver Shifter - - 1 1
1 2 12 15

Nos/ Shft Rate Shfts Amount


Skilled 1 10,000 2 20,000
Semi-Skilled 2 8,000 2 32,000
Un-Skilled 12 6,000 2 1,44,000
1,96,000

S&W
ELECTRICITY PER MONTH : KW HP
1 Total Fly Ash Brick Plant Load 31.79 KW 31.79 42.50
2 Total Paver Block Plant Load 7.11 KW 7.11 9.50
3 Lights & Fan & A.C. 2.99 KW 2.99 4.00
4 Laboratory Equipments 3.74 KW 3.74 5.00
5 Total connected load = 45.63 KW 45.63
6 # Considering running load is 55% of the total connected load = 25.10 KW 25.10
7 # Considering Rs. 5.50 per unit cost 5.50
8 Total Units Consumed per Month 10,038.16 10,038.16
9 Total electricity charges per month 55,209.88 55,209.88
10 Surcharge applicable on Total Electricity Bill per month @ 6,073.09 11% -
11 Total electricity charges per month 61,282.97 55,209.88
12 Total Units Consumed per Day 401.53
13 Production per Day 26,880.00
14 Total Units Consumed per Kg 0.01

Elect
OTHER OVERHEAD PER MONTH :
a) Maintenance & Stores approx. on machinery cost 0.50% 2,005
b) Telephone, Postage and Stationary 5,000
c) Insurance on fixed assets Rs. 5/- per Rs.1000 on item no. 1,2,3 & 4 (Excluding the deposit) 2,005
d) Travelling & Conveyance 50,000
e) Legal & Provisional charges 10,000
69,010

OH
COST ANALYSIS OF RAW MATERIALS PER MONTH

TOTAL RAW MATERIAL COST PER MONTH AS BELOW ₹ 29,23,308

One Fly Ash Brick (230 mm X 110 mm X 70 mm) Weight 2.60 Kg


Average Paver Block 3.80 Kg

Production Hourly Daily Monthly


FAL-G Brick 1,680.00 Pc 26,880.00 Pc 6,72,000.00 Pc
Concrete Paver Blocks 87.50 Pc 1,400.00 Pc 35,000.00 Pc
By Weight
FAL-G Brick 4,368 Kg 69,888 Kg 17,47,200 Kg
Concrete Paver Blocks 333 Kg 5,320 Kg 1,33,000 Kg

Raw Materials Mix for FAL-G Bricks


Fly ash 60-65% 62.00% 1.61 Kg 10,83,264 Kg
Sand/Stone dust 18-27% 22.00% 0.57 Kg 3,84,384 Kg
Hydrated lime 8-12% 11.00% 0.29 Kg 1,92,192 Kg
Gypsum 5% 5.00% 0.13 Kg 87,360 Kg
100.00% 2.60 Kg 17,47,200 Kg
Raw Materials Mix for FAL-G Bricks
Cement 1 14.29% 0.54 Kg 19,000 Kg
Sand 2 28.57% 1.09 Kg 38,000 Kg
Stone Cips 4 57.14% 2.17 Kg 76,000 Kg

Raw Material Cost Rs/Unit Total Consumption/Month


Monthly Amt
Fly ash 300.00 PMT 10,83,264 Kg ₹ 3,24,979
Sand 183.82 PMT 38,000 Kg ₹ 6,985
Hydrated lime 7,000.00 PMT 1,92,192 Kg ₹ 13,45,344
Gypsum 10,000.00 PMT 87,360 Kg ₹ 8,73,600
Cement 6,000.00 PMT 19,000 Kg ₹ 1,14,000
Stone Cips 3,400.00 PMT 76,000 Kg ₹ 2,58,400
14,95,816 Kg ₹ 29,23,308

