B Promoters
A Project at Glance
C Key reasons for success of our project
D Management
E Introduction
F Market for MDF & Particle Board
G Raw Materials for MDF & Particle Board
H Environmental, Social & National Objectives
I Global Capacity of MDF & Particle Board
J Future potential for MDF & Particle Board
K Projected Demand of MDF & Particleboard in India
L MDF Manufacturing Process
M Plant & Machinery for MDF Project
N Particle Board Manufacturing Process
O Plant & Machinery for Particle Board Project
P Technical Sequence in Brief of Particle Board Line
Q Building Area requirement
R Details of Cost of Project
S Cost of Plant & Machinery
T Cost of Utility, Services & Misc. Equipments (Indigenous)
U Means of Finance
V Marketing & Selling Arrangements
X Turnover Capacity for all products
P R O J E C T A T A G L A N C E:
1. Name of the proposed unit GAUVARDHAN ORGANICS PVT. LIMITED
2. Registered Office H-7, UPSIDC INDL. AREA‘B’ SITE
MATHURA 281005UTTERPRADESH
3. Location PRESENT: AS ABOVE
PROPOSED: UPSIDC INDL. ARA
KOSI- MATHURA DIST. UP
4. Status PVT. Ltd. Co. Regd vide U74999UP2009PTCO38544
5. Name of Promoters/ Directors: Dr. SK Mittal, Nitin K. Mittal, Chetan K. Mittal
6. Industry Particle Board & other Organic Products made from Cow Dung, Cow Urine & Agro Waste
7. Proposed Products 1 Particle Board (Plain / Pre-Laminated)
2 Phenyl Gomutra Ark
3 Pest Repellant Mosquito Coil
4 Essence Fire Sticks (Havan Samidha)
5 Hand Wash Liquid Hand Wash Powder
6 Essence Sticks Etc
8. Installed Capacity 1000 Cubic Mtr /day + 10 KL cow urine
Name of the Item Name of the Item Proposed Manufacturing Capacities
(i)
(ii) 1 Particle Board 10mm to 40 mm
2 Phenyl
3 Gomutra Ark
4 Pest Repellant
5 Mosquito Coil
6 Essence Fire Sticks (Havan Samidha)
7 Hand Wash Liquid
8 Hand Wash Powder
9 Essence Sticks Etc 20,000 Cub.Mtr 15,000 MT
5000 KL
5000 KL
5 KL
500 MT
500MT
5 KL
500 MT
50 MT
9. Project cost {Rs. in lacs)
TOTAL
i. Present Site as above but Proposed for shifting Land (6270 SQ. Mtr in Kosi UPSIDC INDL AREA Mathura Dist 65
ii. Building – Factory & - Non Factory 45
iii. Plant & Machinery 155
iv. Misc. Fixed Assets 7
v. Pre-operative Expenses 5
vi. Security Deposits 6
vii. Contingencies 7
Viii Margin Money for working Capital 30
Total 320
10. Means of Finance
i. Share Capital & Unsecured Loans 100
ii. Term Loan 170
iii Working Capital Facilities 50
TOTAL 320
11. Capacity Utilization 60% in 1st year 80% in 2nd year 90% in 3rd year 90% in 4th year 90% onward
12. No. Of working days 300 Days
13. No. Of shifts 3 Shifts
14. Man power utilization 80
15. Implementation period In production / Shifting one month
16. Break even point installed capacity on 100% capacity 32.86%
17. Average DSCR 2.78
TOTAL 350
INTRODUCTION: People have used wood for millennia for many purposes, primarily as a fuel or as a construction material for making houses, tools, weapons, furniture, packaging, artworks, and paper. Wood can be dated by carbon dating and in some species by dendrochronology to make inferences about when a wooden object was created. The year-to-year variation in tree-ring widths and isotopic abundances gives clues to the prevailing Wood, in the strict sense, is yielded by trees, which increase in diameter by the formation, between the existing wood and the inner bark, of new woody layers which envelop the entire stem, living branches, and roots. Technically this is known as secondary growth; it is the result of cell division in the vascular cambium, a lateral meristem, and subsequent expansion of the new cells.
Wood is an organic material; in the strict sense it is produced as secondary xylem in the stems of trees (and other woody plants). In a living tree it conducts water and nutrients to the leaves and other growing tissues, and has a support function, enabling woody plants to reach large sizes or to stand up for themselves. However, wood may also refer to other plant materials with comparable properties, and to material engineered from wood, or wood chips or fiber.
Wood has been an important construction material since humans began building shelters, houses and boats. Nearly all boats were made out of wood until the late 19th century, and wood remains in common use today in boat construction.
Wood to be used for construction work is commonly known as lumber in North America. Elsewhere, lumber usually refers to felled trees, and the word for sawn planks ready for use is timber.
New domestic housing in many parts of the world today is commonly made from timber-framed construction. Engineered wood products are becoming a bigger part of the construction industry. They may be used in both residential and commercial buildings as structural and aesthetic materials.
In buildings made of other materials, wood will still be found as a supporting material, especially in roof construction, in interior doors and their frames, and as exterior cladding.
Wood is also commonly used as shuttering material to form the mould into which concrete is poured during reinforced concrete construction. Wood unsuitable for construction in its native form may be broken down mechanically (into fibres or chips) or chemically (into cellulose) and used as a raw material for other building materials such as chipboard, engineered wood, hardboard, medium-density fiberboard (MDF), oriented strand board (OSB). Such wood derivatives are widely used: wood fibers are an important component of most paper, and cellulose is used as a component of some synthetic materials. Wood derivatives can also be used for kinds of flooring, for example laminate flooring
wood products
Further developments include new lignin glue applications, recyclable food packaging, rubber tire replacement applications, anti-bacterial medical agents, and high strength fabrics or composites. As scientist and engineers further learn and develop new techniques to extract various components from wood, or alternatively to modify wood, for example by adding components to wood, new more advanced products will appear on the marketplace.
Furniture and utensils: Wood has always been used extensively for furniture, including chairs and beds . Also for tool handles and cutlery, such as chopsticks, toothpicks, and other utensils, like the wooden spoon.
In the arts: Artists can use wood to create delicate sculptures.Wood has long been used as an artistic medium. It has been used to make sculptures and carvings for millennia. It is also used in woodcut printmaking, and for engraving. Certain types of musical instruments, such as those of the violin family, the guitar, the clarinet and recorder, the xylophone, and the marimba, are made mostly or entirely of wood. The choice of wood may make a significant difference to the tone and resonant qualities of the instrument, and tonewoods have widely differing properties, ranging from the hard and dense (african blackwood used for the bodies of clarinets to the light but resonant European spruce (Picea abies)) traditionally used for the soundboards of violins. The most valuable tonewoods, such as the ripple sycamore (Acer pseudoplatanus), used for the backs of violins, combine acoustic properties with decorative color and grain which enhance the appearance of the finished instrument
Sports and recreational equipment: Many types of sports equipment are made of wood, or were constructed of wood in the past. For example, cricket bats are typically made of white willow. The baseball bats which are legal for use in Major League Baseball are frequently made of ash wood or hickory, and in recent years have been constructed from maple even though that wood is somewhat more fragile. In softball, however, bats are more commonly made of aluminum (this is especially true for fastpitch softball).
Many other types of sports and recreation equipment, such as skis and ice hockey sticks, were commonly made of wood in the past, but have since been replaced with more modern materials such as aluminum, fiberglass, carbon fiber, titanium, and composite materials. One noteworthy example of this trend is the golf club commonly known as the wood, the head of which was traditionally made of persimmon wood in the early days of the game of golf, but is now generally made of synthetic materials
Consequent to multiple usage of wood deforestation put ecological imbalance and this brought scientists do research and thus came the usage of PLYWOOD to replace WOOD.
