DETAILED PROJECT REPORT

ON
AUTO LOOM / RAPIER LOOM (4 Nos)
(SOLAPUR TEXTILE CLUSTER)

Bureau of Energy Efficiency

Prepared By Reviewed By
AUTO LOOM/RAPIER LOOM (4Nos.)

SOLAPUR TEXTILE CLUSTER

 BEE, 2010
Detailed Project Report on Auto Loom/Rapier Loom (4Nos.)
Textile SME Cluster, Solapur, Pune, Maharashtra (India)
New Delhi: Bureau of Energy Efficiency;
Detail Project Report No. SLP/TXT/AL4/15

For more information

Bureau of Energy Efficiency (BEE) Telephone +91-11-26179699
(Ministry of Power, Government of India) Fax +91-11-26178352
th
4 Floor, Sewa Bhawan Websites: www.bee-india.nic.in
R. K. Puram, New Delhi – 110066 Email: jsood@beenet.in/pktiwari@beenet.in
 Acknowledgement

We sincerely appreciate the efforts of industry, energy auditors, equipment manufacturers,

technology providers, consultants and other experts in the area of energy conservation for
joining hands with Bureau of Energy Efficiency (BEE), Ministry of Power, and Government of
India for preparing the Detailed Project Report (DPR) under BEE SME Program in SMEs
clusters. We appreciate the support of suppliers/vendors for providing the adoptable energy
efficient equipments/technical details to the SMEs.

We have received very encouraging feedback for the BEE SME Program in various SME
Clusters. Therefore, it was decided to bring out the DPR for the benefits of SMEs. We sincerely
thank the officials of BEE, Executing Agencies and ISTSL for all the support and cooperation
extended for preparation of the DPR. We gracefully acknowledge the diligent efforts and
commitments of all those who have contributed in preparation of the DPR.
 Contents
List of Annexure vii
List of Tables vii
List of Figures viii
List of Abbreviation viii
Executive summary ix
About BEE’S SME program x
1 INTRODUCTION ........................................................................................................ 1
1.1 About the solapur textile cluster .................................................................................. 1
1.1.1 Production process ..................................................................................................... 1
1.2 Energy performance in solapur textile cluster .............................................................. 4
1.2.1 Specific energy consumption of final product .............................................................. 4
1.3 Proposed equipment to be upgrade ............................................................................ 4

1.3.1 Description of existing equipment ............................................................................... 4

1.3.2 Role in process ........................................................................................................... 5
1.4 Baseline for existing equipment................................................................................... 5
1.4.1 Design and operating parameter ................................................................................. 5
1.4.2 Production cost per kg of final product ........................................................................ 5
1.5.1 Technological Barriers ................................................................................................ 6
1.5.2 Financial Barrier.......................................................................................................... 6
1.5.3 Skilled manpower ....................................................................................................... 6
2 PROPOSED ENERGY EFFICIENT EQUIPMENT ...................................................... 7

2.1 Detail description of technology................................................................................... 7

2.1.1 Description of equipment ............................................................................................ 7
2.1.2 Availability of equipment ............................................................................................. 9
2.1.3 Service/equipment providers....................................................................................... 9
2.1.4 Technology/equipment specification ......................................................................... 10
2.1.5 Justification of technology selected and suitability .................................................... 10

2.1.6 Superiority over existing system ............................................................................... 10

2.1.7 Terms and conditions in sales & service of Rapier loom ........................................... 11
2.1.8 Process down time during Implementation................................................................ 11

2.2 Life cycle assesment and risk analysis ...................................................................... 12

2.3 Suitable unit for implementation of proposed technology........................................... 12
3 ECONOMIC BENEFITS OF PROPOSED EUIPMENT ............................................. 13
3.1 Technical benefits ..................................................................................................... 13
3.1.1 Fuel saving ............................................................................................................... 13
3.1.2 Electricity saving ....................................................................................................... 13
3.3 Social benefits .......................................................................................................... 13
3.3.1 Improvement in working environment ....................................................................... 14
3.3.2 Improvement in skill set of workers ........................................................................... 14
3.3.3 Impact on wages/emoluments .................................................................................. 14

3.4 Envirinmental benefit................................................................................................. 14

3.4.1 Reduction in effluent generation ............................................................................... 14
3.4.2 Reduction in GHG emission such as CO2, NOx, etc ................................................. 14
3.4.3 Reduction in other emissions like Sox....................................................................... 14
4 INSTALLATION OF PROPOSED EQUIPMENT....................................................... 15
4.1 Cost of equipment implementation ............................................................................ 15
4.1.1 Cost of equipment..................................................................................................... 15
4.1.2 Other costs ............................................................................................................... 15
4.2 Arrangement of funds................................................................................................ 15
4.2.1 Entrepreneur’s contribution ....................................................................................... 15
4.2.2 Loan amount ............................................................................................................. 15
4.2.3 Terms & conditions of loan........................................................................................ 15
4.3 Financial indicators ................................................................................................... 16
4.3.1 Cash flow analysis .................................................................................................... 16
4.3.2 Simple payback period.............................................................................................. 16
4.3.3 Net Present Value (NPV) .......................................................................................... 16
4.3.4 Internal rate of return (IRR) ....................................................................................... 16
4.3.5 Return on investment (ROI) ...................................................................................... 16
4.4 Sensitivity analysis .................................................................................................... 16
4.5 Procurement and Implementation schedule .............................................................. 17
List of Annexure

Annexure 1 Establishment of baseline ............................................................................. 18

Annexure 2 Process flow diagram .................................................................................... 19

Annexure 2 Process flow diagram .................................................................................... 19

Annexure 3 Technology assessment report ..................................................................... 20

Annexure 4 Detailed financial analysis of Rapier loom (4 nos) ......................................... 21

Annexure 5 Details of procurement and implementation plan........................................... 25

Annexure 6 Details of equipment and service provider..................................................... 26

Annexure 7 Quotations of proposed equipment ............................................................... 27

List of Tables

Table 1.1 Details of annual energy consumption of a typical unit ....................................... 1

Table 2.1 Benefits of Rapier loom over conventional power loom .................................... 10

Table 2.2 specification of power loom for suitable loom ................................................... 12

Table 3.1 Energy and cost benefit of Rapier loom ............................................................ 13

Table 4.1 Details of Project cost ....................................................................................... 15

Table 4.2 Financial indicator of project ............................................................................. 16

Table 4.3 Sensitivity analysis in different scenario ........................................................... 17

vii
List of Figures

Figure 1.1 Process flow chart of typical textile unit ............................................................. 3

Figure 2.1 Rapier loom....................................................................................................... 7

List of Abbreviations

kWh kilo Watt Hour

SME Small and Medium Enterprises

GHG Green House Gas

BEE Bureau of Energy Efficiency

DPR Detailed Project Report

O&M Operational & Maintenance

NPV Net Present Values

ROI Return on Investment

IRR Internal Rate of Return

DSCR Debt Service Coverage Ratio

PBT Profit Before Tax

PAT Profit After Tax

SIDBI Small Industries Development of India

viii
 EXECUTIVE SUMMARY

Zenith Energy Services Pvt. Ltd is executing BEE-SME program in Solapur textile cluster,
supported by Bureau of Energy Efficiency (BEE) with an overall objective of improving the
energy efficiency in cluster units.

Solapur textile cluster is one of the largest textile clusters in India; accordingly this cluster
was chosen for energy efficiency improvements by implementing energy efficient
measures/technologies, so as to facilitate maximum replication in other textile clusters in
India.