RM
WORKING CAPITAL :
1 Raw material for 15 days 14,61,654
2 Finished goods for One month ( 15 days stock and 15 days in credit) 29,23,308
3 Salary & Wages for one month 1,96,000
4 Electricity for one month 55,210
5 Other overhead for one month 69,010
WORKING CAPITAL: 47,05,183

WC
TOTAL CAPITAL INVESTMENT :
(In Rs.)
A. Fixed cost 65,86,990

B. Working capital 47,05,183


1,12,92,173
TOTAL CAPITAL INVESTMENT
AMT INCL GST
A MACHINERY & EQUIPMENTS : 32,42,497
B ANCILLIARY EQUIPMENTS : 1,35,845
C UTILITIES REQUIRED : 32,500
D ELECTRICAL SECTION: 6,07,000
E OTHERS: 55,000
F OTHER CHARGES ON MACHINERY : 1,50,000
G LAND AND BUILDING : 23,64,148
H 65,86,990
I WORKING CAPITAL : 47,05,183
J WORKING CAPITAL MARGIN : 11,76,296

CAPITAL INVESTMENT GRADING


PROPOSED
1 LAND & SITE DEVELOPMENT 12,84,148
2 BUILDING & CIVIL WORKS 10,80,000
3 PLANT & MACHINERY & ELECTRICAL INSTALLATION 42,22,842
4 PRELIMINARY & PRE-OPERATIVE EXP. 3,50,000
5 MISC. FIXED ASSETS 2,00,000
6 MARGIN FOR WORKING CAPITAL 11,76,296
7 CONTINGENCY FUND 2,00,000
TOTAL 85,13,286

MEANS OF FINANCE
A TOTAL FUND REQUIREMENT
CAPITAL INVESTMENT 83,13,286
CONTINGENCY FUND 2,00,000
WORKING CAPITAL LESS MARGIN FOR WORKING CAPITAL 35,28,887
1,20,42,173

B MEANS OF FINANCE
SHARE CAPITAL 20,42,173
TERM LOAN 64,71,113
CASH CREDIT LIMIT TO MEET WORKING CAPITAL REQUIREMENT 35,28,887
*** TERM LOAN + CC LIMIT = 1 CR 1,20,42,173

CapitStruc
SALES PER MONTH :

Product Monthly Sale Price Amount


FAL-G Brick 6,51,840.00 Pc ₹ 5.00 ₹ 32,59,200
Concrete Paver Blocks 33,950.00 Pc ₹ 8.00 ₹ 2,71,600
35,30,800

Sales
TOTAL VARIABLE EXPENSES PER MONTH
Rs. Per Month
1 Raw Material 29,23,308
2 Salary & Wages 1,96,000
3 Electricity charges 55,210
4 Advertisement Expenses 30,000
5 Other overheads 69,010
6 Interest on Working Capital @ 12.5% p.a. 36,759
33,10,288

VarExp
GROSS PROFIT EARNED PER MONTH 2,20,512
Less : Depreciation per month 48,597

PROFIT EARNED PER MONTH AFTER DEPRECIATION 1,71,915


Considering the project to be made free within 3 years after start
Princpal amount of term loan to be adjusted per month 1,08,333
63,582

H. NET PROFIT EARNED PER MONTH 63,582


* Term loan has been calculated on 75% of the Fixed Cost.
Note : i) Any Govt. subsidy related to the project can be treated as bonus.