Plywood is a type of engineered wood made from thin sheets of wood, called plies or wood veneers. The layers are glued together so that adjacent plies have their grain at right angles to each other for greater strength. There are usually an odd number of plies, as the symmetry makes the board less prone to warping. An common reason for using plywood instead of plain wood is its resistance to cracking, shrinkage, twisting/warping, and its general high degree of strength. In addition, plywood can be manufactured in sheets far wider than the trees from which it was made. It has replaced many dimensional lumbers on construction applications for these reasons. A vast number of varieties of plywood exist for different applications. Softwood plywood is usually made either of Douglas fir or spruce, pine, and fir (collectively known as Spruce-pine-fir), and is typically used for construction and industrial purposes.
Plywood production requires a good log, called a peeler, which is generally straighter and larger in diameter than one required for processing into dimensioned lumber by a sawmill. The log is peeled into sheets of veneer which are then cut to the desired dimensions, dried, patched, glued together and then baked in a press at 140 °C (280 °F) and 19 MPa (2800 psi) to form the plywood panel. The panel can then be patched, resized, sanded or otherwise refinished, depending on the market for which it is intended.
However plywood also over a period put stress on wood since the main raw material for the same is wood. Hence further innovation brought in particle Board.
Particle board has been in use since the 1940s, often used in place of the more expensive plywood as subflooring or instead of natural hardwoods in furniture manufacturing. At one point in its history, however, particle board was considered an expensive designer material, reserved for use in exclusive homes and upscale furniture factories. Modern particle board is now made primarily by combining discarded wood shavings, chips and sawdust with a strong resin and pressing the mixture into serviceable boards and planks
Particle board, or particleboard, (or chipboard in the UK, Australia and some other countries) is an engineered wood product manufactured from wood particles, such as wood chips, sawmill shavings, or even saw dust, and a synthetic resin or other suitable binder, which is pressed and extruded. Particleboard is a composite material.
Particleboard is cheaper, denser and more uniform than conventional wood and plywood and is substituted for them when appearance and strength are less important than cost. However, particleboard can be made more attractive by painting or the use of wood veneers that are glued onto surfaces that will be visible. Though it is denser than conventional wood, it is the lightest and weakest type of fiberboard, except for insulation board. Medium-density fibreboard and hardboard, also called high-density fiberboard, are stronger and denser than particleboard.
A major disadvantage of particleboard is that it is very prone to expansion and discoloration due to moisture, particularly when it is not covered with paint or another sealer. Therefore, it is rarely used outdoors or places that have high levels of moisture, with the exception of some bathrooms, kitchens and laundries, where it is commonly used as an underlayment beneath a continuous sheet of vinyl floor coverings
History and development
Modern plywood, as an alternative to natural wood, was invented in the 19th century, but by the end of the 1940s there was not enough lumber around to manufacture plywood affordably. Particleboard was intended to be a replacement. The first commercial piece was produced during World War II at a factory in Bremen, Germany. It used waste material such as planer shavings, offcuts or sawdust, hammer-milled into chips, and bound together with a phenolic resin. Hammer-milling involves smashing material into smaller and smaller pieces until they pass out through a screen. Most other early particleboard manufacturers used similar processes, though often with slightly different resins.
It was found that better strength, appearance and resin economy could be achieved by using more uniform, manufactured chips. Manufacturers began processing solid birch, beech, alder, pine and spruce into consistent chips and flakes. These finer layers were then placed on the outsides of the board, with the central section composed of coarser, cheaper chips. This type of board is known as three-layer particleboard.
More recently, graded density particleboard has also evolved. It contains particles that gradually become smaller as they get closer to the surface.
Manufacturing Particle board is manufactured by mixing wood particles or flakes together with a resin and forming the mix into a sheet. The raw material to be used for the particles is fed into a disc chipper with between four and sixteen radially arranged blades. The particles are first dried, after which any oversized or undersized particles are screened out.
Resin, in liquid form, is then sprayed through nozzles onto the particles. There are several types of resins that are commonly used. Urea formaldehyde resin is the cheapest and easiest to use. It is used for most non-water resistant boards. Melamine formaldehyde resin is significantly more expensive, as it is moisture resistant. Phenol formaldehyde is also fairly expensive. It is dark colored and highly durable. These resins are sometimes mixed with other additives before being applied to the particles, in order to make the final product waterproof, fireproof, insect proof, or to give it some other quality.
Once the resin has been mixed with the particles, the liquid mixture is made into a sheet. A weighing device notes the weight of flakes, and they are distributed into position by rotating rakes. In graded density particleboard, the flakes are spread by an air jet which throws finer particles further than coarse ones. Two such jets, reversed, allow the particles to build up from fine to coarse and back to fine.
The sheets formed are then cold-compressed to reduce their thickness and make them easier to transport. Later, they are compressed again, under pressures between two and three megapascals and temperatures between 140 °C and 220 °C. This process sets and hardens the glue. All aspects of this entire process must be carefully controlled to ensure the correct size, density and consistency of the board. The boards are then cooled, trimmed and sanded. They can then be sold untreated, covered in a wood veneer or laminated with paper .
Particleboard has had an enormous influence on furniture design. In the early 1950s, particleboard kitchens started to come into use in furniture construction but, in many cases, it remained more expensive than solid wood. A particleboard kitchen was only available to the very wealthy. Once the technology was more developed, particleboard became cheaper.
GLOBAL CAPACITY OF MDF & Particle BOARD–MDF & Particle Board was developed in the US & rather quickly spread around the world. Today the largest producing & consuming region is Europe. following are the aggregate world capacity of Particle /Medium Density Fiber ( MDF) Board in million cubic meters–
The global potential demand for panel boards is estimated at 250 million m3 per year and the market potential for Medium Density Fiber ( MDF) Board alone is 100 million m3. The gap of 150 million m3 can be diverted to MDF and Particleboard
Year – 2004 No. of mills Average size of each Medium Density Fiber ( MDF) Board mill
Africa 4 63,000 m3
Middle East (Israel) 1 86,000 m3
South America 16 1,79,000 m3
Asia Pacific
- Australia 5 1,56,000 m3
- China * 186 45,000 m3
- India 3 50,000 m3
- Indonesia 7 75,000 m3
- Iran 1 30,000 m3
- Japan 4 1,60,000 m3
- Korea 8 1,36,000 m3
- Malaysia 11 1,18,000 m3
- New Zealand 4 2,27,000 m3
- Sri Lanka 1 1,00,000 m3
- Pakistan 2 26,000 m3
- Thailand 7 1,25,000 m3
- Vietnam 1 54,000 m3
- Europe 64 1,87,000 m3
Canada 7 2,15,000 m3
Mexico 1 60,000 m3
United States 18 1,89,000 m3
World Total 350 mills World 1,10,000 m3
Average
* The total no. of Medium density fiber Board Plants in China exceeded 400 during 2004, but the remaining are small lines of 5,000 – 20,000 m3 capacity.
The following figures give the number of Production lines for Medium Density Fiber ( MDF) Board, together with average production capacities in the world
Year – 2004 No. of Production Lines Average size of each Particle Board mill Capacity in 1000 m3
U.S. 54 199,000 m3 10726
Canada 17 223,000 m3 3797
Mexico 10 94,000 m3 937
Europe 251 174,000 m3 43,563
Rest of the World
- China * 263 22,000 m3 5740
- North East
- Asia 26 11000 m3 2624
-South East
-Asia 67 84,000 m3 5635
- other Asia 35 61,000 m3 2127
- Latin/South
- America 53 97000 m3 5157
- Africa 21 58,000 m3 1227
- Australias 18 63,000 m3 1130
World Total 815 mills World 1,01,000 m3
Average 82,663
* Including India.
The present per-capita utilization of MDF & Particle Board is very low in India as evident from the table below, which indicates that there is a large potential market for MDF & Particle Board in future-
The following figures give the number of Production lines for Particle Board, together with average production capacities in the world –
In China, around 200 mills build by using Chinese Plant & Equipments, with total capacities of 3 million m3.\In the rest of Asia, the number of mills & their capacities remained unchanged during the last 2-3 years.