The main energy forms used in the cluster units are electricity and fuel such as wood and
other biomass product. Electricity is mostly used in power looms, winding machines,
doubling machines, warping machines, hang dyeing machine, blowers, hydro extractor,
small pumps and lighting.

Retrofitting of power looms with rapier/auto looms will reduces the power consumption &
production cost and also increases the rate of production.

Project implementation i.e. installation of four rapier/auto loom in place of sixteen conventional
power loom will lead to reduction in electricity consumption by 18720 (4680 x 4) kWh per
annum however; this intervention will not have any effect on the existing consumption pattern of
fuel.

Total investment, debt equity ratio for financing the project, monetary savings, Internal rate of
return (IRR), Net present value (NPV),Debt service coverage ratio (DSCR), Return on
investment (ROI) etc. for implementing energy efficient economizer is furnished in Table below:

S.No Particular Unit Value

1 Project cost `(in lakh) 27.68
2 Electricity saving kWh / year 18720
3 Monetary benefit `(in lakh) 12.83
4 Debit equity ratio ratio 3:1
5 Simple payback period years 2.15
6 NPV `(in lakh) 12.04
7 IRR %age 25.25
8 ROI %age 29.78
9 DSCR ratio 2.77
10 Process down time day 10
The projected profitability and cash flow statements indicate that the project implementation will
be financially viable and technically feasible

ix
 ABOUT BEE’S SME PROGRAM

Bureau of Energy Efficiency (BEE) is implementing a BEE-SME Programme to improve the

energy performance in 25 selected SMEs clusters. Solapur Textile Cluster is one of them.
The BEE’s SME Programme intends to enhance the energy efficiency awareness by funding
/ subsidizing need based studies in SME clusters and giving energy conservation
recommendations. For addressing the specific problems of these SMEs and enhancing
energy efficiency in the clusters, BEE will be focusing on energy efficiency, energy
conservation and technology up-gradation through studies and pilot projects in these SMEs
clusters.

Major activities in the BEE -SME program are furnished below:

Energy use and technology audit

The energy use technology studies would provide information on technology status, best
operating practices, gaps in skills and knowledge on energy conservation opportunities,
energy saving potential and new energy efficient technologies, etc for each of the sub sector
in SMEs.

Capacity building of stake holders in cluster on energy efficiency

In most of the cases SME entrepreneurs are dependent on the locally available
technologies, service providers for various reasons. To address this issue BEE has also
undertaken capacity building of local service providers and entrepreneurs/ Managers of
SMEs on energy efficiency improvement in their units as well as clusters. The local service
providers will be trained in order to be able to provide the local services in setting up energy
efficiency projects in the clusters

Implementation of energy efficiency measures

To implement the technology up-gradation projects in clusters, BEE have proposed to

prepare the technology based detailed project reports (DPRs) for a minimum of five
technologies in three capacities for each technology.

Facilitation of innovative financing mechanisms for implementation of energy

efficiency projects

The objective of this activity is to facilitate the uptake of energy efficiency measures through
innovative financing mechanisms without creating market distortion

x
 Auto loom/Rapier Loom (4 No.)

1 INTRODUCTION

1.1 About the solapur textile cluster

The products manufactured in Solapur Textile Cluster are cotton terry towels and bed
sheets. The towels and bed sheets are renowned in the country and have good market in
India. The main raw material for the units is cotton yarn, which is procured from local
spinning mills and agents. The cost of energy (electrical and thermal energy) as percentage
of manufacturing cost varies between 8 and 10%.

Majority of the cluster units are of integrated type, where the raw material yarn is processed
in-house to the final product. The energy cost is second to the raw materials cost. Majority of
the units in the cluster are dependent on local/ run of the mill technologies of low end and
with little investment initiatives and technology up-gradation.

The main energy forms used in the cluster units are grid electricity, wood, and small quantity
of coal. The electricity is used for power looms, doubling machines, winding machines, hydro
extractors, warping machines and lighting. Wood is used as fuel for boilers, thermic fluid
heaters, and chulhas for hot water generation. The details of annual energy consumption of
a typical unit having a production capacity of 1, 20,000 kg of final product of the cluster are
furnished in the Table 1.1 below:

Table 1.1 Details of annual energy consumption of a typical unit

S.No. Parameter Unit Value

1 Electricity consumption kWh/annum 1,97,784

2 Wood consumption tonne/annum 144

3 Production kg/annum 1,20,000

Production process

The main operational process for production of towels and bed sheets in cluster units are:

Doubling

In the Doubling process, thin single yarn is converted to double yarn for strengthening the
yarn by using doubling machine.

Yarn dyeing

Initially, the yarn is soaked in soap water for 24 hours to remove the dirt and other foreign
materials and after soaking, the yarn is taken for bleaching. Bleaching is carried out by

1
 Auto loom/Rapier Loom (4 No.)

soaking the yarn in tanks mixed with bleaching agents and after completion of the process;
the yarn is washed with normal water.

The hang dyeing machine tanks are filled with required quantity of normal water and
required chemicals and dyeing agents are added. The temperature of the water is raised by
oil circulation or direct steam injection. Fire wood is used as fuel. The required colors are
added to the yarn and the dyeing process takes about 90 to 120 minutes per batch. After
dyeing, the yarn is washed with normal water, and the yarn is taken for soaping for colour
fixation in hot water for about 20 minutes in hang dyeing machines. The water is drained to
the waste drainage lines. The wet yarn is taken to hydro extractors for removing the water in
the yarn and taken for drying in the natural sunlight.

Winding

The yarn after drying is taken for winding in which the yarn is wounded to bobbins and
cones. The winded yarn is taken for further process.

Warping

In warping, the winded yarn is wound to beams according to designed pattern (customized
designs). Then the beams are taken for Weaving.

Weaving

The beams, which are wound with yarn are taken and placed in power looms where the
designed pattern is already set. In power looms, the yarn is converted to final product (Towel
or bed sheets) by weaving. The product obtained from weaving is taken for stitching and
packing. The general process flow diagram of a typical unit for production of towels and bed
sheets is furnished in Figure 1.1.

2
 Auto loom/Rapier Loom (4 No.)

SINGLE YARN

(Raw material)

DOUBLING MACHINES

REALING MACHINES

DYEING
CHULHA MANUAL DYEING IN HOT
Drained water
WATER

HYDRO EXTRACTORS
FUEL OPEN

(Wood)

WINDING MACHINES

To Drain
WARPING MACHINES

POWER LOOMS

STITCHING & PACKING

DISPATCH

Figure 1.1 Process flow chart of typical textile unit

The production process as depicted above is similar for all textile units in Solapur textile
cluster. However, depending on type of product and product quality, the above stated
process flow varies as per the requirement of the industry.

3
 Auto loom/Rapier Loom (4 No.)

1.2 Energy performance in cluster

Majority of the industries located in solapur are engaged in manufacturing of towels and bed
sheets. The main energy sources for Solapur cluster units are electricity and fuels such as
Wood & briquettes. The wood and GN husk briquettes are used as fuel for boilers, thermic
fluid heaters and chulhas for hot water generation and electricity is used for operation of
prime movers of doubling machine motors, ID & FD fans, pumps, hank dyeing machine
drives, power loom drives, winding machine motors, etc. Majority of the units in the Solapur
textile cluster are using wood for thermal energy generation due to easy availability and
economical point of view.

Energy cost is around 8 to 10 percent of manufacturing cost in typical manufacturing unit,

out of which the cost of electrical energy works out to 58 percent of the total energy cost and
remaining accounts for thermal energy.