Profit
Depreciation

Sl No Description Capital 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


1 Civil Works
2 NPV 10,80,000 10,80,000 9,72,000 8,74,800 7,87,320 7,08,588 6,37,729 5,73,956
3 Depreciation 1,08,000 97,200 87,480 78,732 70,859 63,773 57,396
4 Book Value 9,72,000 8,74,800 7,87,320 7,08,588 6,37,729 5,73,956 5,16,561
5 Plant and Machinery
6 NPV 41,36,997 41,36,997 37,23,297 33,50,968 30,15,871 27,14,284 24,42,855 21,98,570
7 Depreciation 4,13,700 3,72,330 3,35,097 3,01,587 2,71,428 2,44,286 2,19,857
8 Book Value 37,23,297 33,50,968 30,15,871 27,14,284 24,42,855 21,98,570 19,78,713
9 Moulds
10 NPV 85,845 85,845 64,384 48,288 36,216 27,162 20,371 15,279
11 Depreciation 21,461 16,096 12,072 9,054 6,790 5,093 3,820
12 Book Value 64,384 48,288 36,216 27,162 20,371 15,279 11,459
13 Furniture and Fixtures and miscellaneous fixed asets
14 NPV 2,00,000 2,00,000 1,60,000 1,06,144 70,416 46,714 30,990 20,559
15 Depreciation 40,000 53,856 35,728 23,702 15,724 10,431 6,920
16 Book Value 1,60,000 1,06,144 70,416 46,714 30,990 20,559 13,639
17 Total depreciation 5,83,161 5,39,482 4,70,377 4,13,075 3,64,802 3,23,583 2,87,992
18 Total FY Ending BV 48,55,297 43,31,912 38,73,607 34,69,586 31,11,575 27,93,085 25,08,912

Deprcn
RE-PAYMENT SCHEDULE MONTHWISE

1 2 3 4 5 6 7 8

Loan O/s at Gross Loan O/s at


beginning Gross Income Surplus Total the end of
Sl No Description of year Surplus Tax Available Principal Interest Outgo the year
Sep-17 64,71,113 - - - 33,704 33,704 64,71,113
Oct-17 64,71,113 - - - 67,407 67,407 64,71,113
2018-19*

Nov-17 64,71,113 - - - 67,407 67,407 64,71,113


Dec-17 64,71,113 - - - 67,407 67,407 64,71,113
Jan-18 64,71,113 2,20,512 42,818 1,77,694 - 67,407 67,407 64,71,113
Feb-18 64,71,113 2,20,512 42,818 1,77,694 - 67,407 67,407 64,71,113
Mar-18 64,71,113 2,20,512 42,818 1,77,694 - 67,407 67,407 64,71,113
Apr-18 64,71,113 2,36,263 54,010 1,82,253 - 67,407 67,407 64,71,113
May-18 64,71,113 2,36,263 54,010 1,82,253 - 67,407 67,407 64,71,113
Jun-18 64,71,113 2,36,263 54,010 1,82,253 - 67,407 67,407 64,71,113
Jul-18 64,71,113 2,36,263 54,010 1,82,253 - 67,407 67,407 64,71,113
Aug-18 64,71,113 2,36,263 54,010 1,82,253 - 67,407 67,407 64,71,113
2019-20

Sep-18 64,71,113 2,36,263 54,010 1,82,253 1,07,852 67,407 1,75,259 63,63,261


Oct-18 63,63,261 2,36,263 54,010 1,82,253 1,07,852 66,284 1,74,136 62,55,409
Nov-18 62,55,409 2,36,263 54,010 1,82,253 1,07,852 65,161 1,73,012 61,47,557
Dec-18 61,47,557 2,36,263 54,010 1,82,253 1,07,852 64,037 1,71,889 60,39,705
Jan-19 60,39,705 2,36,263 54,010 1,82,253 1,07,852 62,914 1,70,765 59,31,853
Feb-19 59,31,853 2,36,263 54,010 1,82,253 1,07,852 61,790 1,69,642 58,24,001
Mar-19 58,24,001 2,36,263 54,010 1,82,253 1,07,852 60,667 1,68,519 57,16,150
Apr-19 57,16,150 2,52,014 65,372 1,86,642 1,07,852 59,543 1,67,395 56,08,298
May-19 56,08,298 2,52,014 65,372 1,86,642 1,07,852 58,420 1,66,272 55,00,446
Jun-19 55,00,446 2,52,014 65,372 1,86,642 1,07,852 57,296 1,65,148 53,92,594
Jul-19 53,92,594 2,52,014 65,372 1,86,642 1,07,852 56,173 1,64,025 52,84,742
Aug-19 52,84,742 2,52,014 65,372 1,86,642 1,07,852 55,049 1,62,901 51,76,890
2020-21