As per the statistics available, there are 14 pre-laminated/plain particleboard manufacturers in India, with a build –up capacity of around 300000 m3. There is a scope to set up at least 10 Particle Board Plants in India over a period of next 5 years, as against only few Plants in operation now.
Despite increase in Plant capacities by 5-10% every year, the demand is increasing at a faster rate & there is a clear shortage of Particle Board in India
Usage Pattern of MDF & Particle Board Per 1,000 capita / year during 2004 –
Canada 48.87 m3
Australia 33.85 m3
Europe 16.47 m3
US 12.36 m3
North East Asia 8.68 m3
South East Asia 4.98 m3
South America 4.92 m3
China 4.53 m3
Africa 0.30 m3
Other Asia (Including India) 0.25 m3
World Average 6.25 m3
Despite increase in Plant capacities by 5-10% every year, the demand is increasing at a faster rate & there is a clear shortage of MDF & Particle Board in India The saw milling industry, consisting of more than 23,000 units utilizes bulk of the industrial round wood in India. It is estimated that each sawmill will generate 100 – 120 tons of sawdust & wood cuttings per year on an average and make available totally 2.5 million tons of wood wastes, which can provide necessary raw material for more than 50 new Particle /Medium Density Fiber ( MDF) Board Plants in India.
Plywood – India has a well-developed Plywood industry, which produces around 220 million sq. meters of Plywood annually of which 20 million sq. meters is decorative. In the Rs. 5,000 crore Plywood market, un-organized sector commands the lion’s share of 80%. And organized sector constitute the balance 20%. Since the Supreme Court has banned further licensing of Plywood factories in India, Plywood industry cannot meet the future demand for Panel products.
Furniture industry - Indian furniture industry has a market size of more than Rs. 15,000 crores in a year. Imports of furniture are estimated to be more than Rs. 1,000 crores per year. Indian panel processing industry is growing rapidly at around 35% every year.
With the introduction of economic reforms since 1992 & more recently, putting a ban on most domestic logging, a unique market opportunity is emerging for Particle/MDF Board forest products in India. The growing prosperity of more than 150 million upper & middle class Indians has opened the market for wood products from furniture to flooring & from lumber to laminates to develop quickly.
J. FUTURE POTENTIAL FOR MDF & Particle BOARD- Since the panel processing industry is growing at a phenomenal rate of 35%, the future potential market for Particle /Medium Density Fiber ( MDF) Board in India is estimated as under –
1. The present demand for Plywood is 250million sq. meters. Taking the average thickness of plywood as 16 mm, this implies a market size of 40 lakh cubic meters or 30 lakh tons of plywood in India.
2. Presently, the construction industry is booming, with a lot of encouragement for the housing sector. Hence the average growth rate for wood in the next 5 years can be taken as 5% & plywood as 10% per year.
3. Since the new Plywood factories cannot be started without permission from the Central Empowered committee, Plywood industry is not able to meet the future demand for panel products. Plywood also needs wood in excess of 30 cm dia, as against Medium Density Fiber (MDF) Board and Particleboard which needs wood waste of Ply-board industry, firewood waste wood of furniture industry and of band saw units.
With new MDF & Particle Board Plants coming up & leading to adequate supplies in the market, MDF & Particle Board is expected to draw slowly the market shares from wood & plywood sector. This has happened in almost all countries of the world. Accordingly, the projected demand for MDF & Particle Board in India is estimated as under –
K.PROJECTED DEMAND FOR MDF & Particle BOARD IN INDIA - (In million cubic meters)
Projections for years 2006 2007 2008 2009 2010
Future demand for sawn wood - (5% growth rate assumed) 50.00 52.50 55.12 57.88 60.77
Future demand for Plywood (10% growth rate assumed) 4.00 4.40 4.84 5.32 5.86
Future projections based on existing demand for PARTICLE /MEDIUM DENSITY FIBRE ( MDF) BOARD (10% growth rate assumed) 0.67 0.74 0.81 0.89 0.98
Future projections for PARTICLE /MEDIUM DENSITY FIBRE (MDF) BOARD which will improve with higher availability, assuming that PARTICLE /MEDIUM DENSITY FIBRE (MDF) BOARD will take away 1%, 2%, 3%, 4% & 5% share from the sawn wood market in the next 5 years and also take away 5%, 10%, 15%, 20% & 25% share from plywood market in the next 5 years 0.67
0.50
0.20 0.74
1.05
0.44 0.81
1.65
0.73 0.89
2.32
1.06 0.98
3.04
1.46
TOTAL 1.37 2.23 3.19 4.27 5.48
Region Particle /Medium Density Fiber ( MDF) Board capacities
(In million m3)
2001 2002 2003 2004
Australia & New Zealand 1.69 1.73 1.73 1.73
China 5.42 7.02 7.36 8.66
South East Asia 2.60 2.76 2.85 3.21
North East Asia 1.72 1.72 1.72 1.72
South America 2.06 2.97 3.22 3.58
Europe 11.52 11.92 12.46 13.18
North America 5.07 5.06 5.45 5.81
Rest of the world * 0.48 0.61 0.64 0.79
Total 30.56 33.79 35.43 38.68
Summarized future projections for Particle /Medium Density Fiber (MDF) Board in India –
Years Potential demand in cubic meters Potential demand in tones Total number of Particle /Medium Density Fiber (MDF) Board Plants which can operate, based on the average factory size of 50,000 m3/year Number of new plants, which can be set up every year, in addition to the existing 3 plants in India
2006 13.70 lakh m3 10.27 lakh tons 27 25
2007 22.30 lakh m3 16.72 lakh tons 44 17
2008 31.90 lakh m3 23.92 lakh tons 63 19
2009 42.70 lakh m3 32.02 lakh tons 85 22
2010 54.80 lakh m3 41.10 lakh tons 109 24
Medium Density Fiber (MDF) Board and Particle board is superior to Plywood in terms of quality & applications. Following table makes the direct comparison –
Functions Plywood Medium Density Fibre (MDF) Board Particle Board
1. Wood borers Attracts wood borers Totally borer – proof, as only wood fibres are bonded together Does not attract borers
2. Machining, carving & post-forming Not suitable Highly suitable Suitable to a limited extend
3. Density of the Board Medium Density is medium / high, as required Low
4. Edge cutting & trimming Suitable to a limited extent Highly suitable Suitable to a limited extent
5. Nail & Screw holding capacity Medium High Low to Medium
6. Board strength & internal bond Medium High Medium
Comparison of solid wood to particleboard
Particleboard’s selling points compared to solid timber are its price, its availability in large flat sheets and its ability to be decorated with melamine based overlays. However, it has several other advantages, one of which is its stability. Solid wood is prone to warping and splitting with changes in humidity, whereas particleboard is not. This stability enables new design possibilities, without having to take into account seasonal variations. Untreated particleboard will disintegrate, however, when exposed to high levels of moisture. This problem is somewhat mitigated by laminating the particle board on both sides with melamine resin to reduce moisture ingress.
Solid wood has structural advantages over particleboard. It is stronger, particularly in extension (as required for horizontal spans), allowing it to support greater weights as shelves or other furniture; unless braced or built with thick material, particleboard shelves may visibly sag over time or snap near the fasteners.
Fasteners should be designed specially for particleboard; ordinary screws and nails will not provide the correct holding power over time. Threads may strip, portions of the particleboard may "blow out" when subjected to extension stress. In part this arises from the lack of elasticity in particleboard resins as compared to the long strands and compressible voids contained in solid wood, a feature that while preserved in the manufacture of plywood is compromised in particleboard.