In a typical textile manufacturing unit annual consumption of electrical energy and wood is
1,97,784 kWh and 144 tonnes respectively for average production capacity of 1,20,000 kg of
final product.

1.2.1 Specific energy consumption of final product

Specific electrical and thermal energy consumption in textile unit depends upon the final
product manufactured in that unit. The electrical and thermal energy consumption of typical
textile unit is 1.65 kWh per kg of final product and 1.20 kg of wood per kg of final product
respectively (includes all colours dyeing in cold water, medium temperature water and high
temperature water)

1.3 Proposed equipment to be upgrade

1.3.1 Description of existing equipment

During energy audit studies in various textile industries in Solapur textile cluster, it was
observed that about 1200 power loom in Solapur Textile cluster. All power looms are of
shuttle type and are too old. These power looms are used for weaving terry towels and bed
sheets.

In the present conventional shuttle looms, it is necessary to pass a shuttle weighing around
half a kilogram through the warp shed to insert a length of weft yarn which weighs only few
grams. The shuttle has to be accelerated rapidly at the starting of picking cycle and also to
be decelerated, stopped abruptly at the opposite end. This process creates heavy noise and
shock and consumes considerable energy. Beat-up is done by slay motion which again
weighs a few hundred kilograms. The wear life of the picker and checking mechanism is also
limited due to heavy shock. Due to the above reasons smooth sequence of weaving is
disturbed which affects the maximum running speed and hence machine production. In multi

4
 Auto loom/Rapier Loom (4 No.)

colour weft insertion, Drop box motion is attached which is also further limits the speed of the
machine. The small weft package in the shuttle requires frequent replenishments and for
each loom stoppage there is a possibility of one defect. The probability of weft way fabric
defects are high to the tune of 70% in shuttle looms. Even in automatic shuttle looms there is
a chance of transfer failures and weft lashing in defects.

1.3.2 Role in process

The power looms are one of the most important equipment in producing of cotton terry
towels and bed sheets. The power looms are used for weaving the dyed yarn to towels and
bed sheets.

1.4 Baseline for existing equipment

Energy consumption for Power loom would depend on following:

• Load on Power loom

• Operational & maintenance practices

1.4.1 Design and operating parameter

Present electricity consumption in power loom machine is 33.6 kWh and connected with 1.0
HP motor. The average production is 48 kg per day per machine. The power loom machines
are operated in two shifts in a day.

1.4.2 Production cost per kg of final product

Production cost for various power loom machine of three typical units in the cluster are
separately furnished in Table 1.2 below:

Table 1.2 production cost by power loom machine

Production Cost Production

Production Production
Name of (Including wages, cost for 4
S.No. per day cost
unit O&M, power cost looms
(kg/loom)
etc)(Rs./day) (`/day) `/kg

Rajashree 190 760 12.5 15.2

1
Industries
Balla Textile 182 728 11.9 15.3
2
Mills Pvt Ltd
Devsani 187 748 14.5 12.9
3
Textiles

5
 Auto loom/Rapier Loom (4 No.)

1.5 Barriers for adoption of proposed equipment

The technology and innovations in SMEs are generally different from that of large firms.
Technology in the SME sector has an increasingly complex or combinative character, most
of the SMEs units in Solapur cluster are labour intensive and utilize local resources. The
SME entrepreneurs are generally not willing to invest in state-or-art technology. Major
barriers in the up-gradation of technology in the cluster are non availability of technology;
distrust on technology supplier, lack of awareness about energy efficiency among small and
medium enterprises, prevents them from adoption of energy efficient technologies.

1.5.1 Technological Barriers

The major technical barriers that prevented the implementation of Rapier loom are

• Lack of awareness and information about the rapier loom and its benefit

• Absence of local Rapier loom supplier

• Dependence on local equipment suppliers, whom doesn’t have technical knowledge

about rapier loom and its proper installation

1.5.2 Financial Barrier

Implementation of the proposed project activity requires investment of ` 27.68 lakh per unit.
Such investment is not commonly seen in the cluster units for energy efficiency
improvement. Further, from the business perspective of SMEs, it is more viable, assured,
and convenient to invest on project expansion for improving the production capacity or
quality, rather than make piecemeal investment in retrofit and replace options for energy
savings. In view of this and given the limited financial strength of the textile mills, it is evident
that the owners would not like to take the risk and invest in energy efficiency measures.

However, the financial attractiveness of the project activity may motivate the owners to move
forward in taking up initiatives in energy conservation and efficiency.

1.5.3 Skilled manpower

The non-availability of skilled manpower having awareness about energy efficiency and
related issues in the cluster is one of the major barriers. Lack of skilled manpower for
operation and maintenance of the rapier looms is also one of the major barriers that
prevented the implementation.

1.5.4 Other barrier (If any)

The recent recession in European and other Asian countries and reduction in market trend
for the products in national and international markets was also one of the major barriers for
the proposed technology.

6
 Auto loom/Rapier Loom (4 No.)

2 PROPOSED ENERGY EFFICIENT EQUIPMENT

2.1 Detail description of technology

2.1.1 Description of equipment

The rapier looms offer unparalleled versatility when it comes to yarns. From the finest counts
of cotton to the thickest Industrial yarns and can handle anything thrown at its negative
rapier head. The soft-pick gear system enables smooth transition of even highly fancy yarns
like embroidery and slub. The rapier loom is upgrade from shuttle-looms to the world of
modern weaving system and shutte-less weaving. Rapier looms has been designed to
replace the old shuttle looms without any major changes to the existing infrastructure. The
Immediate benefits of selecting rapier looms are

Figure 2.1 Rapier loom

• No need for new buildings or any new infrastructure.

• Could fit in place of your current shuttle-looms.

• Configured specially keeping in mind the skills of power-loom operators.

• No special training required for loom operators.

• Immediate reduction of man-power and laborers.

• 20% subsidy under TUFS on our certified looms in addition to State Government
Incentives.

• Step-by-Step consultancy by our engineers to help you upgrade, install & adapt
to new machines.

7
 Auto loom/Rapier Loom (4 No.)

Speed

The normal speed of the conventional power looms is around 120 RPM, where as in rapier
looms, the speeds upto 220 RPM (actual) can be attained and coupled with high efficiencies
of upto 95%, this machine gives upto 3 times more productivity than the conventional power
looms.

Color Weft Insertion

Rapier looms offers up to 8 Color Pick-at-Will weft insertions, so that weave the fanciest of
fabrics can be attained. The pick-at-will system is computerised and microprocessor
controlled, hence letting the programme sequences of more than 1, 00,000 picks. Such
technological edge will definitely give you an edge in the market.

Start-Mark Prevention System

Rapier looms realises the most delicate need of rapier users to prevent start-marks in
weaving. The custom designed ‘HT-Drive’ motor of the machine supplies more than 150%
torque for the first-pick to successfully prevent the start marks.

Lower per meter Costs

Considering 3 times more productivity with same space and even lesser amount of man
power along with lower power consumption, it is quite obvious that rapier looms can offer
lower production costs compared to conventional power-looms or even rapier-shuttle change
machines. Moreover continuous weft-insertion eliminates the need for investing in pirn-
winding machines or even extra operators.

Lower Maintenance

Due to lower vibrations, there’s less wear-n-tear of rotating components and bearings
resulting in lower maintenance costs. Also, centralised lubrication offered on the looms gives
single-point lubrication for the complete machine, thus further reducing the headaches of
maintenance

Shedding

The rapier loom has the flexibility and can easily add and attach any of the shedding motions
available in the market including:

• Dobby

• Jacquard

• Cam Shedding

• Positive Cam: for Heavy plain fabrics (bolting cloth, tirecord cloth etc.)

