Plastic Pipes– Business Opportunity

Indian plastic pipes industry size is estimated at around 2.5 million tonnes per annum. There are around 600 manufacturers of pipes, with the top 20 players accounting for 60 per cent of the market, and small players for the remaining 40 per cent[1].

While large manufacturers make the pipes needed for all domestic, agricultural and industrial applications (such as casing pipes, bore well column pipes, electrical & telecom ducts, agricultural pipes), smaller one’s manufacture pipes needed for last mile connectivity. These include plumbing systems, irrigation systems, electrical conduits and conduit fittings, mostly made of HDPE, LLDPE and PPR as explained in the table below.

Capture9                                  *Poly-Propylene Random Copolymer
The Government spend on agriculture sector and irrigation schemes continues to be the main driver of pipes. For instance, Mission Bhagiratha, Telangana government’s initiative to provide piped water supply to every household in the state has given impetus to the pipe industry here. Apart from the main trunk pipelines for about a length of 5,000 km, the mission requires secondary pipelines, stretching over 50,000 km. These secondary pipelines will carry water to tanks in villages from where a village-level pipeline network extending 75,000 km will supply water to households in the state. The village level pipelines specifically require HDPE pipes[2].

Market:

In value terms, the Indian plastic pipes market stands at INR 22,000 Crores[3] and is forecast to grow at a CAGR of 10%. The market is dominated by PVC pipes that account for more than 70% (see figure 1)

Figure 1: The figure below depicts the polymer share of plastic pipes and fittings industry

Capture6

Apart from national level players such as Astral Poly Technik Limited, Supreme group of companies, Finolex industries, there are a large number of local companies, as shown in the Table 2. The local companies have strong dealer network in their region.

Capture5

Process &Technology:

Manufacturing process can broadly be divided into: mixing, extrusion, pipe sizing and down streaming. The extrusion line is customised to users’ needs, and the most important parameter is pipes’ diameter and wall thickness. 

  1. Formulation & mixing: This is required for PVC but not for any of the above-mentioned material.
  2. Extrusion: Single screw (compulsory for HDPE and LLDPE) and Twin-screw extrusion (TSE). According to the experts, if quality is imperative, one must use TSE, as it can work even without the impact modifiers and flow promoters.
  3. Pipe sizing: This can be in two ways; a) Pressure sizing, which is suitable for higher diameter pipes and b) Vacuum sizing, which is suitable for lower diameter pipes.
  4. Down streaming: This includes a number of functions such as cooling the pipes, cutting the pipes, Socketing and printing. 

Capture3

Budget:

The entry level plant (One extrusion line for manufacturing pipes for construction and irrigation industry of capacity about 100 Kg per hour) can be set up in INR 3 Crores including land, building, and working capital. Requirements for working capital would be large due to large raw material inventory and dealer credit.

Table 3 gives typical cost of machinery, which may change according to the specifications such as wall thickness and diameter of the pipes.

Capture7

How Can We Help You?

If you are interested in setting up a pipe extrusion unit, we can assist you. Our services include

  1. Market & Financial viability assessment
  2. Technical consultancy
  3. Detailed project report preparation
  4. Support in project execution 

Reach Us

Call us @ 800 888 4932

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

[1] Source: Finolex’s MD, Saurabh Dhanorkar interview with DNA – May, 2016

[2]Source; Livemint news article – August, 2016.

[3]Source: HDFC securities – initiative coverage –  May, 2017

Share This:

Business Opportunity: Pre-Stressed Concrete Sleepers

PSC sleeper refers to steel reinforced concrete sleeper, commonly used on railway tracks. Besides Indian Railways, power plants, refineries and cement plants also use sleepers for their rail tracks. Demand driver

Indian Railways has a network of over 65,000 kilometers encompassing length and breadth of the country.  The growing population and increasing economic activity has resulted in over-utilization of its existing network.  So much so that the trunk routes of the railways comprising merely 16% of the network carry about 50 percent of the work load. The Indian railways has been routinely upgrading its network (see Table 1), however the capacity upgradation has been far below the actual requirements and the network continues to remain congested.