The strength of particleboard, in the context of the application and cost, can offer advantages over solid wood. In cabinet carcase construction, relatively thick particleboard is used (typically ¾"). Particularly in the sidewalls of cabinets, where stress owing to support of loaded shelves or appliances is compressive, particleboard can be an excellent choice. In the context of bending strength, which goes mathematically as the third-power of thickness, the greater thickness of particleboard as compared to thinner grades plywood otherwise used for cabinet carcases may provide indeed greater strength for a given content of wood.Solid wood is more durable than particleboard. Damage to solid wood can be repaired by removing and replacing damaged material then refinishing using known wood treatments that can be matched. Since particleboard is typically faced with by a non-wood veneer, it may be impossible to match the original finish. In addition, damage to particleboard is typified by structural failure and exposure of sizable jagged faults. Damage to particleboard is therefore normally very difficult to repair, usually requiring replacement of the damaged particleboard elements.
The reduced durability of particle board furniture is a consequence of reduced strength in extension. This drawback contributes to damage when furniture is moved; if possible, the furniture should be disassembled to eliminate the possibility of damage in transit.
Most people consider solid wood furniture to be more attractive than particleboard. Recognizing this, furniture makers often cover particle board with real or imitation veneers, in an effort to simulate the look of solid wood.
Comparison of Wood Particle Board & Cow Dung Board
1st time in the history of Particle board or plywood Dr. SK Mittal has developed technology for the manufacture of Particle board by the use of Cow Dung. It is harmless, Echo Friendly, Anti Radiant, Anti Bacterial,. long lasting, high density product having advantages over and above any kind of Board or Ply wood made by the use of any kind of wood. This plant will be instrumental in saving app. 1,50,000 Trees in turn saving fossil fuel making plant eligible for Carbon Credit under Kyoto Agreement. With Echo Friendly mark and BIS IS:3087 Certification, time to come -this product will be opening new horizon in the Plywood-Particle Board industry.
Both products are great for lamination purposes and furniture making industries Particle Board manufacture over the last 7 decades has under gone vast changes and today particle boards are manufactured with exhaustive research binding, anti radiation like qualities of cow dung are established apart from anti bacterial and medicinal qualities of Cow urine these are proved to be valuable industrial input in several processes. Particle board / tiles as is one potential product which can consume cow dung as 50-60% of its raw material requirement. cow dung is purchased and good price is given to breeder, it will prevent him in selling his live stock to butcher. Apart from this holistic approach, a item with inherent binding, anti radiation, lesser weight quality can play wonders in Indian industrial particle board industrial scenario.
With this introduction Govardhan Organics Pvt. Limited has come out with an eco-friendly range of products for the interior industry apart from holistic livestock safety approach. Till recently plywood replaced substantial use of solid wood in the burgeoning furniture industry. However, in the manufacture of plywood, it is difficult to use the roots, branches, upper top, and the interior core of the timber, where is question of using one billion MT every year generating Cow Dung. There are limitations in size, core gap, uniformity, and workmanship of plywood for mass production. Moreover, this leads to cutting of trees and adversely affects the ecological balance. Therefore, in recent past, the use of plywood has been replaced with Particle Boards and MDF Boards worldwide, wherein over 95% of wood available in tree can be used for manufacture of these boards. This is possible due to the process of chipping in the place of peeling and proves to be highly economical, speedy, exceptional as well as eco-friendly.
Construction, furniture, packaging, low cost housing, Sound proofing, Transport like industry needs BOARD, TILES in their activities. A business of 100 billion is consuming precious wood creating a threat to ecology and environment. Live Stock is known as life line of a nation but due to earning incapacity it can be seen sold for slaughter in spite of stringent Act & rules. He or She a cow progeny generates app.10 Kgs of Dung & 7 Liter of Urine. Cumulative national generation is estimated at one billion MT & 700 Million Kilo Liter which has also become a national danger as it is chocking drainage system and forming slit in our tanks and rivers.
ENVIRONMENTAL, SOCIAL & NATIONAL OBJECTIVES –
1. MDF & Particle Board saves virgin forests by using wood wastes of Ply board Industry and of Band saw units.
2. MDF & Particle Board is a wood substitute, saving precious foreign exchange, as large quantities of wood are being imported into India.
3. MDF & Particle Board not only reduces the growing worldwide pressure on the timber industry, but can also address rural environment concerns.
4. MDF & Particle Board Plants located in a rural agricultural area can create new fiber markets, new jobs and can return revenue & benefits directly to the Locals people.
5. At present, MDF & Particle Board are imported into India at high prices. Attaining self – sufficiency in MDF & Particle Board production will, not only eliminate imports but also makes MDF & Particle Board available to consumers at reasonable prices.
6. There is a worldwide shortage of MDF & Particle Board combined with depleting wood sources. India Is strategically located to export the surplus MDF & Particle Board production to the Middle East & Far Middle East / Far East. Even in China, the internal demand is 12 million m3, as against the production of 9 million m3.
7. MDF & Particle Board plants are eligible to secure funds under international carbon trading, as they reduce carbon- dioxide emissions by creating social forestry
C. Key Reasons for success of our Project:
Freight factor: If anybody imports Particleboard or MDF from any country to Delhi (assumed a central location in India) then the freight per cubic meter comes out to be 100$ per cum (around 50% of product cost). This means we will be always able to compete with the international market.
Abundant raw material in theArea Mathura (Brij Mandal is known for its Cow progeny wealth and also Sugar Cane cultivation. With 6.60,000 Cow progeny this District generates 66,000 MT Cow Dung & 45,000 KL of Cow Urine apart from Millions of Tonnes of Sugar Cane Baggas. Our Unit will be consuming not even1% of total availability.
Location: Present location was slected due to proximity to AGRA – Delhi but due to TAJ Corridor pollution restriction, difficulties are being faced. Moreover, Suger cultivation being patronized in Chhata- Kosi Palval Areas, transportation of 5-7,000 MT Baggas will cost RS.5 Million. More over Delhi being main Market, if plant is shifted to KOSI freight advantage of RS. 2.50 million/ year is estimated Hence a Site in UPSIDC INDL Area in Kosi is under finalization.
Promoters MITTALS are known business family having vast experience in the line of construction and running Sri Chamundi Ceramics, a well known name in Building Hardware. DR. SK Mittal
The site is well connected with road and railways route via Kosi station to all major cities of the country and the nearest airport is Delhi. Educated and skilled labors are available in abundance .
PROMOTORS:
Gauvardhan Organics Private Limited is a Private Limited Company incorporated with Authorized Capital of RS.50,00,000/- with Registrar of Companies UP & Uttranchal vide Regn. No. U74999UP2009 PTCO 38544 on. 29th October, 2009 for manufacturing of Particle Board & other organic Products based on Cow progeny & Agro Waste.
Looking into the great demand and viability of Particle Board and MDF board the firm is interested to set up 20000 cubic meter Particle Board Plant in Mathura District. Initially, it was planned at B Site UPSIDC Indl. Area Opp . IOC Refinery Mathura & necessary SSI / KVIB/ S. Tax and other registrations obtained and commenced production. Looking the large area requirement and also proximity to Sugar Cane Baggas Area being Kosi-Chhata-Palwal belt & also nearness to main Market Delhi it is planned to shift to UPSIDC Indl. Area Kosi – Mathura District. Land measuring 6270 Sq. Mtr & Building (in depleted condition) app. 15,000 sq ft has been negotiated which will require investment of RS 110 Lakhs and suitably incorporated in the Project Report.
Being totally NON WOOD Consuming plant with Technology developed & Patented by DR. SK Mittal, which will be instrumental in saving 1,00,000 trees/ year apart from saving millions of cow progeny. Hon’ble Agriculture Minister Utter Pradesh Sri Lakshmi Narayan Chaudhary has announced all kind of assistance and enragement to this unit.
Apart from State Subsidy there are number of incentives as per Industrial Policy of Govt. of Utter Pradesh.