Sep-19 51,76,890 2,52,014 65,372 1,86,642 1,07,852 53,926 1,61,778 50,69,038


Oct-19 50,69,038 2,52,014 65,372 1,86,642 1,07,852 52,802 1,60,654 49,61,186
Nov-19 49,61,186 2,52,014 65,372 1,86,642 1,07,852 51,679 1,59,531 48,53,335
Dec-19 48,53,335 2,52,014 65,372 1,86,642 1,07,852 50,556 1,58,407 47,45,483
Jan-20 47,45,483 2,52,014 65,372 1,86,642 1,07,852 49,432 1,57,284 46,37,631
Feb-20 46,37,631 2,52,014 65,372 1,86,642 1,07,852 48,309 1,56,161 45,29,779
Mar-20 45,29,779 2,52,014 65,372 1,86,642 1,07,852 47,185 1,55,037 44,21,927
Apr-20 44,21,927 2,67,765 76,502 1,91,262 1,07,852 46,062 1,53,914 43,14,075
May-20 43,14,075 2,67,765 76,502 1,91,262 1,07,852 44,938 1,52,790 42,06,223
Jun-20 42,06,223 2,67,765 76,502 1,91,262 1,07,852 43,815 1,51,667 40,98,371
Jul-20 40,98,371 2,67,765 76,502 1,91,262 1,07,852 42,691 1,50,543 39,90,520
Aug-20 39,90,520 2,67,765 76,502 1,91,262 1,07,852 41,568 1,49,420 38,82,668
2021-22

Sep-20 38,82,668 2,67,765 76,502 1,91,262 1,07,852 40,444 1,48,296 37,74,816


Oct-20 37,74,816 2,67,765 76,502 1,91,262 1,07,852 39,321 1,47,173 36,66,964
Nov-20 36,66,964 2,67,765 76,502 1,91,262 1,07,852 38,198 1,46,049 35,59,112
Dec-20 35,59,112 2,67,765 76,502 1,91,262 1,07,852 37,074 1,44,926 34,51,260
Jan-21 34,51,260 2,67,765 76,502 1,91,262 1,07,852 35,951 1,43,803 33,43,408
Feb-21 33,43,408 2,67,765 76,502 1,91,262 1,07,852 34,827 1,42,679 32,35,556
Mar-21 32,35,556 2,67,765 76,502 1,91,262 1,07,852 33,704 1,41,556 31,27,705
Apr-21 31,27,705 2,83,515 87,451 1,96,065 1,07,852 32,580 1,40,432 30,19,853
May-21 30,19,853 2,83,515 87,451 1,96,065 1,07,852 31,457 1,39,309 29,12,001
Jun-21 29,12,001 2,83,515 87,451 1,96,065 1,07,852 30,333 1,38,185 28,04,149
Jul-21 28,04,149 2,83,515 87,451 1,96,065 1,07,852 29,210 1,37,062 26,96,297
Aug-21 26,96,297 2,83,515 87,451 1,96,065 1,07,852 28,086 1,35,938 25,88,445
2022-23

Sep-21 25,88,445 2,83,515 87,451 1,96,065 1,07,852 26,963 1,34,815 24,80,593


Oct-21 24,80,593 2,83,515 87,451 1,96,065 1,07,852 25,840 1,33,691 23,72,741
Nov-21 23,72,741 2,83,515 87,451 1,96,065 1,07,852 24,716 1,32,568 22,64,889
Dec-21 22,64,889 2,83,515 87,451 1,96,065 1,07,852 23,593 1,31,444 21,57,038
Jan-22 21,57,038 2,83,515 87,451 1,96,065 1,07,852 22,469 1,30,321 20,49,186
RypmtMthlySchedule
RE-PAYMENT SCHEDULE MONTHWISE
2022-23
1 2 3 4 5 6 7 8

Loan O/s at Gross Loan O/s at


beginning Gross Income Surplus Total the end of
Sl No Description of year Surplus Tax Available Principal Interest Outgo the year
Feb-22 20,49,186 2,83,515 87,451 1,96,065 1,07,852 21,346 1,29,198 19,41,334
Mar-22 19,41,334 2,83,515 87,451 1,96,065 1,07,852 20,222 1,28,074 18,33,482
2018-19*

Apr-22 18,33,482 2,99,266 87,451 2,11,816 1,07,852 19,099 1,26,951 17,25,630


May-22 17,25,630 2,99,266 87,451 2,11,816 1,07,852 17,975 1,25,827 16,17,778
Jun-22 16,17,778 2,99,266 87,451 2,11,816 1,07,852 16,852 1,24,704 15,09,926
Jul-22 15,09,926 2,99,266 87,451 2,11,816 1,07,852 15,728 1,23,580 14,02,074
Aug-22 14,02,074 2,99,266 87,451 2,11,816 1,07,852 14,605 1,22,457 12,94,223
2023-24

Sep-22 12,94,223 2,99,266 87,451 2,11,816 1,07,852 13,481 1,21,333 11,86,371


Oct-22 11,86,371 2,99,266 87,451 2,11,816 1,07,852 12,358 1,20,210 10,78,519
Nov-22 10,78,519 2,99,266 87,451 2,11,816 1,07,852 11,235 1,19,086 9,70,667
Dec-22 9,70,667 2,99,266 87,451 2,11,816 1,07,852 10,111 1,17,963 8,62,815
Jan-23 8,62,815 2,99,266 87,451 2,11,816 1,07,852 8,988 1,16,840 7,54,963
Feb-23 7,54,963 2,99,266 87,451 2,11,816 1,07,852 7,864 1,15,716 6,47,111
Mar-23 6,47,111 2,99,266 87,451 2,11,816 1,07,852 6,741 1,14,593 5,39,259
Apr-23 5,39,259 3,15,017 97,591 2,17,426 1,07,852 5,617 1,13,469 4,31,408
May-23 4,31,408 3,15,017 97,591 2,17,426 1,07,852 4,494 1,12,346 3,23,556
Jun-23 3,23,556 3,15,017 97,591 2,17,426 1,07,852 3,370 1,11,222 2,15,704
Jul-23 2,15,704 3,15,017 97,591 2,17,426 1,07,852 2,247 1,10,099 1,07,852
Aug-23 1,07,852 3,15,017 97,591 2,17,426 1,07,852 1,123 1,08,975 0
2024-25

Sep-23 0 3,15,017 97,591 2,17,426 - 0 0 0


Oct-23 0 3,15,017 97,591 2,17,426 - 0 0 0
Nov-23 0 3,15,017 97,591 2,17,426 - 0 0 0
Dec-23 0 3,15,017 97,591 2,17,426 - 0 0 0
Jan-24 0 3,15,017 97,591 2,17,426 - 0 0 0
Feb-24 0 3,15,017 97,591 2,17,426 - 0 0 0
Mar-24 0 3,15,017 97,591 2,17,426 - 0 0 0

RypmtMthlySchedule
REPAYMENT SCHEDULE YEARLY

Sl No Description 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


1 Loan O/s at beginning of 64,71,113 64,71,113 57,16,150 44,21,927 31,27,705 18,33,482 5,39,259
year
2 Gross Surplus 6,61,536 28,35,155 30,24,165 32,13,175 34,02,186 35,91,196 37,80,206
3 Income Tax - 5,13,811 6,48,120 7,84,467 9,18,029 10,49,408 11,71,093
4 Gross Surplus Available 6,61,536 23,21,344 23,76,045 24,28,708 24,84,156 25,41,789 26,09,114