Capture2

The pace of railway infrastructure upgradation has picked up over the past one year, driven by the government’s initiatives to improve quality and safety of Indian railways. The Railways has committed to building 7 kms of infrastructure per day in 2016-17, which will increase to 13 Kms per day in 2017-18 and 19 kms per day in 2018-19.  Railways have identified following priority projects (See table 2) to be taken up in the medium term.

Capture1

In addition to these, Indian Railways has also proposed to create a high speed corridor network of around 10,000 kilometers. In light of the above mentioned plans, the railways are likely to develop at least 5000-8000 kilometers of rail network per year, almost 30-40% more than in the past. Assuming that per kilomer of rail would need 1600 sleepers, these plans are likely to result in an annual demand of about 1.3 crore of sleepers.

Key suppliers

The sleeper industry is dominated by a few players who are present across the country. The current capacity of the industry is around 1 crore sleepers per annum. More details on the players are provided below.

Capture

Given the expected increase in demand by 30% to 40%, there seems to be enough room for new capacities to come up. However, one needs to analyze the regional demand and supply balance carefully.

Govt approvals and Budget

Setting up a railway sleeper unit would require approvals from Railway RDSO (Research Design and Standards Organization) as well as the Zonal Railway office.

The process of manufacturing the PSC entails strengthening of concrete, casting it into pre-defined mould and curing it. There are two popular technologies: Long line and Short bench manufacturing, with short bench manufacturing being more popular in India.

The budget requirements for a capacity of 3-4 lakh sleepers per annum could be upwards of Rs. 15 crore. Further, one needs to consider the cost of the land, the sleeper plant would need to be located in the vicinity of a railway station for the ease of transport of sleepers.

How can we Help You?

We can help you assess techno economic feasibility of a sleeper manufacturing plant including the market assessment, regulatory compliance framework, capital requirements, machinery evaluation and profitability and return on investment.

Reach Us

Call us @ +91 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

 

Share This:

Business Opportunity: Organic Fertilizers

Organic fertilizer is a mixture of decayed organic matter. It is usually made by gathering plant material such as leaves, grass clippings, and vegetable peels and animal waste into a pile or bin and letting it decompose with the help of earthworms, fungi or bacteria. Organic compost contains essential macro and micro nutrients for plants, often absent in synthetic fertilizers. Compost releases nutrients slowly over the cultivation period, which helps plants soak those nutrients better and make a healthy food in our plates.

The demand for organic fertilizers is rising in India as well as internationally due to increasing awareness of organic farming and sustainable agricultural practices. The market size for organic fertilizers in India stands at 2547 lakh metric tonnes as of FY 2015-16.[1]

The major consumers of organic fertilizers are horticulture farmers, farmers of export oriented crops, farmers of crops such as ginger and turmeric and urban households that use compost for their home gardens.

What are different types of organic Fertilizers?

As per the Fertiliser Control order, 1985, the organic fertilisers can be divided into three categories:

Vermin compost: Most popular form of organic fertiliser, made by decomposing the organic material with the help of Vermi, FCO has specified guideline in terms of nutrient percentage, moisture levels etc

City compost: The compost made from city waste, including household waste, municipal waste etc.

Organic manure: Compost made from animal and plant waste (including the vermi and city compost). Manure typically has higher organic content vis a vis other organic fertilisers.

Capture6

What is the market?

The market has two segments:

Horticulture farmers: Farmers growing fruits and vegetable crops use compost to reduce chemicals residue from their crops. Further, these crops are relatively more profitable vis a vis traditional field crops such as paddy, cotton and hence can afford to purchase organic compost. This segment is dominated by large fertiliser companies who have the dealer network and sales force required to reach the farmers. Below are the large players in Andhra Pradesh and Telangana.

Capture4

Nurseries: This segment has a lot of small and medium enterprises. Here the product packaging is important. Some of the players in this segment also sell only through online network.

How to get started with manufacturing of organic compost?

One needs to have a detailed understanding of the processes involved in manufacturing, marketing and selling the compost.

