ACNielsen ORG-MARG
Situation Analysis for SME
Sector
Submitted to TERI
By
Jamnagar Cluster
ACNielsen ORG-MARG
SUMMARY OF FINDINGS
• There are approximately 1000 units in this cluster who are engaged in manufacture
of various types of brass related products.
• ANNUAL TURNOVER
Annual Turnover (In crores)
3
12
3739 36
2720
1611
6 61 1 2
97104
111
0
25
50
75
100
125
2005-06 2006-07 2007-08
Upto 1 crore 1 to 3 crore 3 to 5 crore
5 to 7 crores 7 to 10 crores Above 10 crores
ACNielsen ORG-MARG
➢ PRODUCTION
Annual Production (In Tonnes)
5055
86
3438
21
7
19
3
3126
9104 3
85
13 3 1
31 32
67
0
10
20
30
40
50
60
70
80
90
2005-06 2006-07 2007-08
Upto 200 Tonnes 200 to 300 Tommes 300 to 400 Tonnes 400 to 500 Tonnes
500 to 750 Tonnes 750 to 1000 Tonnes 1000 to 1500 Tonnes Above 1500 Tonnes
ACNielsen ORG-MARG
➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per annum Number of Units using the fuel
Electricity 16275625 Units 198
Coal / Hard Coke 59777 Tonnes 191
Firewood 4425 Tonnes 7
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
Usage of Electricity (In Units consumed per annum)
8%
27%
29%
12%
14%1%9%
Upto 20000 Units
20000 to 40000 Units
40000 to 60000 Units
60000 to 100000 Units
100000 to 200000 Units
200000 to 500000 Units
Above 500000 Units
• USAGE OF COAL / HARD COKE (IN TONNES PER ANNUM)
Usage of Petro Coal (In Tonnes per annum)
3%3%
18%
52%
8%
16%
Upto 40 Tonnes
40 to 60 Tonnes
60 to 100 Tonnes
100 to 500 Tonnes
500 to 2000 Tonnes
Above 2000 Tonnes
ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
Qty consumed per annum Number of Units using the raw material
Brass 295067 Tonnes 155
Iron 13850 Tonnes 29
Clay 41925 Tonnes 100
Sand 36521 Tonnes 49
• USAGE OF BRASS (IN TONNES PER ANNUM)
Usage of Brass (In Tonnes per annum)
23%
6%
36%
25%
3%
3%
4%
Upto 100 Tonnes
100 to 200Tonnes
200 to 300 Tonnes
300 to 500 Tonnes
500 to 1000 Tonnes
1000 to 10000 Tonnes
Above 10000 Tonnes
• USAGE OF IRON (IN TONNES PER ANNUM)
Usage of Iron (In Tonnes per annum)
14%
14%
36%
34%
2%
Upto 200 Tonnes
200 to 500 Tonnes
5 to 10 Tonnes
500 to 1000 Tonnes
Above 1000 Tonnes
ACNielsen ORG-MARG
• USAGE OF CLAY (IN METRES PER ANNUM)
Usage of Clay (In Tonnes per annum)
2%
39%
41%
18%
Upto 1250 Tonnes
250 to 500 Tonnes
500 to 1500 Tonnes
Above 1500 Tonnes
• USAGE OF SAND (IN TONNES PER ANNUM)
Usage of Sand (In Tonnes per annum)
6%
39%
16%
37%
2%
Upto 250 Tonnes
250 to 750 Tonnes
750 to 1500 Tonnes
1500 to 2500 Tonnes
Above 2500 Tonnes
ACNielsen ORG-MARG
FIELD OBSERVATIONS
✓ Jamnagar is known as the hub of Brass components.
✓ The major areas where the units are located - GIDC (Phase-1, 2), Patel
Colony, M.P.Shah Industrial Area, Hapa Industrial Area & 46 Digvijay Plot
✓ Majority of the units in this cluster are family owned business, which through
experience, trials have grown over the years. All the units are using the local
technology and there has been no outsource of technology.
✓ The units are normally working for 10-12 hours; very few units are running for
all the shifts.
✓ Brass scrap, which is imported from Kandla port, has registered a hike of 300
per cent in the last two years from Rs 80 to Rs 265 per kg
✓ Major energy consuming equipments are Blower, Lathe machine, Cutting
machine/ Pantograph, Electric Furnace, Annealing Furnace.