5 Principal - 7,54,963 12,94,223 12,94,223 12,94,223 12,94,223 5,39,259


6 Interest 4,38,148 7,85,296 6,40,371 4,78,593 3,16,815 1,55,037 16,852
7 Total Outgo 4,38,148 15,40,260 19,34,593 17,72,815 16,11,037 14,49,260 5,56,111
8 Loan O/s at the end of 64,71,113 57,16,150 44,21,927 31,27,705 18,33,482 5,39,259 -
the year
9 DSCR - 3.76 2.34 2.48 2.63 2.77 -
10 Avg. DSCR 2.20 (GS)/(P+Int)
11 Equal Annual 12,94,223
Installment

RypmtYrly
CASH FLOW - STATEMENT

Sl No Description 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


Efficiency 70% 75% 80% 85% 90% 95% 100%
Expenses
1 Share Capital 20,42,173 - - - - - -
2 Term Loan 64,71,113 - - - - - -
3 Working Capital 35,28,887 - - - - - -
4 Raw Material 87,69,925 3,75,85,395 4,00,91,088 4,25,96,781 4,51,02,474 4,76,08,167 5,01,13,860
5 Operating Expenses 11,60,938 49,75,450 53,07,147 56,38,844 59,70,540 63,02,237 66,33,934
6 Total 2,19,73,037 4,25,60,845 4,53,98,235 4,82,35,625 5,10,73,014 5,39,10,404 5,67,47,794
7 Cumulative 2,19,73,037 6,45,33,882 10,99,32,117 15,81,67,741 20,92,40,756 26,31,51,159 31,98,98,953

Revenue
1 Sales 1,05,92,400 4,53,96,000 4,84,22,400 5,14,48,800 5,44,75,200 5,75,01,600 6,05,28,000
2 Cumulative 1,05,92,400 5,59,88,400 10,44,10,800 15,58,59,600 21,03,34,800 26,78,36,400 32,83,64,400
3 Gross Profit -1,13,80,637 -85,45,482 -55,21,317 -23,08,141 10,94,044 46,85,241 84,65,447

CashFlow
PROFITABILITY STATEMENT

S.No. Item 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


1 Gross Profit (PBDIT) 6,61,536 28,35,155 30,24,165 32,13,175 34,02,186 35,91,196 37,80,206
2 Depreciation
3 Civil Works 1,08,000 97,200 87,480 78,732 70,859 63,773 57,396
4 Plant and Machinery 4,13,700 3,72,330 3,35,097 3,01,587 2,71,428 2,44,286 2,19,857
5 Miscellaneous Fixed Asets 40,000 53,856 35,728 23,702 15,724 10,431 6,920
6 Total depreciation 5,61,700 5,23,386 4,58,305 4,04,021 3,58,011 3,18,490 2,84,173
7 Profit before interest and tax but after depreciation (PADBIT) 99,836 23,11,769 25,65,860 28,09,154 30,44,175 32,72,706 34,96,034

8 Interest on Term Loan 4,38,148 7,85,296 6,40,371 4,78,593 3,16,815 1,55,037 16,852
9 Profit after depreciation and interest but before tax (PADIBT) -3,38,312 15,26,473 19,25,490 23,30,562 27,27,360 31,17,669 34,79,182