It’s not a very capital intensive business and hence capital requirements are not very large. One does not need many plants and equipment’s except for pits /wilgrows to dump the waste, shredder and a palletising machine. The main cost of establishing will be land and labour. A unit of capacity to process 20-30 tonnes of waste per day can be set up within a budget of INR 50 Lakhs.

The compost is also made as a by-product of a biogas plant. The biogas plant converts the organic waste into bio gas through anaerobic digestion and produces a slurry, which can be dried and used as compost.

Government incentives

There are a number of incentives available to manufacturers and farmers. It can broadly be categorized as incentives for farmers and incentives for entrepreneurs as given below.

Farmers are offered organic fertilizers at a subsidized cost

Entrepreneurs are offered incentives to set up compost manufacturing facility. For example, under National Program for organic farming, manufacturers of compost from vegetable waste are offered a subsidy of 33% of the cost of project.

Challenges
  • The market is still in its formative stage and awareness of the benefits of organic compost has just begun to spread across farmers and farmer groups.
  • Reliable Data on organic input market is not present.
  • Organic system of farming is far more expensive than doing farming using chemical fertilisers
  • The economics depend on the waste procurement cost, so those have to be tightly controlled

How can we help?

We can help you set up a compost manufacturing unit through a number of services including

  • Market viability assessment
  • Technical consultation and
  • Project execution support.

[1] Source: National Centre for Organic Farming

Reach us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

Share This:

HOW TO SELECT RIGHT PACKAGING FOR YOUR READY TO EAT PRODUCTS

For ready to eat products, packaging plays a vital role in preserving the quality of food, extending its shelf life and making it look attractive. With the upsurge in demand for ready to eat foods, the packaging technology is continuously evolving to facilitate customer convenience, minimize processing and keeping the product as natural as possible. This blog discusses different packaging technologies and their suitability to your product as well as budget.

Packaging Technology:

The choice of packaging technology depends on the nature of food (Acidity level, moisture content), expected shelf life (few weeks, months, years) and the conditions in which it would be stored (Room temperature, frozen).  As such the packaging technology for ready to eat foods can broadly be divided into three categories.

Thermal Heating: Food is packed in pouches/containers and heated to high temperature. The thermal heating can be done through different technologies including Retort, MATS and Hot fill & pasteurization.

MAP (Modified Atmosphere Packaging):  Filled and packaged product is exposed to UV and then MAP sealed. MAP sealing refers to removing the air from the pack and replacing it with a combination of nitrogen and carbon dioxide that can extend the shelf life of the food.

ASEPTIC: The product and package/container are sterilized separately first and then product is packed and sealed in sterile conditions.

More details on the packaging technology are available in picture 1.

Picture: 1 
Capture1
Source: Printpack Packaging Supplies (India) Pvt Ltd.

Costs

The cost of packaging   has two elements; fixed cost of the equipment and cost of the packaging material (cups/pouches). The fixed cost varies significantly across technologies as can be seen below.

Pic 2: Cost of packaging Technology

Capture5

The cost of packaging material depends on the shape and weight of the packaging container. As such the cost of packaging material does not depend on the technology that is being used for packaging.

How can we help?

Are you looking to set up a ready to eat/convenience food unit, we can

  1. Help you understand the market, technology, capital and operating costs
  2. Prepare the project proposal and assist you in obtaining bank funding
  3. Technical consultation to assist you identify right machinery, packaging material providers

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

Share This:

Business Opportunity: PET Sheets

PET sheets provide a convenient way of packaging product across a number of industries – consumer products, pharmaceuticals, food & beverages, etc. PET sheets are increasingly getting popular as a preferred option for packaging of food and pharma products, due to their visual appeal, their ability to keep the product safe from moisture and easy thermoform-ability.

The table below depicts various types and forms of packaging made out of PET sheets:

Capture4

Types of PET Sheets

Various PET sheets, based on their properties, are used in different applications. For example, CPET which has a very high working heat resistance (can withstand a temperature of up to 220 degree Celsius for more than 25 minutes) is used for microwaveable containers. The table below depicts the application of various types of PET Sheets.