✓ The major raw material is scrap, which is being imported, and sometimes due
to shortage as well as high price the units are working partially. Majority of the
units are sourcing the scrap through brokers/ traders. The current rates have
fallen by nearly 30%
✓ Customs duty on imported brass is now more than double. As a result, there
has been a backlog of nearly 300 brass scrap containers lying at the Kandla
Port in Kutch district.
✓ With a total brass consumption of 50 lakh containers per month, each weighing
20 tonnes, Jamnagar accounts for 80 per cent of the total brass components
(electrical, automobile or sanitary) produced in India.
✓ There are two types of units, one that are completely integrated and have
electric furnace & use scrap, waste have the testing facilities – spectrometer to
test the content of Cu in the total melt. The other type of units which are spread
across in each & every area that is melting in crucible / underground bhatti,
wherein the raw material is machining waste / powder.
✓ The various grades being manufactured are IS 319 which has 56% Cu and is
used largely for hardware products. Other grades such as IS3488 are used for
locks wherein Cu is 50 –55%. IS3488 is the forging grade which has 60.5 –71%
Cu used for LPG valves.
✓ The major products are Brass Rods, Profiles, and Sections etc.
ACNielsen ORG-MARG
✓ The normal time taken is I hour 20 min for melting 300 kg wherein the molten
metal is pored in moulds for making billets.
Electricity
❖ Supplied by Gujarat State electricity board.
❖ Getting 24 hr power supply ( weekly off on Wednesday)
❖ Per unit rate Rs. 5.50/-
❖ Energy/Fuel cost is 15 to 20% of total production cost.
Major equipments are
❖ Electric Furnace / Crucible/Bhatti
❖ Annealing Furnace
❖ Blower
❖ Extrusion Press
❖ Cutting machine
❖ Sand muller
❖ Pantograph/Lathe
Raw materials
❖ Brass Scrap
❖ Zinc
❖ Aluminum
❖ Copper
✓ Major products like Brass Screws, Brass Nuts, Brass Fasteners, Brass Inserts,
Brass Screws, Machine Screws India, Brass Fasteners, Brass Terminals, Brass
Casting, Brass PPR inserts, Brass Moulding inserts, Brass hose fittings, Brass
hose barbs, Brass Anchors, Brass turned parts, Brass turned components,
Brass Neutral Links, Brass forged fasteners, Brass Pipe Fittings, Sanitary
fittings, Brass Hex Bolts Hex Nuts, Brass washers, Copper Washers, Bronze
Casting etc.
ACNielsen ORG-MARG
Process (Brass foundry)
In some case where the units are doing job work of making billets, majority of
the units are using Crucibles – underground bhatti – MOOSE wherein maching
waste scrap powder is being used, normal capacity is 380kg in 3 hours, pouring
in molds and preparing the billets.
Raw materials –
scrap & other
metals, casting
waste
Melting –electric
furnace
Annealing furnace
– oil fired 800-
900 deg.
Pouring in molds- after
necessary testing of
molten metal for Cu &
other metal contents
After knock out billets
are formed – 3 ft Knock out
Cleaning (finish
product) Extrusion Press –Die –
Straitening -Drawing
Cutting
ACNielsen ORG-MARG
Process (Brass Parts)
Raw materials –
Brass rods
Cutting
Packaging &
ready for market
Drilling
Finish product Threading
/Turning
ACNielsen ORG-MARG
Raw materials
Raw material (Scrap)
ACNielsen ORG-MARG
Sand Muller
Preparing for moulding
ACNielsen ORG-MARG
Knock out brass
Product from knock out
ACNielsen ORG-MARG
Press machine (Rod shape)
Electric furnace (700 oC)
ACNielsen ORG-MARG
Hammer sand mixing for moulding
Cutting machine
ACNielsen ORG-MARG
Cutting machine
Threading machine
ACNielsen ORG-MARG
Power press machine-1
ACNielsen ORG-MARG
Power press machine-2
ACNielsen ORG-MARG
Drill machine
Packaging machine
ACNielsen ORG-MARG
SERVICE PROVIDERS
Sidharth Extrusion
S.No. 492, WAGHAWADE ROAD,
MACHE,
BELGAUM - 590 014,
MICO Hydraulics
Jamnagar
SPM Hydraulics
1486/ A, 'Shraddha', Mahaveer Nagar, Piranwadi,
Belgaum - 590014,
Gupta Brass Trader
Shankar Tekri, Jamnagar, Ph-2561486
Sky press & metals co.