• Negative Cam: for light sensitive fabrics

8
 Auto loom/Rapier Loom (4 No.)

Take-Up

Universal 7-wheel Wretchet-n-Pawl semi-positive take-up is the most widely used and well
established Take-Up system offered in rapiers around the world. The well designed take-up
is capable of handling a weft-density of 4-120 picks per Inch.

Let-Off

The capability of rapier looms to weave any and all kinds of fabrics has been created due to
3 different let-off options available with the machine depending on your fabric.

Ruti-Type

For weavers of regular cotton-fabrics who’ve been used to highly versatile Ruti-Type let-off.

Microprocessor Controller

The heart of the complete control system, this microprocessor is one of the most powerful
control systems offered today for crank-type rapier looms. The system can be programmed
to output any kinds of pick programs. The standard functions include:

• Constant monitoring of weft and warp yarn for breakages Cloth Length Counter

• Pick-programming

• Weft-Controller

Exclusive Feature

For all power loom users, investing in Rapier looms normally require them to erect a
completely new building infrastructure. But, with AWT-250EX, we’re proud to say that we are
the only rapier-loom manufacturer in the world whose machines can fit in the regular ’16-feet
sheds’, thus eliminating the need for any additional investment and hence brings down the
up-gradation costs considerably. In Solapur Textile Cluster units, majority of the units has
power looms, Considering the above facts and benefits of the rapier loom and for reducing
the overall production cost, it is suggested to replace power looms with rapier looms. The
details of production cost per kg in power looms is provided in Annexure 1

2.1.2 Availability of equipment

The Rapier loom suppliers are available in Pune, which is 200 km from Solapur city and M/s
Laxmi Shuttleless loom is also planning to appoint a dealer at Solapur.

2.1.3 Service/equipment providers

The service providers are available in Pune. Details of service providers are given in
Annexure 6.

9
 Auto loom/Rapier Loom (4 No.)

2.1.4 Technology/equipment specification

Benefits of rapier loom over power loom machine are shown in Table 2.1 below.

Table 2.1 Benefits of Rapier loom over conventional power loom

Conventional Power-Loom Rapier loom

55-65% Efficiency 85-95% Efficiency

Max. 110 RPM (eff. 70 RPM due to lower Max. 220 RPM (eff. 200 RPM due to Higher Efficiency)
efficiency)
Lower Output per shift Upto 2.5 times more output per shift

Lower Output per operator Upto 2.5 times more output per operator

High Labor requirement Low labor requirement

‘Kandi / Shuttle / Pirn-Winder’ machine & operator Shuttle less (No Kandi, No Pirn, No Pirn Machine
required Operator)
High Maintenance because of extremely high Extremely Low vibration, hence lower maintenance
vibration
Higher & Faster Wear-n-Tear of components Lower vibration leads to better & longer life

Light-Weight leading to shorter life and higher Heavy-Duty Structure to reduce vibration thus leading
vibrations to longer life
Lower Output per unit area of floor space 3 times more output per unit area of floor space

High Production Cost Lower Production Cost

Due to lower labor productivity and lower Due to lower labor and lower area and lower power
efficiencies and higher costs per meter of fabric. requirement per meter of fabric.

2.1.5 Justification of technology selected and suitability

As discussed above, the production cost per kg of final product i.e., towels or bed sheets is
high due to low production per loom, more breakdowns, more power consumption, more
manpower cost and also the quality is poor compared with the product produced in rapier
looms.

2.1.6 Superiority over existing system

The benefits of the rapier looms over conventional power looms are furnished in Table 2.1
below:

• High productivity due to high speed and wider width of looms.

• Reduced labour cost due to higher allocation of looms and productivity.

10
 Auto loom/Rapier Loom (4 No.)

• Defect free cloth for longer length.

• Better environment due to low noise level.

• Pirn winding process is eliminated

• Less value loss of fabrics.

• Low consumption of stores and spares.

• Less space requirement per meter of cloth.

• More colours in weft direction (upto 12) by Pick and Pick method.

• Wider width fabrics and multi width fabrics can be woven,

• High degree of flexibility to suit a wide range of fibers and counts

• Easily adaptable for market trends

• Bigger flanges can accommodate 3 times more yarn

• Due to less beam changes lower down-time and lesser wastages

• Less dependency on labour skills

• Higher design capabilities due to microprocessor and electronic controls

• Easy maintenance and less work load for Jobbers

2.1.7 Terms and conditions in sales & service of Rapier loom

Terms of payment

50% advance with purchase order, and remaining 50% along with taxes and duties against
Performa invoice before dispatch.

Excise duty, sales tax & other levies

The quoted prices are exclusive of all taxes, duties, levies such as excise duty, central/local
sales tax, octroi, etc. as are applicable at the time of dispatch or imposed by any statutory
authorities subsequently or paid by us, shall be paid by you extra at actual. However CVD is
charged at 8% plus 4% on the unit price plus 3% education cess and VAT is charged at 5%.

Warranty

The supplier shall repair or replace at free of cost, on ex – works basis the whole or any
portion of material which under normal and proper use and maintenance proves defective in
material and/or workmanship within 12 months from the date of commissioning or 18 months
from the date of shipment of equipment whichever is earlier, provided prompt notice is given
of such defects.

2.1.8 Process down time during Implementation

11
 Auto loom/Rapier Loom (4 No.)

The process down time is envisaged as installation of Rapier loom will take 10 days for
installation.

2.2 Life cycle assesment and risk analysis

Life cycle of Rapier loom is considered as 15 years.

2.3 Suitable unit for implementation of proposed technology

Four conventional power looms can be replaced with a single rapier loom. The suitable unit
has some specification of power loom which is furnished in Table 2.2 below:

Table 2.2 specification of power loom for suitable machine

Parameter Details Parameter Details

Driving System By Push Button Control On Weft Selection Electronic

Both Side of Loom

Running Speed 160-180 RPM Weft Feed By Weft Feeder

Reed Space 200, 230, 250, 260, 280 cm Driving Motor 1.5 kW, 960 RPM

Weft Insertion Both Side Flexible Rapier Applicable Yarn Cotton, All Man Made
System Yarns
Weft Colours * Up to 6 Colors Terry Loop By Movable Reed
Operated By Solenoid.
Weft Detection By Piezo Electronic Slide Terry Loop Height 0-10 mm
Sensor
Shedding Motion * Electronic Dobby / Cramming Motion Electronic
Jacquard
Cloth Roll dia. 400 mm Control Panel LCD System With
Keypad For
Programming of Dobby
Selvedge Independent Positive Leno - Beam Flange Dia. Ground Beam: 600 mm
Flase Selvedge Motion Top Beam: 750 mm
Warp Yarn zetection 2 Row Electrical Type For Lubrication Centralised Lubrication
Top Beam & Ground Beam. System
Electronically Operated
Braking System By Electromagnetic Brake Letting Off Motion for Ground / Pile
Beam.

12
 Auto loom/Rapier Loom (4 No.)

3 ECONOMIC BENEFITS OF PROPOSED EUIPMENT

3.1 Technical benefits

3.1.1 Fuel saving

No fuel saving is possible by the implementation of the project activity.

3.1.2 Electricity saving

Total electricity saving would be about 18720 kWh per year by the installation of proposed
four rapier loom equipment.