10 Income Tax Payment - 5,13,811 6,48,120 7,84,467 9,18,029 10,49,408 11,71,093


11 Profit after depreciation, interest and tax (PAT) -3,38,312 10,12,662 12,77,370 15,46,095 18,09,331 20,68,262 23,08,089
12 Add back
13 Depreciation 5,61,700 5,23,386 4,58,305 4,04,021 3,58,011 3,18,490 2,84,173
14 Interest on Term Loan 4,38,148 7,85,296 6,40,371 4,78,593 3,16,815 1,55,037 16,852
15 Post Tax Operational Income (Coverage Available) 6,61,536 23,21,344 23,76,045 24,28,708 24,84,156 25,41,789 26,09,114
16 Calculation for DSCR
17 Coverage Available 6,61,536 23,21,344 23,76,045 24,28,708 24,84,156 25,41,789 26,09,114
18 Total Debts to be Repaid
19 Installments of term loan - 7,54,963 12,94,223 12,94,223 12,94,223 12,94,223 5,39,259
20 Interest on term loan 4,38,148 7,85,296 6,40,371 4,78,593 3,16,815 1,55,037 16,852
21 Total debts to be repaid 4,38,148 15,40,260 19,34,593 17,72,815 16,11,037 14,49,260 5,56,111
22 DSCR - 3.76 2.34 2.48 2.63 2.77 -
23 Average DSCR 2.20

Profitability
INCOME EXPENSE STATEMENT

Sl No Description 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


Efficiency 70% 75% 80% 85% 90% 95% 100%
Income
1 Sales 1,05,92,400 4,53,96,000 4,84,22,400 5,14,48,800 5,44,75,200 5,75,01,600 6,05,28,000
2 Cumulative 1,05,92,400 5,59,88,400 10,44,10,800 15,58,59,600 21,03,34,800 26,78,36,400 32,83,64,400

Expenses
1 Raw Material 87,69,925 3,75,85,395 4,00,91,088 4,25,96,781 4,51,02,474 4,76,08,167 5,01,13,860
2 Operating Expenses 11,60,938 49,75,450 53,07,147 56,38,844 59,70,540 63,02,237 66,33,934
3 Total 99,30,864 4,25,60,845 4,53,98,235 4,82,35,625 5,10,73,014 5,39,10,404 5,67,47,794
4 Cumulative 99,30,864 5,24,91,709 9,78,89,944 14,61,25,568 19,71,98,583 25,11,08,987 30,78,56,780
Net
1 Gross Surplus 6,61,536 28,35,155 30,24,165 32,13,175 34,02,186 35,91,196 37,80,206
2 Cumulative GS 6,61,536 34,96,691 65,20,856 97,34,032 1,31,36,217 1,67,27,413 2,05,07,620

IncomeExp
IRR & BCR STATEMENT

S.No. Item 2018-19* 2019-20 2020-21 2021-22 2022-23 2023-24 2024-25


1 Capital Cost 42,22,842
2 Recurring Cost
3 Cost of Raw Material 87,69,925 3,75,85,395 4,00,91,088 4,25,96,781 4,51,02,474 4,76,08,167 5,01,13,860
4 Operating Expenses 11,60,938 49,75,450 53,07,147 56,38,844 59,70,540 63,02,237 66,33,934
5 Total recurring cost 99,30,864 4,25,60,845 4,53,98,235 4,82,35,625 5,10,73,014 5,39,10,404 5,67,47,794
6 Total Cost 1,41,53,706 4,25,60,845 4,53,98,235 4,82,35,625 5,10,73,014 5,39,10,404 5,67,47,794
7 Benefits
8 Benefits ( net tax) 1,05,92,400 4,53,96,000 4,84,22,400 5,14,48,800 5,44,75,200 5,75,01,600 6,05,28,000
9 Book Value
10 Total benefits 1,05,92,400 4,53,96,000 4,84,22,400 5,14,48,800 5,44,75,200 5,75,01,600 6,05,28,000
11 Net benefit -35,61,306 28,35,155 30,24,165 32,13,175 34,02,186 35,91,196 37,80,206
12 Discounting Factor 15.00%
13 NPW Cost @15% DF 17,19,51,502 Rs
14 NPW Benefit @15% DF 17,94,89,261 Rs
15 NPW @15% DF 75,37,758 Rs
16 BCR 1.04 :1
17 IRR 0.83

IRR