Capture1

Market

PET sheet market is currently small, comprising just 1.5% of PET resin consumption in India. However, this market is rapidly growing and the resin consumed by PET sheet industry has nearly doubled from 6,400 tonnes/year in FY-14 to 11,150 tonnes/ year[1] in the FY 17.

Presently most of the PET sheet is manufactured by companies that make different kinds of packaging material. Two of the Hyderabad based players include Nirmala Pet A Pack Pvt Ltd and Spear Pet Pvt Ltd.

Process &Technology

Process
The process of PET sheet making broadly involves: Raw material pre-treatment, Extrusion and Drying & Winding/ Cutting the finished sheet

Fig1: Process flow

Capture

Sometimes, the final product requires one more layer of PET or coatings, in such cases a co extruder will be required.

Single Versus Double Screw Extrusion

Screw is the most important part of any extruder. The screw is divided into three equal zones; feeding, transition, and metering. The primary functions of the three zones are:

  • Feed – taking in the resins and feeding it forward in the screw
  • Transition – compressing and melting the resin
  • Metering/ Pumping– homogenizing/ blending the melted resins and pumping out through the extruder at a constant rate.

There are mainly two types of extruders; Single screw and Twin screw.The single screw extruders typically cost less than twin screw, however they offer less operational flexibility.

Budget

The overall budget for starting a PET sheet extrusion unit with a minimum viable capacity i.e. 300 KG/hr would be Rs. 5 Crores. The machinery cost of twin screw and single screw alone would approximately be Rs. 3 Crores and Rs. 2 Crores respectively[2].

How Can We Help You?

If you are interested in setting up a PET sheet manufacturing unit, we can assist you in starting a processing unit. Our services include

  1. Market & Financial viability assessment
  2. Technical consultancy
  3. Detailed project report preparation
  4. Support in project execution

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

 

[1]Source: PRESENTATION OF RELIANCE INDUSTRIES LTD. – March1,2016

 

[2] Source: Based on discussion with extrusion machinery suppliers

Share This:

Business Opportunity in Ginger Processing

Ginger, one of the most important spice crops in India, is known for its aromatic and medicinal properties. Ginger is used as a flavouring agent in many food items.  Ginger powder and oil are extensively used in herbal medicines.

India is the largest ginger producer in the world, accounting for nearly 40 per cent of world’s production. In India, Assam is the largest cultivator, followed by Gujarat and Karnataka.  In Telangana, ginger grows in Medak district. India produces 3.85 Lakh tonnes[1] of ginger per annum and most of which is domestically consumed.

Pic 1: State wise breakup for ginger production in India 
Capture2

NOTE: Other states include Arunachal Pradesh, Meghalaya, Sikkim, Orissa, Mizoram, West Bengal, Uttaranchal, Kerala, Andhra Pradesh and Telangana.

Ginger Processing Technology

Ginger can be processed into three products; ginger powder, paste and ginger oil. The ginger oil manufacturing is typically not taken up by small businesses as it requires large capital investment towards oil distillation and oleoresin extraction plant. The ginger processing machinery is explained below.

Pic 2: Ginger processing Machinery 

 Capture4

Key Players in Telangana

Ginger paste and powder: There are a number of manufacturers including national players such as Priya, Aachi, Mother’s, Smith & Jones, Hommade, and Eastern as well as local manufacturers. Some of the local brands include Capital, Red Boss, Mega Rose, Mayuri, MSR, Surya etc. These products are available in packing sizes of 50 grams to 1 kg.

Ginger oil: There are not many local players. Ginger oil manufacturers are largely based in Kerala. 

Budget

The capital requirements for ginger processing plants is discussed below.

Capture5

How Can We Help

We can help you start a “Ginger Processing Unit” through a number services including business viability assessment, market landscaping, technical consultation and project execution support.

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

[1] http://agriexchange.apeda.gov.in/Market%20Profile/one/GINGER.aspx

Share This:

Manufacturing Fruit Bars: Solar Dehydration Technology

Fruit bars are healthy, nutritious and minimally processed,  thus make a great snack. Fruits such as Mangoes and Guavas are very widely cultivated in India. Given their pulpy constitution, these fruits are well suited to be processed into a bar.

