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The Complete Technology Book on Electroplating, Phosphating, Powder Coating and Metal Finishing (2nd Revised Edition)
The Complete Technology Book on Electroplating, Phosphating, Powder Coating and Metal Finishing (2nd Revised Edition) ( New Arrival ) ( ) ( ) ( ) ( )
Author NIIR Board of Consultants & Engineers ISBN 9788194099536
Code ENI129 Format Paperback
Price: Rs 1675   1675 US$ 45   45
Pages: 504 Published 2021
Publisher Asia Pacific Business Press Inc.
Usually Ships within 5 days

Description:

 

The Complete Technology Book on Electroplating, Phosphating, Powder Coating and Metal Finishing (2nd Revised Edition)

 Electroplating is the process of depositing a metal coating onto the surface of an object through the use of an electrical current. Electroplating has evolved into a highly complex process requiring a high level of precision and expertise. Phosphating is the process of converting a steel surface to iron phosphate. This is mostly used as a pretreatment method in conjunction with another method of corrosion protection.

 Powder coating is a finishing process in which a coating is applied electrostatically to a surface as a free-floating, dry powder before heat is used to finalize the coating. The powder can be made of any number of products: polyester, polyurethane, polyester-epoxy, straight epoxy, and acrylics. Metal finishing is the final step in the manufacturing process used to provide aesthetics and environmental protection.

 The electroplating market mostly is driven by the electronics and electrical industry and followed by the automotive industry. The demand for electroplating is rising rapidly from the end user industries which propel the growth of the market. The increasing demand for durable metals and growing use of adaptable manufacturing processes for a wide range of applications in the automotive, aerospace & defense, and electrical & electronics industries are likely to boost the demand for electroplating. With the growing demand for high-performance automobile components having excellent resistance to corrosion to enhance the appearance of exterior automobile parts, such as emblems, door handles, hood ornaments, and wheel rims, is driving the demand for electroplating and likely to continue owing to the increasing automobiles production in Asia-Pacific and other emerging economies in the Middle East & Africa. The zinc-nickel electroplating is one of the popular methods of electroplating in the automotive industry.

 The book cover various aspects related to different Electroplating, Phosphating, Powder Coating and Metal Finishing with their manufacturing process and also provides contact details of machinery suppliers with equipment photographs and plant layout.

 A total guide to manufacturing and entrepreneurial success in one of today’s complete process of electroplating to metal finishing in industry. This book is one-stop guide to one of the fastest growing electroplating, phosphating, powder coating and metal finishing industry, where opportunities abound for manufacturers, retailers, and entrepreneurs. The book serves up a feast of how-to information, from concept to purchasing equipment.

 

 

Content

 

Contents

1. INTRODUCTION

 