3.1.3 Improvement in product quality

Proposed equipment has significant impact in improving the quality of the product.

3.1.4 Increase in production

The proposed equipment increased in production is almost 2.5 to 3 times per loom.

3.1.5 Reduction in raw material consumption

Raw material consumption is reduces due to reduction in breakages of the yarn in shuttle
power loom.

3.2 Monetary benefits

The monetary savings due to installation of one rapier looms is ` 3,20,700 per year hence
for 4 rapier looms, the monetary benefit works out at ` 12,82,800. The monetary savings are
due to result of power savings, less manpower cost, improved quality, low maintenance,
more output/machine etc. Detail monetary benefit is given in Table 3.1 below:

Table 3.1 Energy and cost benefit of rapier loom

S.No. Parameter Unit Value

1 Present electricity consumption in power loom kWh/annum 33.6

2 Operational hours hours/day 12

3 Operational days per annum days/annum 300

4 Electricity consumption after installation of Rapier loom kWh/annum 18.0

5 Cost of electricity `/kWh 2.50

6 Electricity Cost savings after implementation ` in lakh 11,700

7 Total monetary benefit per auto/repier loom ` in lakh 3,20,700

8 Total monetary benefit ` in lakh 12,82,800

13
 Auto loom/Rapier Loom (4 No.)

3.3 Social benefits

3.3.1 Improvement in working environment

As installation of Rapier loom eliminates Mechanical shock, Vibration and sound etc., this
may less the breakdowns and working environment may improved.

3.3.2 Improvement in skill set of workers

The technology selected for the implementation is new and energy efficient. The technology
implemented will create awareness among the workforce about energy saving.

3.3.3 Impact on wages/emoluments

No impact on wages or emolument of workers.

3.4 Envirinmental benefit

3.4.1 Reduction in effluent generation

The effluent generation due to implementation of the project activity is insignificant.

3.4.2 Reduction in GHG emission such as CO2, NOx, etc

The major GHG emission reduction source is CO2 and this equipment will reduce electricity
consumption. The total emission reductions are estimated as 16 tonne of CO2 per annum
due to implementation of the project activity.

3.4.3 Reduction in other emissions like Sox

No significant impact on SOx emissions.

14
 Auto loom/Rapier Loom (4 No.)

4 INSTALLATION OF PROPOSED EQUIPMENT

4.1 Cost of equipment implementation

4.1.1 Cost of equipment

The total cost for installation of 4 nos Rapier loom is estimated at `.26.00 lakh, which
includes, Panel, switches, cabling etc.

4.1.2 Other costs

The total cost of implementation of the proposed rapier loom is estimated at ` 27.68 lakh.
The above cost includes cost of equipment/machinery, cost of fabrication (and/or)
commissioning charges and the details are furnished in Table 4.1 below:

Table 4.1 Details of Project cost

S.No Particular Cost ( ` in lakh)

1 Equipment and machinery 26.00
2 Civil Work 1.00
3 Interest during implementation 0.68
4 Total Cost 27.68

4.2 Arrangement of funds

4.2.1 Entrepreneur’s contribution

The total cost of the proposed technology is estimated at ` 27.68 lakh. The entrepreneur’s
contribution is 25% of total project cost, which is ` 6.92 lakh.

4.2.2 Loan amount

The term loan is 75% of the total project, which is ` 20.76 lakh. As the overall energy
efficiency in the project is more than 15% it qualifies for subsidy of 25% of the project cost as
per the NMCP scheme of Ministry of MSME, GoI. 25 % of the project cost in this case works
out to ` 6.92 lakh. As the subsidy is normally available after implementation of the project the
same has not been taken in the project cost and means of finance. On receipt of subsidy
from Ministry of MSME, GoI through the nodal agency the amount of subsidy is generally set
off [reduced] from the loan outstanding by the lending bank. Availability of this subsidy will
make the project economically more attractive

4.2.3 Terms & conditions of loan

The interest rate is considered at 10.00% which is SIDBI'S Lending rate for energy efficiency
projects. The loan tenure is assumed 5 years and the moratorium period is 6 months.

15
 Auto loom/Rapier Loom (4 No.)

4.3 Financial indicators

4.3.1 Cash flow analysis

Considering the above mentioned assumptions, the net cash accruals starting with ` 8.64
lakh in the first year operation and gradually increases to ` 25.79 lakh at the end of sixth
year.

4.3.2 Simple payback period

The total project cost of the proposed equipment is ` 27.68 lakh and monetary savings due
to reduction in electricity consumption is ` 12.83 lakh and the simple payback period works
out to be 2.15 years (26 months).

4.3.3 Net Present Value (NPV)

The Net present value of the investment at 10.00% works out to be ` 12.04 lakh.

4.3.4 Internal rate of return (IRR)

The after tax Internal Rate of Return of the project works out to be 25.25% thus the project is
financially viable.

4.3.5 Return on investment (ROI)

The average return on investment of the project activity works out at 29.78% for an
investment of ` 27.68 lakh.

Table 4.2 Financial indicator of project

S. No Particulars Unit Value

1 Simple Pay Back period year 2.16
2 IRR %age 25.25
3 NPV ` in lakh 12.04
4 ROI %age 29.78
5 DSCR ratio 2.77

4.4 Sensitivity analysis

A sensitivity analysis has been carried out to ascertain how the project financials would
behave in different situations like there is an increase in electricity savings or decrease in
electricity savings. For the purpose of sensitive analysis, two scenarios are considered are.

16
 Auto loom/Rapier Loom (4 No.)

• Increase in electricity savings by 5%

• Decrease in electricity savings by 5%

In each scenario, other inputs are assumed as constant. The financial indicators in each of
the above situation are indicated along with standard indicators.

Details of sensitivity analysis for different scenario are furnished in Table 4.3 below:

Table 4.3 Sensitivity analysis in different scenario

Particulars DSCR IRR ROI NPV

Normal 2.77 25.25% 29.78% 12.04

5% increase in electricity savings 2.91 27.69% 30.20% 14.09

5% decrease in electricity savings 2.62 22.78% 29.30% 10.00

As could be seen from the above table, though the project is highly sensitive to electricity
savings, DSCR works out to be 2.77 times in worst scenario, which indicates the strength of
the project.

4.5 Procurement and Implementation schedule

The project is expected to be completed in 8-10 weeks from the date of financial closure.
The detailed schedule of project implementation is furnished in Annexure 5.

17
 Auto loom/Rapier Loom (4 No.)

Annexure 1 Establishment of baseline

Conventional Monetary
S. No Parameter Auto looms
Power looms `)
Benefit (`)

1 No. of Looms 4 1 0

Power consumption of each loom 8.4 18.0 0.0

2
(kWh/day)

3 Total power consumption (kWh/day) 33.6 18.0 15.6

Monetary benefit due to power savings - - 11700.0

4
per annum

Average production per loom (12 12 50 -

5
hours/day) [kg]

6 Total production per day (kg) 48 50 -

7 Manpower 4 1 3

8 Manpower cost (`) 5000 7000 0

9 Total manpower cost (`) 20000 7000 13000

10 Reduction in labour cost per annum - - 156000

11 Market price for the product per kg 96 105 9

Monetary benefit due to quality - - 135000

12
improvement

13 Maintenance Cost per loom/annum 6000 6000 0

14 Total Maintenance Cost for looms (`) 24000 6000 18000

Total Monetary benefit per auto loom - - 320700

15
(`/annum)

18
 Auto loom/Rapier Loom (4 No.)

Annexure 2 Process flow diagram

Yarn

Doubling Yarn

Dyeing & Washing

(Hang dyeing machine) (60 0C) (Hydro extractor)