Rising demand for healthy snacks, ample availability of fruits and relatively modest capital requirements make fruit bar manufacturing an attractive opportunity for small businesses.

Solar Dehydration Technology

Traditionally fruit bars were made by sun drying the fruit, the process is prone to contamination, making the product unfit for consumption. The process of solar dehydration refers to dehydrating the pulp in solar dryer, which dries the fruit evenly and keeps it safe from contamination. This technology is provided by SEED (Society for Energy and Environment Development), an NGO based in Hyderabad.

1

Fruit Bar Manufacturing Process

Capture

Budget

The minimum viable size of the project is 1 tonne per annum  and the cost of machinery (fruit pulper, boiler solar dryer and quality testing equipment) is around Rs. 10 lakhs. The total project including working capital and marketing budget can be set up within Rs. 15 lakhs. The land requirement would be around 800 sft, of which atleast 300 sft should be open space that gets direct sunlight.

How can we help you?

We can help you start a Fruit bar manufacturing unit through a number of services including business viability assessment, technical consultation and support in project execution.

 Reach us

Write to us: bchhatre@finetrain.com, admin@finetrain.com

Call us: 800 888 4932 /9032398367

Visit us: www.finetrain.com

Share This:

T- PRIDE: Promoting Entrepreneurship among Scheduled Caste and Scheduled Tribes

The Telangana State Program for Rapid Incubation of Dalit Entrepreneurs (T-PRIDE) aims to develop entrepreneurship among Scheduled Caste and Scheduled Tribes. The scheme, which covers both manufacturing and service sector establishments offers a number of incentives to start a new enterprise or expand an existing business. This blog discusses key features of the scheme and its contribution to Dalit entrepreneurship.

Picture 1: Key incentives for Micro and Small enterprises under T- PRIDE

 Capture2

What type of enterprises are eligible?

In order to claim incentives under T-PRIDE, an enterprise

  • Should be 100 percent owned by SC or ST entrepreneur or both together in case of a joint venture.
  • Should commence operation on or after 1st January 2015 and before 31st March 2019.
  • Can be manufacturing or a service sector unit. For manufacturing units, certain sectors are considered ineligible (list included). For service sector, the government has specified a list of industries that are eligible (list attached).
  • Can be set up anywhere in the state, manufacturing enterprises if set up under GHMC limit, should be set up in the existing industrial estates[1], service enterprises can be set up anywhere
  • Can be a new or an existing enterprises that is expanding or diversifying its business, as shown in the table below.
Picture 2:  Eligibility parameters for existing and new enterprises

Capture3

When are these incentives given?

Generally, these incentives are given as reimbursements within 6 months of starting commercial production.  However in some cases, investment subsidy can be claimed before start of commercial production, provided the bank loan has been sanctioned.

How do I arrange finance for my project?

The finance for these projects can be obtained under Stand up India scheme, a scheme that aims to increase capital availability to SC/ST enterprises. In order to read more about Stand up India, please click here.

How many units have benefited thus far?

Based on our analysis of proposals sanctioned by SLC (State level investment committee of Commissioner of Industries, Telangana) during last two years, around 1100 enterprises have obtained approvals for incentives under T-PRIDE.  As can be seen in the picture below, transport and construction sector together account for around 60 per cent of incentive claims. Others, include hospitality, hospitals, mining, and engineering. In terms of geography, Warrangal accounts for highest number of claims, followed by Nalgonda and Karimnagar.

As such, there is a need to promote formation of new enterprises in manufacturing, agri related sectors as these boost employment and lead to development of district economy.

Capture  Capture1

How can we help you?

FineTrain is an advisory firm for small businesses; we assist our clients in starting or expanding their businesses.  We offer

  1. Advisory to help you to choose suitable business opportunity and DPR preparation
  2. Technical consultation
  3. Project implementation support
Reach us:

Write to us: bchhatre@finetrain.comadmin@finetrain.com

Call us: 800 888 4932

[1] The manufacturing units established in Sanathnagar, Azamabad, Chandulal Baradari and Kattedan Industrial Estates of Hyderabad and Ranga Reddy Districts are not eligible for any incentives/concessions.