2. CLEANING, PICKLING AND DIPPING

Routine Operations in Cleaning

Preliminary Cleaning and Degreasing

Solvent Cleaning

Aqueous Neutral Detergent Pre-Cleaners

Mersol Soak Cleaner

Solution Composition

Solution Preparation

Operating Conditions

Operating Procedure

Ultrasonic Cleaning

Alkaline Cleaners

Hot Alkaline Cleaners

Classification of Metal Cleaners

Electrolytic Cleaning

Equipment for Hot Alkaline Cleaners

Barrel Cleaning

Active Cleaner

Equipment

Solution Preparation

Solution Concentration and Operating Conditions

Cleaning of Zinc Base Alloy Die Castings

Barrel Cleaning

Solution Maintenance

Nuvax Cleaner

Equipment

Solution Preparation

Cleaning of Zinc Base Alloy Die Castings

Barrel Cleaning

Solution Concentration and Operating Conditions

Solution Maintenance

Cleaner

Equipment

Solution Preparation

Solution Concentration and Operating Conditions

Solution Maintenance

Multiklense

Equipment

Solution Preparation

Solution Maintenance

Cleaner No. 50

Solution Concentration and Operating Conditions

Solution Composition

Solution Preparation

Operating Conditions

Solution Maintenance

Anozyn

Equipment

Solution Composition

Solution Preparation

Operating Conditions

Solution Maintenance

10-15 Cleaner

Equipment

Solution Concentration and Operating Conditions

Solution Preparation

Solution Maintenance

10-55 Cleaner

Equipment

Solution Preparation

Operating Conditions

Solution Maintenance

Emphax

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Zonax Metal Cleaner

Solution Concentration and Operating Conditions

Anodax Metal Cleaner

Equipment

Solution Composition

Solution Preparation

Operating Conditions

Solution Maintenance

Alkaline Cleaners for Aluminium

For Cleaning without Etching the Surface

For Light Etch Cleaning of Aluminium

For Frosted Etch Finish

Minco Cleaner

Equipment

Solution Concentration and Operating Conditions

Solution Maintenance

Kelco Cleaner

Equipment

Solution Composition

Solution Preparation

Operating Conditions and Procedure

Solution Maintenance

Maintenance of Metal Cleaners

Additions of Metal Cleaner

Pickling and Dipping

Zonax Dry Acid Salt

Equipment

Solution Concentration and Operating Conditions

Solution Preparation

Sulphuric Acid Pickling

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Hydrochloric Acid Pickling

Solution Composition

Equipment

Operating Procedure

Skalene Pickle for Iron and Steel

Alkaline Deruster Salts

Additional Uses of Alkaline Deruster Salts

Equipment

Section a—Cyanide-free Solution for Rust Removal

Solution Composition

Solution Preparation

Operating Conditions

Section B.—Cyanide Solution for Rust and Scale Removal

Solution Composition

Operating Conditions

Process Sequence used in Sections A and B

Treatment of High Tensile Steels

Spray Suppression

Effluent Treatment

Solution Maintenance

Hydrofluoric Acid Pickling

Solution Composition

Equipment

Operating Procedure

Pickling of Magnesium Alloys

Pickling of Stainless Steel

Equipment

Operating Procedure

Pickle Aid

For Combined Pickling and Degreasing Solutions

As a Spray Suppressant

Equipment

Concentration

Operating Conditions

Solution Maintenance

Bright Dipping of Copper Alloys

Aqua Fortis Bright Dipping Acid

Solution Composition

Equipment

Bright Dipping Procedure

Chromic Acid Dip for Brass, Copper and its Alloys

Solution Composition

Equipment

Operating Procedure

Nitric Free Bright Dip C22924 for Copper and its Alloys

Solution Composition

Equipment

Operating Procedure

Solution Maintenance

Barrel Pickling

Second Stage or Surface Activation Cleaning

Cyanide Containing Cleaners

Klenewell

Equipment

Solution Composition

Solution Preparation

Operating Conditions

Operating Procedure

Solution Maintenance

Kleenax

Solution Concentration

Operating Conditions

Operating Procedure

Solution Maintenance

Non-Cyanide Cleaners

Activax Cleaner

10-55 Cleaner and Anodax Metal Cleaner

Anozyn

Alkaline Deruster

Emphax Cleaner

Acid Etching

Anodic Sulphuric Acid Etching of Iron and Steel

High Concentration Acid Etch for Steel

Equipment

Solution Composition

Solution Preparation

Operating Conditions

Operating Procedure

Solution Maintenance

Acid Etching of Steel and Iron before Heavy Deposition

Solution Composition

Solution Preparation

Operating Conditions

Solution Maintenance

Pre-Treatment Systems

Pre-Cleaning

Typical Cleaning Cycles

Nickel Plating of Mild Steel

General Method

Where a cyanide-free cleaning line is required

Use of a sulphuric acid etch to ensure maximum adhesion of deposit

D.—Energy Saving Cleaning Line

Cadmium and Zinc Plating of Mild Steel

Rack Plating

Notes

Barrel Plating

Notes

Plating on High Carbon Steel

Plating on Cast Iron and Malleable Castings

Plating on Stainless Steel

Nickel Chloride Strike for Stainless Steel

Nickel Sulphate Strike for Stainless Steel

Nickel Plating of Brass and Other Copper Alloys

General Method

Alternative method where a cyanide-free cleaning line is required

Nickel Plating of Copper

Nickel Plating of Leaded Brass

Copper and Nickel Plating on Zinc Base Alloy Die-Castings

Plating on Aluminium and its Alloys

The Bondal Process

Bondal Cleaner

Equipment

Solution Composition

Solution Preparation

Operating conditions

Solution Maintenance

Bondal Dip

Standard process sequence for electro-plating on Aluminium and its alloys

Modification to the standard process

Articles likely to carry over solution

Articles having unpolished areas

Deposition of metals other than nickel

Jigging

Dips and Rinses

Dilute Acid Dips

Cyanide Dips

Rinsing or Swilling

Rinse-Aid

Scouring

 

3. ELECTROLYTIC AND CHEMICAL PROCESSES FOR THE

POLISHING OF METALS

Electro-polishing Solutions

Aluminium and Aluminium Alloys

Aluminium Electro-polishing Solution

Equipment

Solution Composition

Solution Preparation

Operating Conditions

Operating Procedure

Solution Maintenance

Brytal Process

Equipment

Operating Conditions

Desmutting

Stainless Steels

Canning Stainless Steel Electro-polishing Solution

Solution Composition

Equipment

Operating Conditions

Process Sequence

Solution Maintenance

Copper, Brass and Nickel Silver

Canning Non-Ferrous Electro-polishing Solution

Solution Composition

Equipment

Operating Conditions

Process Sequence

Solution Maintenance

Chemical Polishing of Aluminium

Typical Operating Conditions

 

4. COPPER PLATING

Properties of Copper

Decorative Applications

Functional Applications

Copper Plating Solutions

Rates of Deposition and Specification Requirements

Cathode Efficiency of Copper Plating Solutions

Rates of Deposition

Deposit Specifications

Equipment

Cyanide Solutions

Anodes

Cyanide Copper Plating Processes

Copper Strikes

PH Control

Cuprax High Efficiency Copper Solution

Anodes

Solution Composition

Operating Conditions

Solution Maintenance

Purification

Analytical Standards

Plating Procedure for Zinc based diecastings

Zonax Copper Solution

Anodes

Solution Composition

Operating Conditions

Maintenance of the Solutions

Low Cyanide Strike Solution for Cast Iron, Lead and Soldered Articles

Analytical Standards

Rochelle Copper Solution

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Acid Copper Plating Processes

Cuprasol Mk 2 Bright Levelling Acid Copper Plating Sollution

Preparation of the Cuprasol Mk. 2 Base Solution

Solution Composition

Operating Conditions

Solution Maintenance

Chloride Content

Visual Control of the Cuprasol Solution

Acid Copper Sulphate Solution

Solution Compositions

Operating Conditions

Solution Maintenance

Correction of Faults in Acid Copper Sulphate Solutions

Copper Pyrophosphate Plating Solution

Super Pyrobrite Copper Pyrophosphate Plating Solution

Solution Composition

Solution Maintenance

Plating Procedure

Neutral Copper Plating Solutions

Solution Composition

Operating Conditions

Plating Procedure

Immersion Plating Without Applied Current

On Steel

Solution Composition

On Brass

Solution for Barrel Copper Plating

Barrel Plating with Zonax Copper Solution

Solution Compositions

Operating Conditions

Maintenance of Solutions

Analytical Standards

Barrel Plating with Cuprax Copper Solution

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

BarRel Plating in Rochelle Copper Solution

Operating Conditions

Analytical Standards

Solutions for Heavy Copper Deposition

Cuprasol Mk. 2 Acid Copper Plating Process for Heavy Deposits

Preparation of the Acid Copper Base Solution

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Copper Fluoborate Solution

Equipment

Operating Conditions

Solution Maintenance

Purification

Analytical Standards

Super Pyrobrite Copper Pyrophosphate Plating Solution

Properties of the deposit

Operating Conditions

Purification

Cuprax Cyanide Copper Solution

Copper Plating Procedure

Cyanide Copper Solutions

Zinc Base Alloy Diecastings

Special Techniques used in Printing Application

Photogravure

Building Up Copper Cylinders

Skin Deposits

Cast Iron and Steel Cylinders

Aluminium Cylinders

Copper Electrotypes

Lithography

Stopping-Off

Methods for Stripping Copper Deposits

From Steel

Universal Stripping Salts for Steel

Alkaline Cyanide Solution

Immersion Process

Sulphuric Acid Etch

From Zinc Alloy Diecastings

5. ELECTROFORMING

Applications of Electroforming

Materials for Electroforming

Nickel Solution

The Watts Solution

The Sulphamate Solution

The Ni-spoed Solution

Zero-stress conditions for the Ni-speed process

Nickel/Cobalt Alloy Solutions

Copper Plating Solution

Throwing power

Sodium High-Sulphate Nickel Solution

Operating Techniques

Mandrels for Electroforms

Permanent Mandrels

Stainless steel

Mild Steel

Copper and Brass

Electroformed Nickel

Rigid Plastic

Collapsible Plastics

Expendable Mandrels

Aluminium

Zinc alloys

Fusible alloys

Plastics

Wax

Other Materials

Post Plating Treatment

Electroforming in Gramophone Record Production

Printing Application

Printing Methods

Electroplating Techniques Special to the Printing Industry

Electroplating Solutions used in the Printing Industry

 

6. BRASS PLATING

Decorative Brass Plating

Zonax Brass Solution for Decorative and General Plating

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Colour Consistency and Control

Analytical Standards

Plating Procedure

Brass Plating upon Cast Iron and Lead

Barrel Brass Plating

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Brass Plating for Rubber Adhesion

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Plating Procedure

Correction of Faults in Zonax Brass Plating Solutions.

 

7. SILVER PLATING

Cyanides Systems

High-Speed Selective Plating

Non-cyanide System

Iodide Solutions

Trimetaphosphate Solution

Thiosulfate Solutions

Succinimide Solutions

Organic Solvent Solutions

Summary

Tin, Lead, and Tin-Lead Plating

Additives

Tin, Lead, and Tin-Lead Plating Baths

Tin Barrel, Still, and High-Speed Baths

Lead Barrel and Still Baths

60 Tin/40 Lead Solder Barrel, Still, and High-Speed Baths

90 Tin/10 Lead Barrel, Still, and High-Speed Baths

93 Lead/7 Tin Barrel and Still Baths

10 Tin/88 Lead/2 Copper Ternary Alloy Barrel and Still Baths

Fluoborate Plating

Methane-Sulfonic-Acid-Based Plating

Tin Plating from Stannate Baths

Anodes in Stannate Baths

Operation of Stannate Baths

Reflowing Tin Deposits

Determination of Acid Neutralization Value

 

8. GOLD PLATING (GILDING)

Properties of Gold

History of Gold Plating

Applications of Gold Plating

Rates of Deposition and Specification Requirements

Specification Requirements

Undercoats

Corrosion Resistance

Carat Value

Equipment for Gold Plating

Anodes

Effluent Treatment

Gold Deposits and Solutions

Ultra-pure Gold Deposits

Low-Alloy Gold Deposits

High-Alloy Decorative Golds

General Gold Plating Procedure

Plated Undercoats

Barrier Layers

Strike solutions

Post plating treatment

Traditional Gold Plating Practice (Gilding)

Gilding Articles Inside

Immersion Gilding

Stripping Gold Deposits

Electrolytic Process for Stripping Flux and Oxide from Gold

 

9. CADMIUM PLATING

Properties of Cadmium

Applications and Corrosion Resistance

Cadmium Deposits on Non Ferrous Metals

Passivation Processes

Specification Requirements and Rates of Deposition

Rates of Deposition and Plating Times

Determination of Deposits Thikness

Strip and re-weigh method for average thickness of cadmium deposits

Test for Porosity of Deposit

Cadmium Plating Equipment

Cadmium Plating Solutions

Cadmium Plating Salts

Zonax Candmium Plating Solution

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Kadax Cadmium Solution for Barrel Plating

Solution Composition

Operating Conditions.

Solution Maintenance

Analytical Standards

Kadamax High Speed Bright Cadmium Plating Solution

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Cadmium Plating Procedure

Cleaning and Preparation of Work

Removal of Embrittlement

Treatment after Cadmium Plating

Kadip Bright Dip

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Chromic Acid Dip

Equipment

Solution Composition

Operating Conditions

Stripping Cadmium Deposits

Using Ammonium Nitrate Solution

Using Ammoniacal Persulphate Solution

Using Hydrochloric Acid

 

10. ZINC PLATING

Properties of Zinc

Applications Corrosion Resistance

Specification Requirements and Rates of Deposition

Thickness Requirements for Zinc Deposits

Determination of Thickness of Zinc Deposit

Rate of Deposition

Zinc Plating Equipment

Cyanide solutions

Zinc Plating Solution

Cyanide Zinc Plating Solutions

Base Solution Composition

Unizin Universal Zinc Brightner

Anodes

Solution Composition

Operating Conditions

Solution Maintenance

Analytical Standards

Purification

Hylite 80 Bright Zinc Solutions

Solution Composition

Operating Conditions

Solution Maintenance

Zinc Oxide

Zinc Cyanide

Purification

Analytical Standards

Treatment after Plating

Cyanide Zinc Plating Procedure

Cleaning and Preparation of Work

Treatment After Zinc Plating

Bright Zinc Plating

Dilute Nitric Acid Bright Dip

Dull Zinc Plating

Correction of Faults In Cyanide Zinc Plating Solutions

Alkaline Non-Cyanide Zinc Solutions

Envirozin 2 Bright Alkaline Non-Cyanide Solution

Solution Composition: Rack

Solution Composition: Barrel

Solution Preparation

Operating Conditions

Rate of Deposition

Solution Maintenance

Analytical Standards

Purification

Alkaline Non-Cyanide Plating Procedure

Acid Zinc Plating Solutions

Zincalux Bright Acid Zinc Solution

Solution Composition

Operating Conditions

Rate of Deposition

Solution Maintenance

Purification

Analytical Standards

Treatment after Plating

Chloride Zinc Plating Solution

Equipment

Solution Composition

Operating Conditions

Rate of Deposition

Solution Maintenance

Treatment of Work after Plating

Acid Zinc Plating Procedure

Stopping-off

Stripping Zinc Deposits

Immersion Process

Correction of Faults in Acid Chloride Zinc Plating Solutions

Electrolytic Process

 

11. THE PLATING OF PLASTICS AND OTHER

NON-METALLIC MATERIALS

Plating-on-Plastics

Applications and Advantages

Properties of Plated Plastics

Moulding for Plating on Plastics

Physical faults and their effects

Faults caused by variations in machine parameters

Simplas Process

Equipment

Swilling or Rinsing

Cleaning

Pre-etch

Hot Alkaline Cleaner

Etching

Etch Composition for ABS Type Polymers

Operating Conditions

Solution Maintenance

Analytical Standards

Etch Composition: For PP co-polymers

†Alternatives:

Operating Conditions

Solution Maintenance

Analytical Standards

Neutralising

Solution Composition

Solution Maintenance

Simplas Neutraliser

Solution Composition

Operating Conditions

Activation

Solution Composition

Operating Conditions

Solution Maintenance

Acceleration

Solution Composition

Operating Conditions

Niplas Electroless Nickel

Equipment

Solution Composition

Operating Conditions

Solution Maintenance

Solution Life

Analytical Standards

Electroplating on Electroless Nickel Plated Surfaces

Plating Jigs

Barrel Plating of Plastics

Barrel Plating Technique

Silvering

Spray Silvering

Solution Composition

Operating Procedure

Sensitiser

Immersion Silvering

Operating Procedure

Electroplating on Silvered Surfaces

Jigging

Special Techniques Used In Printing Applications

Metallising with Copper Bronze Powder

Preparation

Metallising

Electroplating

Polishing with Powered Graphite

Vacuum Evaporation and Electrical Sputtering

 

12. PHOSPHATING PROCESSES

Applications

Pre-treatment Prior to Organic Coatings

Protection against Corrosion

Anti-wear Coatings

Phosphating as a Production Aid

Types of Phosphate Coating

Iron Phosphate

Zinc Phosphate

Manganese Phosphate

Lead Phosphate

Surfaces To Which Phosphate Coatings May Be Applied

Preparation of Surfaces for Phosphating

Specifications

British Standard 1389: 1973 Phosphate Treatment of Iron and Steel

DEF STAN 03-11/1 Phosphate Treatment of Iron and Steel

Treatment of High Tensile Steels

Equipment for Phosphating

Immersion Phosphating Plant

Spray PhospHating Equipment

Tanks

Solution Heating

Fume Extraction

Sludge Removal

Phosphating Processes

Key to Table

Light Weight Iron Phosphate Processes

Canphos 301

Canphos 304

Equipment

Solution Composition and Operating Conditions

Preparation of the 300 Range Phosphating Solutions

Operating Sequences

Solution Maintenance

Heavy Zinc Phosphate Processes

Equipment

Canphos

Canphos

Solution Composition and Operating Conditions

Preparation of the 400 Range of Phosphating Solutions

Solution Maintenance

Visual Control

Calcium Modified Zinc Phosphate Processes

Canphos

Canphos

Canphos

Equipment

Solution Preparation

Operating Sequences

Solution Maintenance

Addition Rates

Light Weight Zinc Phosphate Processes

Canphos

Canphos

Solution Composition and Operating Conditions

Solution Preparation

Solution Maintenance

Addition Rates

ManganEsE Phosphate Processes

Canphos

Equipment

Solution Composition

Operating Conditions

Solution Preparation

Operating Sequences

Solution Maintenance

Phosphating Process Sequences

Pre-Treatment Processes

Alkaline Cleaners

Equipment

Maintenance

Defoaming

Pickling and Derusting

Conditioning

Post Phosphating Treatments

Sealing Treatment

Chromic Rinse Solution (DEF STAN 03-11/1)