BIS Standard Specification PHYSICAL AND MECHANICAL PROPERTIES OF PLAIN &
PRE-LAMINATED PARTICLE BOARDS GRADE I – EXTERIOR GRADE GRADE II – INTERIOR GRADE
Sr. No Properties Unit PlainParticleBoards
IS 3087 Pre-laminated
Particle Boards
IS 12823
Grade-II Grade-I Grade-II Grade-I
1 Density Kg/m3 500-900 500-900 500-900 500-900
2 Density Variation % +/-10 +/-10 +/-10 +/-10
3 Moisture Content % 5 to 15 5 to 15 5 to 15 5 to 15
4 Modulus Of Rupture
Up to 20mm thickness
Above 20mm thickness
N/mm2
11
11
15
12.5
11
11
15
12.5
5 Tensile Strength Perpendicular To Surface
a) After cyclic test
b) Accelerated water
resistance test N/mm2
0.2
0.15
0.2
0.15
6 Water Absorption
2 Hours
24 Hours %
40
80
10
20
15
30
7
15
7 Thickness Swelling, 2Hours
Soaking, Thickness, Length, Width % 12
0.5
0.5 8
0.5
0.5 8 5
8 Swelling Due To Surface Absorption % 9 6
9 Tensile Strength Perpendicular To Surface
Up to 20mmthickness
Above 20mmthickness N/mm2
0.3
0.3
0.45
0.40
0.3
0.3
0.45
0.40
10 Screw Withdrawal Strength
Face
Edge N
1250
700
1250
850
1250
750
1250
800
11 Abrasion Resistance
1) Type I
2) Type II
3) Type III Revolution
450
250
80
450
250
80
F. MARKET FOR MEDIUM DENSITY FIBRE (MDF) BOARD & Particle board: Since its invention during 1960’s, MDF & Particle board became the market leader in Panel Board applications. MDF & Particle Board exceeds Wood, Plywood in terms of quality & applications. The properties of edge cutting, post- forming, nail holding, bonding & moisture resistance are far better in MDF & Particle Board. We cannot think of modern wood decorations in houses & offices without MDF & Particle Board. They are used for doors, windows, kitchen & office cabinets, drawers, tables & chairs, furniture, indoor stadiums, auditoriums and entertainment halls. They are also used for interior decorations for offices, houses, hotels & restaurants. More & more applications of MDF & Particle Board are being invented now days.
The worldwide market for MDF & Particle Board is increasing at a faster rate of 12% – 16% per annum. The international market prices of MDF Board range from $250 – 310 per m3. The international prices of Particle board range from 175$-200$ per m3.
MDF & Particle Board is engineered wood. Excellent machinery & application properties makes MDF & Particle Board an economic & future-oriented substitute of solid timber. The uses of MDF & Particle Board are limited only by imagination. Doors, windows, furniture, partitions, panelling, packaging, almost everything wood can do better. MDF & Particle Board are flawless, smooth & uniformly strong, easy to cut, machine & joint. MDF & Particle Board won’t splinter or crack. MDF can also be carved like natural timber. MDF & Particle Board can be made available for interior & exterior grades, plain or laminated. The possibilities from MDF & Particle Board go on & on. MDF & Particle Board has made every other wood belong to the past. High Density Fiber board can be used to make wooden floorings.
MDF & Particle Board have the durability, look, texture, richness & feel of seasoned-treated timber, providing the following advantages –
- No knots or grain - Homogenous, super smooth surface - No seasoning required
- No warping, cracking or splitting - Free from termites & fungus - Moisture resistant
- Fire retardant - Uniform strength in all directions - Unbeatable mach inability
- Compatible with all kinds of finishes - Cuts wastage & production costs.
G. RAW MATERIALS FOR MDF & PARTICLE BOARD –The manufacturing of MDF & Particle Board uses the waste wood, firewood and waste of existing plywood and band saw units which will help in reducing the pollution created by the wood waste of mainly wood based industry.
1. Waste of plywood industry and band saw unit;
2. Wood cuttings & trimmings from sawmills;
3. Sawdust & furniture industry wastes;
4. Lops & tops of poplar & eucalyptus and other similar social forestry
5. MDF & Particle Board from Waste The manufacturing of MDF & Particle Board uses the agro wood, waste wood, and waste of existing plywood and band saw unit which will help in reducing the pollution created by the wood waste of mainly wood based industry.
The saw milling industry, consisting of more than 23,000 units utilizes bulk of the industrial round wood in India. It is estimated that each sawmill will generate 100 – 120 tons of sawdust & wood cuttings per year on an average and make available totally 2.5 million tons of wood wastes, which can provide necessary raw material for more than 50 new MDF & Particle Board.
The Plywood industry produces around 220 Million Sq.Mt. of plywood annually that is around 30 lakh tons of plywood, which generates wood cuttings and dust etc. approximately 20 lakh tons which can be utilised for MDF & Particle Board Plant.
D. MANAGEMENT Company is managed by Board of Directors namely Dr. SK Mittal, Mr. Nitin Kumar Mittal, Chetan Kumar Mittal, apart from professional expertise. At present directors are engaged in Building Hardware business with their mother in the name & style Sri Chamundi Ceramics, the Biggest Ceramic Mall of Mysore city- Present bankers are J&K Bank Limited, Mysore. All are regular income tax payers educated and with full of working experience, market potential & resources.
Key Personnel. DR. S K Mittal Chairman aged 58 Years B.com (Hons.) from Delhi University LLM, P.hD from Belford University USA a known Social Worker & pioneer in this direction of this project . Served as Member Animal Welfare Board of India, Min. of Env., & Forest Govt of India, Member Kerala State Animal Welfare Board and National Executive Committee & South India In charge Govans Vikas Prokost. Recipient of Udyog Patra by the gracious hands of His Excellency President of India Dr. Shankar Dayal Sharma, Udyog Ratna by His Excellency Governor Sri Bhishm Naarayan Singh, Karuna Sagar Award by Hon’ble S. K Patil apart from many laurels citations.
With his was experience in serving cow progeny raw material availability to the tune of 1300-1400MT per day from the waste of the existing he developed many products by the use of Cow dung & Cow urine like Particle Board and applied for Patent on Technology. Looking great advertise value in the field of Service to Speechless Cow Progeny Dr.Mittal selected Mathura for manufacturing activity and installed World’s 1st Cow dung basedParticle Board Plant few months earlier. Looking the VAST market scope
Shri Nitin K Mittal Director Aged 36 Years with Commerce Graduation, a well experienced one of the DIRECTORS of the project and will be looking into the aspects of finance, management, procurement, infrastructure and closely co-ordinate with other promoters in accomplishing the tasks as per the schedule for implementation of the project. Mr Nitin K. Mittal is in charge of the plant who has over 15 years experience in the line of tiles, ceramics.
Shri Chetan K. Mittal Director Aged 30 Years with Commerce Graduation, a well experienced one of the DIRECTORS of the project and will be looking into the aspects of finance, management, procurement, infrastructure and closely co-ordinate with other promoters in accomplishing the tasks as per the schedule for implementation of the project. Aged 30 Year young Graduate entrepreneur one of the DIRECTORS engaged in family business of Building Hardware with marketing experience will be handling project marketing. Mr Chetan K. Mittal is in charge of the Marketing who has over 10 years marketing experience in the line of tiles, ceramics.
PARTICLE BOARD MANUFACTURING PROCESS –
Till now PARTICLE Board making Plants are designed to utilizes low-cost wood wastes, saw dust, & waste of ply board industry lops and tops of plantation forests viz eucalyptus and poplar as the raw material. A big danger to Echology and environment. A new process has been developed by DR. SK Mittal eliminating the use of any kind of wood and to consume Cow dung available in abundance in each and every corner of country. The result is a quality & highly versatile panel product with unlimited applications in furniture, packaging construction & related industries.