Share This:

Business Opportunity in Tamarind Processing in India

Tamarind is a popular spice and the products from Tamarind family are being used in Indian food since ages. Tamarind pulp is commonly used in all households, restaurants, roadside eateries etc in food preparations. Not just the fruit, even Tamarind seed powder is extensively used in industries such as Textile, Paper, Confectionary, Cosmetics and Pharmaceuticals.

Opportunity

India is the world’s largest producer of tamarind products, with a production of over 200 thousand tonnes[1]. Tamarind is cultivated in Karnataka, Tamil Nadu, Kerala, Andhra Pradesh, Maharashtra, Telangana, Pondicherry and Mizoram (see the picture below).

Capture3

The value of the production of tamarind in India is estimated to be around Rs.1608crs[2], exports account for over 11% of the total value. Processed tamarind is exported mainly to European and Arab countries.

Budget

The capital requirements for a tamarind pulp making unit should be around Rs 50 lakhs including machinery and working capital needs.  The budget for the seed powder unit would vary, depending upon the process. For a totally integrated unit that includes roasting and removing the skin, grinding the seed and processing the seed powder into starch, the budget would exceed Rs. 1 crore. However, the capital requirements would reduce if one purchases clean seed (pappu, where the skin has been removed).

The biggest challenge in this business is raw material availability, also the area required to set up a processing facility would be upwards of 10000 sft.

Budget Estimation for Tamarind Processing Units

Capture

How can we help 

We can help you start “Tamarind Processing Industry” through number services as shown below:

  1. Business viability assessment, market landscaping and expert consultation.
  2. Viability of setting up a Tamarind processing unit.
  3. Identifying most cost effective local suppliers for tamarind manufacturing unit.
  4. Connect you with the experts who can help you in setting up the tamarind processing plant.
  5. Preparing the detailed project report.
Reach Us

Write to us: bchhatre@finetrain.com, admin@finetrain.com

Call us: 800 888 4932

[1] Source: NHB, production figures are for 2014 -15.

[2] Assumed average price of tamarind is Rs. 80/kg which is then converted into tonnage price and multiplied with the total production of 200 thousand tonnes.

Share This:

Business Opportunity: Animal Feed Manufacturing

India’s animal feed industry, currently valued at around $ 15 billion[1] is expected to double in the next five years.  The feed consumption is estimated to be 21.5 million tonnes, of which cattle feed accounts for 7.5 million tonnes, aqua feed 1 million tonne and poultry feed around 13 Million tonnes.

The state of Telangana and AP contribute to a large chunk of Indian feed consumption, as can be seen in the table below. Given the large size of the industry and its growth, it presents an attractive opportunity for small and medium enterprises.

Animal feed industry in AP and Telangana

Capture

Competitive landscape of the Industry

The industry is competitive, with international, national and regional companies vying for the market share.  The table below provides information on important players in AP and Telangana.

Animal feed companies in AP and Telangana

Capture7

Manufacturing process and budget

The feed manufacturing operations comprise four steps; raw material preparation, mixing and grinding the feed, palletisation and packaging. The plant capacity typically starts from 2-3 tonnes per hour to 15 tonnes per hour.

Animal feed manufacturing process

Capture8

An automated plant with a capacity of 3- 5 tonnes per hour can cost up to Rs. 40 lakhs. Considering the machines and raw material inventory and infrastructure required to store the raw material, the budget requirement for the unit could be up to Rs. 1 crore.

How can we Help

  • We can help you assess viability of animal feed and related opportunities through a number of services including market research, detailed viability assessment and technical consultation.
  • We also offer support in executing your ideas by connecting you with sector experts and professionals.

Reach Us

Call us @ 800 888 4932,

Write to us- bchhatre@finetrain.com

Visit us- www.finetrain.com

 

[1] As per Yes Bank report on The Indian Feed Industry – Revitalising Nutritional Security

Share This: