Profile No.

: 11 NIC Code: 22208

MANUFECTURING OF LEVEL CONTROLLER

FOR HOUSE HOLD TANKS

1. INTRODUCTION:

In many homes and other public places, ground water is used, which is
pumped up to overhead tanks using water pumps which are controlled by
electric motors. Controlling the pumps is often a necessity to avoid wastage
of water.

The level controller is a system to sense water level. When water level in
the overhead tank exceeds the required upper level, it helps in
automatically turning off the pump motor thereby preventing the over flow
of water. Similarly, it can also have lower water level sensor to
automatically switch on pump motor. These systems are useful in reducing
the water wastage and ensures un-interrupted water supply to consumers.

2. PRODUCT & ITS APPLICATION:

The level controller consists of water level sensors, and electric circuit system to
control power supply to pump motor. It uses a relay to cut off the power supply to
the water pump.

Level sensors are one of the very important sensors and play very important role in
a variety of consumer/ industrial applications. As with other types of sensors, level
sensors are available or can be designed using a variety of sensing principles.
Selection of an appropriate type of sensor suiting to the application requirement is
very important. A variety of sensors are available for point level detection of solids.
These include vibrating, rotating paddle, and mechanical diaphragm, microwave,
and capacitance, optical, pulsed-ultrasonic and ultrasonic level sensors. There are
 many physical and application variables that affect the selection of the optimal
level monitoring method for industrial and commercial processes. Also important
are the application constraints: price, accuracy, appearance, response rate, ease of
calibration or programming, physical size and mounting of the instrument,
monitoring or control of continuous or discrete point levels.

Water level sensor and switch also called float switch is a device used to detect the
level of liquid within a tank. The switch may be used to control a pump, as an
indicator, an alarm, or to control other devices like pump motor. Common type is a
float mounted in a tube that rises on a rod and actuates a micro switch. Another
pattern of float, contains a magnet, surrounds the tube and is guided by it. Almost
all systems use electronic systems are used to automatically control operations.

Now days preferred level sensor is ultrasonic systems due to non-contact –

movement free operations that is reliable and almost maintenance free. The
ultrasonic sensor senses the level of water in the tank by transmitting ultrasonic
signals towards the tank. The water in the tank reflects back the ultrasonic signals,
and received by the receiver. The signal received is converted to electric signal
pulses that denote the level of water in the tank. The signals are fed to the Micro
controller and compared to set levels. As the water level decreases or increases
above or below certain level, the Micro controller causes the MOSFET to be
switched on or off power supply to relay to operate the pump motor.

Any or all of the systems can be selected in the project for development and
supply level controllers for domestic as well as industrial applications.

3. DESIRED QUALIFICATIONS FOR PROMOTER:

Any ITI, Diploma or Graduate with some background in manufacturing or

marketing.

4. MARKET POTENTIAL AND MARKETING ISSUES. IF ANY:

Potable clean Water is becoming scarce commodity and there is growing

 awareness for preservation will lead to steps to reduce wastage. One of the major
wastage is tank overflow in residential overhead water storage systems. This is a
strong demand driver for the water level controllers in huge quantity in coming
years. The demand is likely to grow for long time due to population growth and
ever growing construction sector.

Besides level controllers have many industrial chemical, pharma, dairy, beverages
etc. processes and machinery sector, thereby having good potential for the
entrepreneur to grow in this field.

5. RAW MATERIAL REQUIREMENTS:

Main components and raw materials are based on design of water level sensors.
Most electronic components like sensors, micro – controller, etc. are procured from
large suppliers. For Mechanical construction of floats and switch etc. steel/ PVC
tubes and, molded plastic floats are procured or produced.

6. MANUFACTURING PROCESS:

The manufacturing process consists of procuring standard components like control

circuit and sensors like mechanical floats, relays and switches. The control circuit is
assembled and configured as per the requirements of installation and tested for
correct operations. These per-configured sub-assemblies are assembled and
mounted at the site with brackets, and mountings. The system undergoes for final
testing at the as per specified configuration and connected with alarm, and motor
controls.

7. MANPOWER REQUIREMENT:

The unit shall require highly skilled service persons. The unit can start from 10
employees initially and increase to 25 or more depending on business volume.

Type of Monthly
Sr No Number of employees required
Employees Salary
Year
Year 1 Year 2 Year 3 Year 5
4
1 Skilled Operators 18000 2 3 4 5 6
 Semi-Skilled/
2 8000 4 5 6 10 12
Helpers
1 Supervisor/ Manager 25000 1 1 3 3 3
2 Accounts/ Marketing 16000 2 2 2 2 2
3 Other Staff 7000 1 2 2 2 2
TOTAL 10 13 17 22 25

8. IMPLEMENTATION SCHEDULE:

The unit can be implemented within 3 months from the serious initiation of project
work.