421/GIDC, estate, Jamnagar-361004
0288-254674/2561383
Prakash Impex
Panchvati Area, Jamnagar
Gujarat NRE Coke,
Panchvati area,
Saru section road,
Jamnagar.
ACNielsen ORG-MARG
Shiv Coal Trading co.
Char rasta,
Udyognagar,
Rajkot
Indian Enterprises
58, Udyognagar Road,
Near Hariya Engg, Bank of Baroda Street,
Jamnagar - 361 004 (Mr. Satish Nanda)
Ranjit Industries
C/2 - 114, Shanker Tekri,
Udyog Nagar,
Jamnagar - 361 004.
Ph-0288 - 2561199 / 2563099
Mr. Ravipal Singh
Marvel Metal corporation
120, 1st floor,
Manek Center, P. N. Marg, Jamnagar - 361 008
M-9925630333, Mr Milan Upadhyay
Raj Laxmi Industries
C-2/98, G.I.D.C. Industrial estate, Shankar Takeri, Udyog nagar,
Jamnagar - 361004
Ph-0288-2560001/2556850 , M-9824299991
Mr. Bijal Gada (Proprietor)
Brass product Jamnagar ltd
Plot- 1255, GIDC Industrial Estate,
Shanker tekri Jamngar 361004
ACNielsen ORG-MARG
Association
Jamnagar Factory owener's Association
Plot no. 370/372, GIDC, Industrial area, Udyognagar, Jamnagar-361004
0288-2560002/3 (Mr. Ramji bhai Patel, President)
Jamnagar Brass components
C-2 Industrial Estate, Shanker Tekari,
Udyognagar,
Jamnagar,
ACNielsen ORG-MARG
BANKERS
Allahabad Bank
3, Nandanvan Society, Sadhana Colony,, Jamnagar
Ph-0288 – 2671874
ICICI Bank Limited
P N Marg, Solarium Road, Nr M P Shah Medical College, Jamnagar
Ph-0288 – 2660017
Indusind Bank Limited
Shivam Complex, Teen Batti, Jamnagar
Ph-0288 – 2664322
Union Bank Of India
4, Digvijay Plot, O/S Of Khambhalia Gate, Opp New School, Jamnagar-361005
Ph-0288 – 2676787
The Lakshmi Vilas Bank Ltd
1st Floor, Shree Dhan Palace, Nr Town Hall, P B No 116, Jamnagar-361001
Ph-0288 – 2661762
Syndicate Bank
Anjaria Chamber, K V Road, Jamnagar-361001
Ph-0288 – 2676756
Punjab & Sind Bank Ltd
B-8, Ajanta Society, Bedi Road,, Jamnagar-361002
Ph-0288 – 2676708
State Bank Of Saurashtra
S S I Branch, Shankar Tekri,, Jamnagar-361004
Ph-0288 – 2553503
ACNielsen ORG-MARG
Dena Bank
Hawai Chowk,Shesth Fali,,Yadvendra Bhavan,,Jamnagar - 361 001
Ph-0288 – 2676580
State bank of India
Jamnagar- 361001, jamnagar, Gujarat – 361001
0288 – 2672919
UCO Bank
Woolen Mill Campus,Jamnagar
Ph-2677050
Punjab National Bank
Ranjit Road, Jamnagar
Ph-2558451, 2676751
Oriental Bank of Commerce
Unique Shopping Centre, Jamnagar
Ph-2673998,2670958
Gujarat Industrial Co.Op. Bank
Jamnagar. Ph-2679518
Bank of Baroda
Manoj Chambers,Sumair Club Road,Jamnagar
Ph-2675172,2552727, 2676676
Bank Of India
Shankar Tekri (SSI Branch),Jamnagar.
Ph-2561542
SIDBI Bank
4, Patel colony, Jamnagar
Ph-2753055