Particle Board is nearest to the natural wood among all wood-based panels. Particle Board has the most extensive applications because it possesses many merits such as smooth face, uniform core layer, superior performance of machining and shaping at the surface & edge.
The Particle Board production line mainly includes chipping, screening, flaking, glue preparation, drying, mat forming, pre-pressing, loading & unloading, hot pressing, edge trimming & sanding. The process starts from the wood yard of wood, wooden chips wood waste/ saw dust yard, which is designed to ensure continuous & un-interrupted supply of wood for the following stages–
Particleboard Fiber arrangement
O PLANT & MACHINERY FOR PARTICLE BOARD PROJECT
1 Hammer Mill to crush 1 Set
2 Dryer 2 Sets
3. Conveyor System 3 Sets
4 Multi Size Vibration Separator 1 Set
5 Resin Plants including reactors, storage tanks & pipelines - 1 set
6 Thermal fluid heaters, air compressors Exhaust , and other utilization 1 set
7 Particle Board production line complete individual equipments lined up for production, with a capacity of 20,000 m3 / year(15,000 tons), 8’X4’ & 4’ X 3’ size
8. DD Saw Cutting Machine
9. Surface Sanding Machine
10 Cooling Chambers
11 Electrical control panels, motors, starters & cabling - 1 set
12 Erection, commissioning, trial run & training the staff
The project is planned to provide an alternate to the plywood. Since manufacturing of plywood leads to cutting of invaluable forest cover, therefore the Particle Board as well as is the future requirement of India. The manufacturing of Particle Board uses the waste wood, firewood and Saw Dust and waste of plywood industry and waste of furniture industry. This will also help in reducing the pollution created by the wood waste of many wood based industries. The proposed project will give employment to more than 500 persons in the state in addition to the employment by the small ancillary units came up with the establishment of the proposed project.
P. TECHNICAL SEQUENCE IN BRIEF OF PARTICLE BOARD LINE
FLOW CHART
Photo Diagram of Particle Board a product developed by the use of Dung & Agro Waste
By Dr. SK Mittal B.Com (Hons) LLM, P.hD
.
Top Surface Inner Portion showing Cow Dung & Fiber Corner & Side Position Side internal position
Another top and side position International Core Position Side & Middle position
PROCESS FLOW DIAGRAM FOR THE PRODUCTION OF PARTICLE BOARD – DEVELOPED by DR.SK Mittal B.Com (Hons) LLM. P.hD
Cow Dung Cake making & Drying Cutting Crushing
Sugar Mill Bagass Drying Cutting Crushing Sieving
Glue Mixer Cattle Body Mixture Tray Casting Pre Press
Boiler Hydraulic Power Press Board Drying Raw Board
DD Saw Cutter Sanding Machine Pasting Machine Cold Press
Plain Veneer + Laminated Reinforced High Tensile
Particle Board Plain –Veneer – Laminate Laminated - Water proof-Heat Resistant-Anti Radiant- Termite Proof – high tensile Echo friendly Particle Board made by the use of Dung & other agro Waste Thickness 3 mm to 45 mm in different Sizes for different uses.
Different Uses of Particle Board
Carving Toys Partition Modular Furniture Dressin g Table Office Furniture Sound Box Office Furniture
Dressing Table Shiel d Ash Tray Prefab Hut Modular Furniture TV TROLLY Floorings.
This line comprises chipper, flakes preparation section, drying and sifting section, glue regulating and applying section, forming and hot pressing section, rear-processing section and sanding section.
1. Drying section Raw material is sun dried in open yards before feeding to Crushing Hammer mill.
2. Drying and Screening Section The dried Cow Dung & Sugar Cane Bagasse is Crushed and dust parts removed & conveyed by a screw conveyer to the rotary dryer, to dry until its water content meeting technical requirement, then transported by a fire-proof screw to a swing screen and blow to a wind separator. Oversize flakes are send to double-stream mill to be re-crushing, together with fine flakes from the separator, are blown to surface flake bin. Qualified flakes come from the separator are sent to core flake bin.
4. Size bifurcation – Material is passed through Agitator Sieve for grading and size bifurcation
3. Glue regulating and applying section After scaling, the core and surface flakes are to be effectively and uniformly mixed with qualified glue in the blender. Usually urea formaldehyde resin is used as the binding agent in the blender Glue is made from urea-formaldehyde, wax emulsion and ammonia chloride etc according to reasonable proportion.
4. Forming and hot-pressing section The surface and core flakes are sent into forming Table and forming which features by top and bottom layer with fine flakes, coarse flakes in the core layer, gradually changed structure.
The Loose mat is fed to the continuous prepress and compact mat formed. This mat is fed to the hot press after being cut to desired length and width cut by longitudinal and crosscutting saw,. Mat after pressing will be transported to next process by conveyors. The stacked raw board will be shifted to the storage godown for curing.
6. Sanding section The boards will be sent to sanding machines to reach a high quality surface.
Q Building area requirement for MDF/ Particle Board Plant
a) For Plant & Machinery 10,000 sq. ft.
b) For Plant & Machinery outside the main building (only roofing & side covering required)
2,000 sq. ft
c) For storage & dispatch 5,000 sq. ft
d) For security, office, stores, workers changing room, canteen, R & D, laboratory, utilities etc.
1,500 sq. ft
18,500, sq. ft
e) Cow dung / Bagasse storage yard 50,000 sq. ft
Minimum total required land area 68,500 sq. ft.
6. Estimated total land requirement 6270 Sq. Mtr
R. Details of cost of the project: (Rs.in Lakhs)
i. Land 85
ii. Building – Factory - Non Factory 70
iii. Plant & Machinery 155
iv. Misc. Fixed Assets 12
v. Pre-operative Expenses 12
vi. Security Deposits 6
vii. Contingencies 10
viii Margin Money for working Capital 30
TOTAL 380
1. Land The project is planned in UPSIDC INDL AREA KOSI at 6.270 MTR land at Industrial Park at The cost of land including land and site development is Rs85 lacs.
2. Civil Work Construction of Building with area of 18,500 sq ft @ amounting to Rs70 Lacs has been considered.
3. Plant & Machinery The cost of plant & machinery has been estimated based on orders placed and Performa invoices received from suppliers the details are at RS.155.00 Lakhs
5. Pre-operative expenses
Pre-operative expenses of Rs.5.00 lakhs are mainly on account of traveling expenses, interest during construction, cost on labour, employees, foreign travel, statutory expenses, etc. The project has gestation period of 14 months till the date of trial production.
6. Interest during construction
Since the production is likely to commence from April 2009, the interest has been worked out as per the loan drawl schedule, which is given as a part of the project report. The disbursement for the term loan will commence from January, 2008. It is also proposed that advance for the equipments shall be paid out of proposed contribution to be brought in by Promoters. The Interest during construction has been estimated at Rs.1000.00 lakhs and same is capitalized on a pro-rata basis to respective assets
All the above raw materials (Paper, Chemicals, Resin, PVC & Wood etc.) are easily available in market. The company in the up stream project shall manufacture main raw material i.e Particle Board, MDF & Impregnated Paper, which will be used for making value added products. None of the item required by the company is proprietary or patented in nature.
7. Contingencies
Provision for contingencies has been considered @5%of the civil work, and misc fixed assets 2%on plant & machinery, and preoperative expenses to cover cost escalation and unforeseen expenses
8. Margin Money for Working Capital
The working capital requirement has been worked on the basis of raw material levels of 60 days, work in progress of 3 days and finished goods of 30 days, 15 days credit period from suppliers and 45 days credit period to customers have been considered
The total net requirement of the company works out Rs 5544 lacs. The margin money requirement works out to be Rs1386 lacs , which has been provided in the project cost. The increase in margin money requirement in future years will be met through internal accruals.