Drying

Winding

Warping

Power looms

Stitching

Finished Product

19
 Auto loom/Rapier Loom (4 No.)

Annexure 3 Technology assessment report

In the conventional shuttle looms, it is necessary to pass a shuttle weighing around half a
kilogram through the warp shed to insert a length of weft yarn which weighs only few grams.
The shuttle has to be accelerated rapidly at the starting of picking cycle and also to be
decelerated, stopped abruptly at the opposite end. This process creates heavy noise and
shock and consumes considerable energy. Beat-up is done by slay motion which again
weighs a few hundred kilograms. The wear life of the picker and checking mechanism is also
limited due to heavy shock. Due to the above reasons smooth sequence of weaving is
disturbed which affects the maximum running speed and hence machine production. In multi
colour weft insertion, Drop box motion is attached which is also further limits the speed of the
machine. The small weft package in the shuttle requires frequent replenishments and for
each loom stoppage there is a possibility of one defect. The probability of weft way fabric
defects are high to the tune of 70% in shuttle looms. Even in automatic shuttle looms there is
chance of transfer failures and weft lashing in defects.

20
 Auto loom/Rapier Loom (4 No.)

Annexure 4 Detailed financial analysis of Rapier loom (4 nos)

Assumptions
Name of the Technology Auto Looms (4 Nos.)
Rated Capacity NA
Details Unit Value Basis
Installed Capacity Kcal 4
No of working days Days 300
No of Shifts per day Shifts 1 (Assumed)
Capacity Utilization Factor %
Proposed Investment
Plant & Machinery ` (in lakh) 25.00
Erection & Commissioning ` (in lakh) 1.00
Investment without IDC ` (in lakh) 1.00
Interest During Implementation ` (in lakh) 27.00
Other charges(Contingency) ` (in lakh) 0.68
Total Investment ` (in lakh) 27.68
Financing pattern
Own Funds (Equity) ` (in lakh) 6.92 Feasibility Study
Loan Funds (Term Loan) ` (in lakh) 20.76 Feasibility Study
Loan Tenure years 5 Assumed
Moratorium Period Months 6 Assumed
Repayment Period Months 66 Assumed
Interest Rate % 10.00 SIDBI Lending rate
Estimation of Costs
O & M Costs % on Plant & Equip 4.00 Feasibility Study
Annual Escalation % 5.00 Feasibility Study
Estimation of Revenue
Monetary Savings per loom `/Loom 320700
No. of looms 4
St. line Depn. %age 5.28 Indian Companies Act
IT Depreciation %age 80.00 Income Tax Rules
Income Tax %age 33.99 Income Tax

Estimation of Interest on Term Loan

(` in lakh)
Years Opening Balance Repayment Closing Balance Interest
1 20.76 1.20 19.56 1.88
2 19.56 3.30 16.26 1.81
3 16.26 4.00 12.26 1.47
4 12.26 4.60 7.66 1.04
5 7.66 5.10 2.56 0.55
6 2.56 2.56 0.00 0.07
20.76

WDV Depreciation

Particulars / years 1 2 3 4 5 6
Plant and Machinery
Cost 27.68 5.54 1.11 0.22 0.04 0.01
Depreciation 22.14 4.43 0.89 0.18 0.04 0.01
WDV 5.54 1.11 0.22 0.04 0.01 0.00

21
 Auto loom/Rapier Loom (4 No.)

Projected Profitability

Particulars / Years 1 2 3 4 5 6
Revenue through Savings
Fuel savings 12.83 12.83 12.83 12.83 12.83 12.83
Total Revenue (A) 12.83 12.83 12.83 12.83 12.83 12.83
Expenses
O & M Expenses 1.11 1.16 1.22 1.28 1.35 1.41
Total Expenses (B) 1.11 1.16 1.22 1.28 1.35 1.41
PBDIT (A)-(B) 11.72 11.67 11.61 11.55 11.48 11.42
Interest 1.88 1.81 1.47 1.04 0.55 0.07
PBDT 9.84 9.85 10.14 10.51 10.93 11.34
Depreciation 1.46 1.46 1.46 1.46 1.46 1.46
PBT 8.38 8.39 8.67 9.04 9.47 9.88
Income tax - 1.84 3.14 3.51 3.70 3.85
Profit after tax (PAT) 8.38 6.55 5.53 5.53 5.77 6.03

Computation of Tax
` (in lakh)
Particulars / Years 1 2 3 4 5 6
Profit before tax 8.38 8.39 8.67 9.04 9.47 9.88
Add: Book depreciation 1.46 1.46 1.46 1.46 1.46 1.46
Less: WDV depreciation 22.14 4.43 0.89 0.18 0.04 0.01
Taxable profit (12.30) 5.42 9.25 10.33 10.90 11.33
Income Tax - 1.84 3.14 3.51 3.70 3.85

Projected Balance Sheet

` (in lakh)
Particulars / Years 1 2 3 4 5 6
Liabilities
Share Capital (D) 6.92 6.92 6.92 6.92 6.92 6.92
Reserves & Surplus (E) 8.38 14.93 20.46 25.99 31.76 37.79
Term Loans (F) 19.56 16.26 12.26 7.66 2.56 0.00
Total Liabilities D)+(E)+(F) 34.85 38.10 39.63 40.57 41.23 44.70

Assets
Gross Fixed Assets 27.68 27.68 27.68 27.68 27.68 27.68
Less: Accm. Depreciation 1.46 2.92 4.38 5.84 7.31 8.77
Net Fixed Assets 26.21 24.75 23.29 21.83 20.37 18.91
Cash & Bank Balance 8.64 13.35 16.34 18.74 20.86 25.79
TOTAL ASSETS 34.85 38.10 39.63 40.57 41.23 44.70
Net Worth 15.30 21.85 27.38 32.91 38.68 44.70
Dept equity ratio 2.83 2.35 1.77 1.11 0.37 0.00

22
 Auto loom/Rapier Loom (4 No.)

Projected Cash Flow:

` (in lakh)
Particulars / Years 0 1 2 3 4 5 6
Sources
Share Capital 6.92 - - - - - -
Term Loan 20.76
Profit After tax 8.38 6.55 5.53 5.53 5.77 6.03
Depreciation 1.46 1.46 1.46 1.46 1.46 1.46
Total Sources 27.68 9.84 8.01 6.99 6.99 7.23 7.49
Application
Capital Expenditure 27.68
Repayment of Loan - 1.20 3.30 4.00 4.60 5.10 2.56

Total Application 27.68 1.20 3.30 4.00 4.60 5.10 2.56

Net Surplus - 8.64 4.71 2.99 2.39 2.13 4.93
Add: Opening Balance - - 8.64 13.35 16.34 18.74 20.86
Closing Balance - 8.64 13.35 16.34 18.74 20.86 25.79

Calculation of Internal Rate of Return

` (in lakh)
Particulars / months 0 1 2 3 4 5 6
Profit after Tax 8.38 6.55 5.53 5.53 5.77 6.03
Depreciation 1.46 1.46 1.46 1.46 1.46 1.46
Interest on Term Loan 1.88 1.81 1.47 1.04 0.55 0.07
Salvage/Realizable value - -
Cash outflow (27.68) - - - - - -
Net Cash flow (27.68) 11.72 9.82 8.46 8.04 7.78 7.56
IRR 25.25%

NPV 12.04

Break Even Point

` (in lakh)
Particulars / Years 1 2 3 4 5 6
Variable Expenses
Oper. & Maintenance Exp (75%) 0.83 0.87 0.92 0.96 1.01 1.06
Sub Total (G) 0.83 0.87 0.92 0.96 1.01 1.06
Fixed Expenses
Oper. & Maintenance Exp (25%) 0.28 0.29 0.31 0.32 0.34 0.35
Interest on Term Loan 1.88 1.81 1.47 1.04 0.55 0.07
Depreciation (H) 1.46 1.46 1.46 1.46 1.46 1.46
Sub Total (I) 3.62 3.56 3.24 2.82 2.35 1.89
Sales (J) 12.83 12.83 12.83 12.83 12.83 12.83
Contribution (K) 12.00 11.96 11.91 11.87 11.82 11.77
Break Even Point (L= G/I) 30.16% 29.81% 27.19% 23.79% 19.86% 16.05%
Cash Break Even {(I)-(H)} 17.98% 17.59% 14.92% 11.47% 7.50% 3.63%
BREAK EVEN SALES (J)*(L) 3.87 3.82 3.49 3.05 2.55 2.06

23
 Auto loom/Rapier Loom (4 No.)

Return on Investment
` (in lakh)
Particulars / Years 1 2 3 4 5 6 Total
Net Profit Before Taxes 8.38 8.39 8.67 9.04 9.47 9.88 53.84
Net Worth 15.30 21.85 27.38 32.91 38.68 44.70 180.81
29.78%

Debt Service Coverage Ratio

` (in lakh)
Particulars / Years 1 2 3 4 5 6 Total
Cash Inflow
Profit after Tax 8.38 6.55 5.53 5.53 5.77 6.03 37.79
Depreciation 1.46 1.46 1.46 1.46 1.46 1.46 8.77
Interest on Term Loan 1.88 1.81 1.47 1.04 0.55 0.07 6.83
Total (M) 11.72 9.82 8.46 8.04 7.78 7.56 53.38

Debt
Interest on Term Loan 1.88 1.81 1.47 1.04 0.55 0.07 6.83
Repayment of Term Loan 1.20 3.30 4.00 4.60 5.10 2.56 20.76
Total (N) 3.08 5.11 5.47 5.64 5.65 2.63 19.31
Average DSCR (M/N) 2.77

24
 Auto loom/Rapier Loom (4 No.)

Annexure 5 Details of procurement and implementation plan

Project Implementation Schedule

Weeks
S. No Activity
1-2 2-4 4-6 6-8 8 - 10

1 Collection of quotations and order

2 Delivery
3 Commissioning and trial runs

Break up of process down time

days
S. No. Activities
1 2 3 4 5 6/7 8/9

1 Time required for dismantling or re-

2 Civil works and curing
3 Erection
4 Commissioning and trial runs

25
 Auto loom/Rapier Loom (4 No.)

Annexure 6 Details of equipment and service provider

Equipment details Service/technology provider

Laxmi shuttleless loom Pvt limited

21, Punmaji Industrial Estate, Shahpur, Dhobighat,

Ahmedabad – 380004 Gujarat, INDIA

Rapier looms
Phone: 91 (79) 2562-2510 / 2562-4393 / 2562-0604

Fax: 91 (79) 2562-2845

Mr. Hemang M. Shanghvi (Mobile 09824083935)

26
 Auto loom/Rapier Loom (4 No.)

Annexure 7 Quotations of proposed equipment

27
Auto loom/Rapier Loom (4 No.)

28
 Standard application form for financial assistance to existing units
(upto and including Rs. 50 lakh)

I Applicant details
1 Name of Unit
2 Address for correspondence
3 Constitution
4 SSI Registration. No.
5 Date of Incorporation
6 Date of Commencement of Operations
7 Activity / Industry

Registered Office Factory / Service Establishment Factory / Service

(existing) Establishment (proposed)
Full Address
Contact Person(s)
Tel No.
Fax No.
E mail address

II Promoters/Directors

Bio-data of all the promoters/directors of the unit (Preferably make separate sheet for each
promoter/director)

Promoter/Director
Name
Full Address( incl Tel no./ mobile no)
Age
Passport No.
Father's / husband's name
Qualification
Experience
Functional responsibility in the unit
Relationship with Chief Promoter
Shareholding in the unit
Net worth

Pl. furnish details of any other shareholder having more than 5% in the unit.

III. Products Manufactured

Sl. No. Product Installed capacity Present capacity utilisation End use of product Export orientation
p.a.
Yes/ No

Page 1 of 7
 Application form for
Loans upto and including Rs. 50 lakh

IV. Existing Facilities with Banks /FIs incl. SIDBI

a Name of the Bank(s) / FI, Branch,

b Dealing person and contact tel. no.(s)..
c Dealing since (each Bank / FI)

Facilities enjoyed :

Nature of facility Amount (Rs. lakh) Rate of Nature of Security and value
(bankwise) interest
Sanctioned Outstanding as on ___ ___
Fund based
Basedkfjdffkldkfjdfkjdfkjdfkdjfkdjf
-Term Loan
-Working capital
Non Fund Based

Are there any defaults ? Yes/No

V. Financial Position of applicant unit/ associate concern

(Rs. lakh)
Net-worth Sales Net profit
Y1 Y2 Y3 Y1 Y2 Y3 Y1 Y2 Y3
Applicant unit
Associate concern I
Associate concern II

Details of Associate concerns to be given as per Annexure I.

VI. Project Details

6.1. Purpose for which assistance now required :

Purpose
1 Indicate whether Expansion /diversification / modernisation and Technology Upgradation for Energy Efficiency
details
2 If new products envisaged give details N/A
3 Details of expected incremental qualitative / quantitative benefits Saving in the fuel bill to the extent of 20-25% leading
to commensurate improvement in the bottom line of
the applicant unit.
4 Expected month/year of implementation 8-10 weeks
5 No. of employees existing and additional

Cost of Project (Rs. Lakh)

S. No Details Total Amount

1 Civil Works 1.00

2 Plant & Machinery (incl. installation) * 26.00
-Indigenous
-Imported
3 Professional charges -
4 Erection & commisioning charge -
5 Preliminary & pre-operative expenses [Loan syndication fee etc.] 0.68
&

Page 2 of 7
 Application form for
Loans upto and including Rs. 50 lakh

6 Taxes(CST)
7 Contigency -
TOTAL 27.68
* Details of Plant and machinery/ Misc. fixed assets at Annexure II and III

Indicate details of expenditure already incurred, if any and how the expenditure was financed ?
6.3. Means of Finance
(Rs. Lakh)
S. No. No. Details Total
1 Additional share capital / Internal accruals 6.92
2 Interest free Unsecured Loans -
3 Term Loan proposed from SIDBI / Banks inclusive of subsidy #### 20.76
Total 27.68
# ### In terms of existing guidelines of Ministry of MSME , GoI the subsidy amount is received on implementation of the project
Say within 3 months therefore the amount of subsidy is included in the term laon amount as bridge loan and funded by the bank
On receipt of the subsidy from the GoI it is adjusted towards the loan amount.

#
6.4 Whether additional Working Capital required for the unit. If yes, amount and arrangements proposed may
be indicated:

6.5 Technology

S. No. Item
1 Any Technical collaboration? If yes, details
2 Details of main technical professionals employed
3 Any quality certification obtained ? If yes enclose certificate.

6.6 Raw material / Labour/ Utilities

1 Raw material
(Details, arrangement, sources and
distance)
2 Power Connected Load

Utilised load

Requirement of power for Additional machines

Back-up arrangement (DG)

3 Other critical inputs if any

6.7 Marketing & Selling Arrangements

Items Applicants remarks

Main Markets (Locations)
Main buyers, Indicate clearly if the unit is relying on a single buyer
Locational
Indicate advantages
competitors
Whether product has multiple applications
Distribution channels ( e.g. direct sales, retail network, distribution network )

Page 3 of 7
 Application form for
Loans upto and including Rs. 50 lakh

Marketing team details, if any.

Orders on hand (enclose copies)

6.8 Projected profitability : Statement to be enclosed as per Annexure IV.

6.9 Others

Items
Please indicate the various licenses / consents for the project / unit already obtained from the
respective authorities
Please indicate licenses / consents for the project / unit that are yet to be obtained.
Category as per pollution control dept. If polluting, pollution control measures taken
Whether the project is entitled for any govt. subsidy, tax exemptions. Details thereof
Repayment period (in months) sought including repayment holiday requested, if any,
Details of Collateral security offered and value (basis).
List of guarantors for the proposed loan
Enclose documents as indicated in the check list at Annexure V.

6.10 Strengths / Weaknesses of the borrower (such as market standing, product/ service differentiation,
technical expertise, infrastructure facilities etc.)
Strengths

Weaknesses

DECLARATION
I/We certify that all information furnished by me/ us above and in the appendix/ annexures/ statements and other
papers enclosed is true; I/we have no borrowing arrangements for the unit with any bank / FI except as indicated in
the application; that there are no overdues / statutory dues/government enquiry/proceedings/prosecution against
the unit/associate concerns/ promoters/directors except as indicated in the application; that no legal action has
been/ is being taken against the unit/associate concerns/promoters/directors; that I/ we shall furnish all other
information that may be required by SIDBI in connection with my/our application and I/ We have no objection to
your furnishing the information submitted by me/ us to any agency as you may deem fit in connection with
consideration of the assistance. We have no objection to SIDBI/ its representatives making suitable enquiries while
considering the application.
Place : Signature
Date Name & Designation

Page 4 of 7
 Application form for
Loans upto and including Rs. 50 lakh

Annexure I
Details of Associate Concerns

Name , Address & products Existing Name & Address of existing Banker Facilities Enjoyed Share holding of the
manufactured since (s) main promoter(s) of
applicant unit

Annexure II

Particulars of machinery proposed for the project

Name of Name of manufacturer, Lead time Invoice Purpose /use Basis of Remark
machinery, contact person, for delivery price (for of machine selection of s reg.
(model / e-mail address of indigenous supplier after
specification) telephone no. machinery machinery) / sale
CIF price service
(for etc.
imported )
(Rs. lakh)
Rapier Laxmi shuttleless loom Pvt limited 3 Weeks 24.59 Weaving Crediability
machines 21, Punmaji Industrial Estate, of cloths of the
Shahpur, Dhobighat, Technolgy
Ahmedabad – 380004 Gujarat, Provider
INDIA
Phone: 91 (79) 2562-2510 / 2562-
4393 / 2562-0604
Fax: 91 (79) 2562-2845

Furnish competitive quotations, catalogues / invoice for each machinery proposed to be acquired

In case of second hand /fabricated machinery, indicate the need / reasons for acquiring such machinery. Also enclose
Chartered Engineer's certificate regarding residual value and life in respect of second hand machinery.

Annexure III
Details of Misc. Assets / equipment Proposed

S.No. Name of item Supplier Cost Purpose/ use of MFA Remarks

(Rs. lakh)

Page 5 of 7
 Annexure IV
Profitability projections for the Unit/ Company as a whole*
S.No. Item Actuals for Y1 Y2 Y3 Y4 Y5 Y6 TOTAL
previous
year
1 Total Income 12.83 12.83 12.83 12.83 12.83 12.83 76.97
2 Raw materials
Power and fuel
Wages and salaries
Selling expenses
Other expenses 1.11 1.16 1.22 1.28 1.35 1.41 7.53
Total Cost 1.11 1.16 1.22 1.28 1.35 1.41 7.53
3 Profit before depreciation, Interest and
11.72 11.67 11.61 11.55 11.48 11.42 69.44
taxes (PBDIT) (2 - 1)
4 Interest on Term Loan 1.88 1.81 1.47 1.04 0.55 0.07 6.83
5 Interest on Working Capital
6 Interest on unsecured loans
7 Depreciation 1.46 1.46 1.46 1.46 1.46 1.46 8.77
8 Profit before Tax (3 - 4 - 5 - 6 - 7) 8.38 8.39 8.67 9.04 9.47 9.88 53.84
9 Tax 0.00 1.84 3.14 3.51 3.70 3.85 16.05
10 Profit after Tax (8 - 9) 8.38 6.55 5.53 5.53 5.77 6.03 37.79
11 Dividends/ Withdrawals
12 Cash Accruals ( 10 - 11 + 7) 9.84 8.01 6.99 6.99 7.23 7.49 46.56
13 Repayments of all term liabilities
1.20 3.30 4.00 4.60 5.10 2.56 20.76
(Principal)
14 Debt Service Coverage Ratio 3.81 1.92 1.55 1.42 1.38 2.87 2.77
((10+7+4)/(13+4))
15 Average DSCR (Total of 10+7+4 for
projected period/(Total of 13+4 for
projected period) 2.77
* Please give projections for the entire tenure of SIDBI / Bank loan.

Page 6 of 7
 Annexure V
CHECK LIST of documents to be
submitted along with the application

S. No. Documents Y/N Reasons for Non-submission

1 SSI Regn. / CA certificate certifying SSI status
2 Certified copies of Memorandum & Articles of
association / Partnership Deed
3 Audited financial results for the last three years of
Applicant unit
4 Copies of lease deed / sale deed on which the
unit is situated
5 Copies of sanction letters from commercial banks
/ FIs which have sanctioned assistance to the unit
6 NOC from pollution control board/consent letter, if
applicable
7 IT Returns/Assessment orders/Sales tax returns
of the Applicant Unit/ promoters/directors for 2
years
8 List of existing plant and machinery
9 Competitive quotations for machines and Misc.
fixed assets proposed to be acquired under the
scheme
10 Duly signed latest net worth statements of
promoters/directors & guarantors in SIDBI format;
In case of guarantors please furnish, Name, Age,
Father's/Husband's name, residential address.
Details of similar guarantee, if any, given to other
institutions
11 2 sets of photographs along with signatures of all
promoters/directors/guarantors duly certified by a
Bank or Gazetted Officer.
12 Audited financial results for last three years for
each associate concerns. If applicable.
13 Copy of title deed of collateral security and
valuation report

*****

Page 7 of 7
 Bureau of Energy Efficiency (BEE)
(Ministry of Power, Government of India)
4th Floor, Sewa Bhawan, R. K. Puram, New Delhi – 110066
Ph.: +91 – 11 – 26179699 (5 Lines), Fax: +91 – 11 – 26178352
Websites: www.bee-india.nic.in, www.energymanagertraining.com

Zenith Energy Services Pvt. Ltd India SME Technology Services Ltd
10-5-6/B, My Home Plaza, Masab DFC Building, Plot No.37-38,
Tank HYDERABAD, AP 500 028 D-Block, Pankha Road,
Phone: 040 23376630, 31, Institutional Area, Janakpuri, New Delhi-110058
Fax No.040 23322517 Tel: +91-11-28525534, Fax: +91-11-28525535
Website: www.zenithenergy.com Website: www.techsmall.com