Time Required in
Sr No Activities
Months
1 Acquisition of Premises -
2 Construction (if Applicable) -
Procurement and Installation of Plant and
3 2
Machinery
4 Arrangement of Finance 2
5 Manpower Recruitment and start up 2
Total Time Required (Activities run concurrently) 3

9. COST OF PROJECT:

The unit will require total project cost of Rs 31.85 lakhs as shown below:

Sr No Particulars In Lakhs

1 Land 0.00
2 Building 0.00
3 Plant and Machinery 8.22
4 Fixtures and Electrical Installation 1.60
Other Assets/ Preliminary and Preoperative
5 1.00
Expenses
6 Margin for working Capital 21.03
TOTAL PROJECT COST 31.85
10. MEANS OF FINANCE:

The project will require promoter to invest about Rs 23.73 lakhs and seek bank
loans of Rs 8.12 lakhs based on 70% loan on fixed assets.

Sr No Particulars In Lakhs

1 Promoters Contribution 23.73

2 Loan Finance 8.12
TOTAL: 31.85

11. WORKING CAPITAL REQUIREMENTS:

Working capital requirements are calculated as below:

Gross Margin Bank

Sr No Particulars Margin %
Amount Amount Finance
1 Inventories 20.04 40 8.02 12.02
2 Receivables 14.65 40 5.86 8.79
3 Overheads 1.81 100 1.81 0.00
4 Creditors 13.36 40 5.34 8.02
TOTAL 49.86 21.03 28.83

12. LIST OF MACHINERY REQUIRED:

Quantit
Sr No Particulars UOM Rate Total Value
y

Main Machines/ Equipment

1 Incoming Inspection unit Nos 1 25000 25000

2 Coil winding machine Nos 1 35000 35000
3 Component Assembly /soldering Nos 1 60000 60000
4 PCB Test Station Nos 1 30000 30000
5 Component Test station Nos 1 30000 30000
6 Assembly line for PCB Nos 1 35000 35000

7 Assembly inspection Station Nos 1 20000 20000

 8 PCB Testing Station Nos 1 25000 25000
9 Assembly Line of Final product Nos 1 15000 15000
10 Testing Micro-controllers Nos 1 25000 25000
12 Packing Labeling Station Nos 1 20000 20000
13 Oscilloscope single/ dual waves Nos 1 130000 130000
14 Shear machines Nos 1 12000 12000
15 DC power supply LS 2 25000 50000
16 Welding machine Nos 2 40000 80000
17 Final Product test set up Nos 1 40000 40000

subtotal: 632000

Quantit
Sr No Particulars UOM Rate Total Value
y
Tools and Ancillaries
Jigs Fixture Tools for Assly line
1 LS 1 150000 150000
etc.
2 Hand Tools and gauges LS 1 40000 40000
subtotal: 190000
Fixtures and Elect Installation
Storage and transport bins and
LS 1 60000 60000
trolleys
Office Furniture LS 1 20000 20000
Telephones/ Computer LS 1 30000 30000
Electrical Installation LS 1 50000 50000
subtotal: 160000
Other Assets/ Preliminary and
LS 1 100000 100000
Preoperative Expenses
TOTAL PLANT MACHINERY
1082000
COST

13. PROFITABILITY CALCULATIONS:

Sr
Particulars UOM Year Wise estimates
No
 Year
Year 1 Year 2 Year 3 Year 4
5
1 Capacity Utilization % 30 40 50 60 70
Rs. 410.1
2 Sales 175.78 234.37 292.96 351.55
Lakhs 4
Raw Materials & Other Rs. 374.1
3 160.33 213.77 267.22 320.66
Direct Inputs Lakhs 0
Rs.
4 Gross Margin 15.45 20.59 25.74 30.89 36.04
Lakhs
Rs.
5 Overheads Except Interest 9.74 9.74 9.74 9.74 9.74
Lakhs
Rs.
6 Interest 1.14 1.14 1.14 1.14 1.14
Lakhs
Rs.
7 Depreciation 1.08 1.08 1.08 1.08 1.08
Lakhs
Rs.
8 Net Profit Before Tax 3.49 8.64 13.79 18.94 24.08
Lakhs

14. BREAK EVEN ANALYSIS

The project is can reach breakeven capacity at 23.22% of the installed capacity as
depicted here below:

Sr No Particulars UOM Value

1 Sales at Full Capacity Rs. Lakhs 585.92

2 Variable Costs Rs. Lakhs 534.43
3 Fixed Cost incl. Interest Rs. Lakhs 11.96

4 Break Even Capacity % of Inst Capacity 23.22