Equipment

Oils and Lubricants

Black Finishes

Sealphos 721 Black Stain

Sealphos 708 Matt Black

Aluminium Pre-Treatment

Alibond 802

Equipment

Solution Composition

Operating Conditions

Operating Sequence

Solution Maintenance

Solution Analysis

General Phosphating Information

Sludge Removal

Control of Solution Composition and Chemical Balance

Effluent Treatment

 

13. ELECTROPAINTING OF ALUMINIUM

The Process

Principles of Electropainting

Process Details

Jigging

Pre-treatment

Paint Application

4 Rinsing and Ultrafiltration

Stoving

Costs

Conclusion

Developments

The Future

 

14. POWDER COATING OF ALUMINIUM

Method of Application

Equipment

Electrostatic Generator and Gun

Powder Recovery

Stoving

Powder Coating Production

Colour

Thermoplastic Powder Coatings

Polyethylene (Polythene)

PVC

Nylon

Factors Affecting Use of Thermo-plastic Coatings

 

15. BRIGHT NICKEL ELECTROPLATING

Brighteners

Levellers

Stress Relievers

Wetting Agents

Properties of electro-deposited bright nickel

Brightness

Reflectivity

Roughness and Pitting

Porosity

Corrosion Resistance

Chromability

Adhesion and Surface Preparation

Ductility

Internal Stress

Hardness

Effect of hydrogen absorption

Properties of Bright Nickel Baths

Stability

Cathode and anode efficiencies

Operating range

Simplicity of operation

Throwing power

The incorporation and effect of organic addition agents

Mechanisms of incorporation of organic compounds in electro-deposits

Cathodic Reduction

Interaction of organic additions

Levelling

Effect of additives on structure

Grain size, orientation and brightness of electro-deposits

Effect of additions on stress, ductility and hardness

Stress first decreases, then rises as concentration is increased.

 

16. BIS SPECIFICATIONS

 

17. PHOTOGRAPHS OF MACHINERY WITH SUPPLIER’S CONTACT DETAILS

Electroplating Rectifiers

Electroplating Process Tank

Rotating Barrel

Auto Stat

Automatic Voltage Controller

Automatic Powder Coating Plant

ED Coating Plant / CED Coating Plant

Control panels

Advance Controller

Painting Booth

Metal Finishing Machines

Rotary Dryers

Shot Blasting

Vibratory Finishing Machines

Polyamide (Glide) Coating

Zinc Plating Plants

Material Handling System

Flocking Units

Electric Oven

Industrial Oven

Plating Barrel

Servo Stabilizer

 

18. PLANT LAYOUT AND PROCESS FLOW SHEETS

 

ABOUT NPCS

NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
  • Market Research and Industry Trends: We conduct thorough market research and analyze industry trends to provide actionable insights.
  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
  • Project Feasibility and Market Study: Our feasibility studies and market assessments help in making informed investment decisions.
  • Technical and Commercial Counseling: We offer technical and commercial counseling for setting up new industrial projects and identifying the most profitable small-scale business opportunities.

Publications

NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

  • Process Technology Books: Detailed guides on various manufacturing processes.
  • Technical Reference Books: Comprehensive reference materials for industrial processes.
  • Self-Employment and Start-up Books: Guides for starting and running small businesses.
  • Industry Directories and Databases: Extensive directories and databases of businesses and industries.
  • Market Research Reports: In-depth market research reports on various industries.
  • Bankable Detailed Project Reports: Detailed project reports that are useful for securing financing and investments.

Our Approach

Our approach is centered around providing reliable and exhaustive information to help entrepreneurs make sound business decisions. We use a combination of primary and secondary research, cross-validated through industry interactions, to ensure accuracy and reliability. Our reports are designed to cover all critical aspects, including:

  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
  • Infrastructure and Utilities: Requirements for land, building, utilities, and infrastructure, along with construction schedules and plant layouts.

Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

Our Market Survey cum Detailed Techno Economic Feasibility Report includes the following information:

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
  • Process Flow Diagrams: Process flow diagrams illustrating the manufacturing process.

Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.

Annexures

Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.

Testimonials

Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.

FAQs

Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.