U. MEANS OF FINANCE:
The project is proposed to be funded by term loans from banks and equity contribution from promoters in debt equity ratio of 2.33:1 .The proposed means of finance are as under:
Particulars Cost (Rs Lacs)
Promoter’s contribution 100
Term Loan 220
Total 320 Promoters contribution The total promoters contribution is 30-32 % of the project cost which is already brought as Paid up Capital RS.50.00 Lakhs & Unsecured Loans RS.50.00 Lakhs.
Term Loan The company proposes to part finance the project through term loan of Rs 220 lacs in two phases. RS. 100 Lakhs immediately & RS.120 Lakhs at the time of purchase & shifting of Plant at new site.
V. Marketing & Selling Arrangements:
As the Pilot project was launched few months earlier and marketing set up is already in hand in AGRA, Mathura, Delhi, and even.in South India. Export negotiations are on with US, Madagascar, Gulf buyers
Power Consumption:.
The total requirement of power at full capacity has been estimated at 140 KW utilization, operational load is estimated at 80 kw.The Firm will approach for sanction of power from UP State Electricity Board.. The Company has installed 70 KW DG Set for emergency operations, meeting office and general lighting requirements and the process requirements of critical machines..
Heat Required (K. Cal.)The estimated requirement of heat for various sections of the plant is met by Hot Hoter Generator / Steam Boiler of 2 MT Capacity.
Water The total requirement of water in the operation of the firm is estimated at 7.5 K. Ltr. per day. Manpower
Total Manpower requirement (Plant) -
Particular No.
Works Manager 2
Manager 3
Supervisor 6
Skilled Labor 35
Un-skilled 34
Total 80 Total Manpower requirement (Administrative & Marketing)
GM Finance 1
GM Marketing 1
Marketing 5
Administrative / Office Staff 8
Grand total 15
We are in the process of recruiting manpower for the project and some persons have been already appointed. We are looking for both skilled and unskilled manpower across various functional areas and ensure their technical / professional competence. We are looking at recruiting personnel from various parts of the country.
Our proposed projects being located at ELDECO SIDCUL INDUSTRIAL PARK SITARGANJ in the State of Uttarakhand, which is an established industrial town, we do not foresee any difficulty in the availability of and recruitment of the requisite quality manpower.
Effluents: In the manufacturing process of all the products there are no major solid, liquid or gaseous effluents having need to treat them before disposal,. The Company will obtain NOC from the Department of Pollution of the State Government. The entire project will be commissioned as per the Norms established by pollution Control Board
Expected Capacity/ Turnover for – All Products (in Cubic meters./ Kilo Ltrs )
% Capacity utilization 2010-11 2011-12 2012-13
Particle Board 60% 80% 90%
Thickness Total
9 mm
12 mm
18 mm
26 mm
31 mm 10%
30%
20%
30%
10%
Capacity 21,000
Cubic Mtr /year
12,600 RS.936 Lakhs 16,800
RS. 1248 Lakhs 18,900
RS.1435 Lakhs
Cow Urine based Products 120KL
Phenyl
Distilled Cow Urine
Shampoo
Han d Wash
Mosquito Repellant Oil Etc. 720KL
RS.180 Lakhs
960 KL
240 Lakhs 1080KL
270 Lakhs
GAUVARDHAN ORGANICS PVT LIMITED
MANUFACTURING - TRADING, PROFIT AND LOSS ACCOUNT FOR THE YEAR ENDING:
<----- 31st March ending ----->
Particulars 2010 2011 2012 2013 2014 2015 2016 2017
Estimated Projected Projected Projected Projected Projected Projected Projected
Installed Capacity 1100 1100 1100 1100 1100 1100 1100 1100
Utilized capacity 20.45% 36.36% 46.36% 54.55% 60.00% 60.00% 60.00% 60.00%
Sales Net 225.00 400.00 510.00 600.00 660.00 660.00 660.00 660.00
Excise 24.11 42.86 54.64 64.29 70.71 70.71 70.71 70.71
Clog Stock WIP & FG 15.00 21.00 21.00 21.00 21.00 21.00 21.00 21.00
TOTAL 264.11 463.86 585.64 685.29 751.71 751.71 751.71 751.71
Opening Stock - 15.00 21.00 21.00 21.00 21.00 21.00 21.00
Purchases 66.00 84.50 102.00 120.00 132.00 132.00 132.00 132.00
Carriage In words 22.50 40.00 51.00 60.00 66.00 66.00 66.00 66.00
Closing Stock of RM 6.00 7.50 7.50 7.50 7.50 7.50 7.50 7.50
Cost of RM Consumed 82.50 132.00 166.50 193.50 211.50 211.50 211.50 211.50
Consumables 6.75 12.00 15.30 18.00 19.80 19.80 19.80 19.80
Power Charges 28.13 50.00 63.75 75.00 82.50 82.50 82.50 82.50
Coal & other fuel exp 4.50 8.00 10.20 12.00 13.20 13.20 13.20 13.20
Insurance 0.21 0.22 0.23 0.24 0.26 0.27 0.28 0.30
Freight, Cartage 22.50 40.00 51.00 60.00 66.00 66.00 66.00 66.00
Repairs & Maint. 3.38 6.00 7.65 9.00 9.90 9.90 9.90 9.90
Duty paid 24.11 42.86 54.64 64.29 70.71 70.71 70.71 70.71
Wages 11.27 33.80 36.50 39.42 42.58 45.98 49.66 53.64
Cost of production 183.33 324.88 405.78 471.45 516.45 519.87 523.56 527.55
Gross Profit 80.77 138.98 179.86 213.83 235.27 231.85 228.16 224.17
Other income 0.19 0.34 0.43 0.51 0.56 0.56 0.56 0.56
Administrative & Selling expenses:
Advertisements exp 0.60 1.20 1.32 1.45 1.60 1.76 1.93 2.13
Bank charges 2.50 0.25 0.28 0.30 0.33 0.37 0.40 0.44
Audit fee 0.25 0.30 0.32 0.33 0.35 0.36 0.38 0.40
Carriage Outwards 2.81 5.00 6.38 7.50 8.25 8.25 8.25 8.25
Donations 0.10 0.11 0.12 0.13 0.15 0.16 0.18 0.19
Estab. Exp 0.18 0.33 0.35 0.36 0.38 0.40 0.42 0.44
Misc expenses 0.14 0.22 0.24 0.27 0.29 0.32 0.35 0.39
Postage, telephone 0.21 0.48 0.53 0.58 0.64 0.70 0.77 0.85
Printg and Stationery 0.31 0.28 0.29 0.31 0.32 0.34 0.36 0.38
Professional Tax 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
VAT Renewal 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Rent leasing charges 0.60 1.26 1.32 1.32 1.32 1.32 1.32 1.32
Gl. Rep. & Maint. 0.06 0.15 0.16 0.17 0.19 0.20 0.22 0.23
Salary to staff 6.93 20.80 23.92 27.51 31.63 36.38 41.84 48.11
Royality / Comm. 11.25 20.00 25.50 30.00 33.00 33.00 33.00 33.00
Travel and Conveya 0.30 0.60 0.63 0.66 0.69 0.73 0.77 0.80
VAT - Net 12.50 22.22 28.33 33.33 36.67 36.67 36.67 36.67
PBDIT 42.19 66.09 90.58 110.08 119.98 111.41 101.83 91.09
Int. on Workg Capital 4.03 4.23 4.15 4.07 3.98 3.90 3.83 3.75
Interest payment 12.33 23.42 19.56 15.61 11.67 7.72 3.78 0.41
PBDT 25.83 38.43 66.88 90.40 104.33 99.79 94.22 86.93
Depreciation 12.50 20.75 18.68 16.81 17.23 17.90 18.61 19.25
PBT 13.33 17.68 48.20 73.59 87.10 81.88 75.61 67.67
Taxation 2.67 5.31 14.46 22.08 26.13 24.56 22.68 20.30
PAT 10.66 12.38 33.74 51.51 60.97 57.32 52.93 47.37
Net profit to cap. A/c 10.66 12.38 33.74 51.51 60.97 57.32 52.93 47.37
GAUVARDHAN ORGANICS PVT LIMITED
BALANCE SHEET AS AT <----- 31st March ending ----->
Particulars 2010 2011 2012 2013 2014 2015 2016 2017
Authorized Capital Estimated Projected Projected Projected Projected Projected Projected Projected
50,000 Shares of Rs. 100each 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00
Issued, Sub. & Paid up Capital 50,000 Shares of Rs.100 each 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00
Unsecured Loans 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00
General Reserve
P&L Account 10.66 23.04 56.79 108.30 169.27 226.59 279.51 326.89
Term Loan 170.00 147.33 120.13 92.93 65.73 38.53 11.33 -
Working Capital 45.00 55.00 55.00 55.00 55.00 55.00 55.00 55.00
Creditors for materails 4.58 7.33 9.25 10.75 11.75 11.75 11.75 11.75
Others 1.46 2.83 3.41 3.94 4.40 4.68 5.01 5.39
Total 316.71 320.54 329.58 355.92 391.15 421.56 447.61 484.02
Fixed Assets 207.50 186.75 168.08 172.27 179.04 186.14 192.52 198.27
Deposits – Non Current 32.50 32.50 32.50 32.50 32.50 32.50 32.50 32.50
Receivables 45.00 66.00 85.00 100.00 110.00 110.00 110.00 110.00
Stock 21.00 28.50 28.50 28.50 28.50 28.50 28.50 28.50
Cash on hand/Bank 10.71 6.79 15.50 22.66 41.11 64.42 84.08 114.75
Total 316.71 320.54 329.58 355.92 391.15 421.56 447.61 484.02
Prepared by:-
Prakash Shri Krishan & Co Dr. SK Mittal B.Com (Hons) LLM, P.hD
Chartered Accountants Chairman Gauvardhan Organics P. Ltd
Mathura Mathutra
DT.21th Dec., 2009
Manager
IDBI Bank Limited
Mathura
Dear Sir,
Greetings to you,
On behalf of million250 National & millions of Cow progeny of Utter Pradesh most out of 150 million GO BHAKT of Utter Pradesh residents, & my behalf, I extend warm thanks for curtsey extended by you during our visit to Mathura Branch of IDBI Bank Ltd and interest shown by you in the project.
As desired please find attached Project Profile for the Manufacture of Particle board and other Products based on Cow Dung and Cow urine
Government Policy In 1997, the Supreme Court restricted the cutting of trees for manufacturing plywood as it required huge quantities of fresh wood and other ligneous wastes. Faced with the task of developing environment-friendly technology for industry due to guidelines issued by the Supreme Court, entrepreneurs are realizing the cost-effective potential of such technologies and innovations. Apart from all kind of enragement for Agro based, Rural industry for employment generation.
Gauvardhan Organics Pvt Ltd has planed to produce particle board and pharmaceutical & FMCG products by the use of non-conventional raw material, cow dung, Cow Urine ,Cow Milk, Agro & Forest Waste & rural man power.
LOCATION : We have selected Mathura District because of location advantage apart from availability of Raw material. Mathura District is blessed with 6,50,000 cow progeny generating app 6500 MT Cow Dung & 4200 KL Cow Urine every day. More than 50,000 Hectare land is under Sugar cultivation in this District apart from much more hectares in nearby Districts. Mathura is surrounded by large cities like Delhi, Faridabad, Agra, Jaipur etc which are fast growing and potential markets with 2-3 hours distance say with in 50-150 KMS.
Land Requirement :Less than one Hectare .
Electric Power : 140 KW
Workers : 100 Directly
Advantages Apart from other general advantages our project will be a boon for the Rural development and village empowerment by
1) Purchasing cow dung & cow urine at best price.
At present breeder is not getting any money or RS.200-250/- per MT for cow dung whereas we propose to pay RS. 1500/- per MT Total quantity estimated at 200000 Kgs per day
Cow urine- there is no use and buyer till date where as we propose to pay RS 4,000/- per Kilo Ltr. It will bring a market Government of Uttranchal has announced opening of Cow Urine Dairy .
2) Our project will work as a Training Center also for the interested breeders & Farmers in many products which they can make and supply
3) We will be providing Organic products made by the use of Cow dung & Cow Urine in turn will help in health & hygiene of the area population.
4) Our project will provide employment directly thousands families and indirectly to families inwhole area
5) Our project will save ecology by saving 1,50,000 trees every year by producing app. 20,000 MT Particle Board apart from Organic Wood Sticks (Havan Samidha), Gojal (Distilled Cow Urine) Hand Wash, Shampoo, Mosquito Repellant Coil & Liquid , Craft Paper, & many innovative items.
6) Our project will generate revenue for the state with projected turnover of RS. 150 Millon / year.
Process The basic raw material used in the manufacture of particle board will be cow dung. This will perhaps make it the first particle board manufacturing facility using cow dung as the raw material. Particle Board emerging as a viable alternative in designing office furniture, Construction, Sound speakers, Lamination and automation products in inland & overseas markets as compared to wood /Ply Boards. Domestic demand has been posting over 10,00,000 MT a year with annual growth of 10%
Technical Know how We will use a technology developed by DR. SK Mittal with his vast experience, for which Patent is also in process, for the manufacture of particle board from cow dung, , making the end-product cheaper than the conventional products available in the market. The range of products included Particle Board of varying thickness ranging from 8 mm to 45 mm. Depending on thickness, different compositions of up to 80 per cent cow dung mixed with binder & fibrous material like Coir/bagasse according to required application.
We have also planned for the manufacture of allied cow progeny waste based products, which was expected to begin production by the next fiscal year..
Marketing State itself are consuming thousands of tones of Particle board importing from Bangladesh- Indonesia and also from Maharastra & Gujarat by spending freight RS.4-5/- per Sq.feet.
Plant & Capacity We propose to install Particle Board Manufacturing Plant with 70 Cub. Mtr - 40 MT / day Capacity size 4' X 8' & bigger size Boards with required lamination, coating, reinforcement which will be consuming Dry cow dung app. 20 MT / day 6,000 MT/year
Cow Urine Distillation Plant with 3.5 Ltr/ day Capacity. 12000 KL/ year
Project Cost is estimated in 1st phase at RS. 320 Lakhs in which Equity participation of RS.50.00 Lakhs & Unsecured family Loans worth RS.50.00 Lakhs are already invested.
There is no gestation period as project has been installed & inaugurated in the holy presence of Karshni Sri Sri Gurusharnanand Ji of RamanReti Gokul and by the auspicious hands of Hon’ble UP Agriculture Minister Chaudhry Lakshmi Narayan Ji & Agra MP Loksabha Sri Ram Shankar Ji Katheria.
With social and rural uplift ,savior of Cow progeny, Health & Hygiene, women empowerment we feel that this unit be a Land Mark in the history of Ecology, Environment, Rural Development & Employment, Use of Agro & Animal generated waste being world’s 1st Cow dung based Particle Board plant, a process developed and r for which undersigned has proceeded for Patent.
Request: Total Requirement Term Loan for Land & Building, Plant & Machinery RS. 220.00 Lakhs
1st phase RS. 50.00 Lakhs,
2nd Phase RS.120.00 Lakhs
Working Capital Facilities RS. 50.00 Lakhs
Total RS.220.00 Lakhs
Securities offered : Plant & Machinery, Stocks, Receivables in 1st phase
Land & Building, Plant & Machinery, Stocks, Receivables in 2nd phase (April-June,2010)
We will be glad to furnish information as and when desired at your end and request you to please consider our project on merit, & oblige.
With RegardsYours in service to speechless animals
DR. SK Mittal Chairman & MG. Director
Gauvardhan Organics Pvt. Limited
(Helping Hands are more hoiler than speaking lips)
