PROJECT REPORT

UPVC DOORS AND WINDOWS

PURPOSE OF THE DOCUMENT

T his particular pre-feasibility is regarding UPVC Doors and

Windows.
The objective of the re-feasibility is primarily to facilitate potential
entrepreneurs’ in project identification for investment and in order
to serve this objective; the document covers various aspects of the
project concept development, start-up, marketing, and finance and
business management.

[We can modify the project capacity and project cost as per your requirement. We can also
prepare project report on any subject as per your requirement.]

Prepared By:

Institute for Industrial development

A unit of M/S Samadhan Samiti

Email: support@iid.org.in

Phone: +91 7408733333, +91 7607655555

 UPVC DOORS AND WINDOWS

Introduction

UPVC, also known as Unplasticized Polyvinyl Chloride, is a low-

maintenance building material used as a substitute for painted wood,
mostly for window frames and doors. UPVC is a cheaper alternative to
expensive hardwood timber and aluminium. It is a popular material due to
its durability and it is a cost-effective option. UPVC is proven to offer
excellent performance and durability; it is long-lasting and requires very
little maintenance making it the perfect material for doors and windows. It
is also recognized for its thermal efficiency, sound insulation, and great
value for money.

Features of UPVC Doors and Windows

1. One of the best properties of uPVC is that it is incredibly strong despite

being lightweight, and uPVC doors and windows can be secured with
multi-point locking systems.
2. UPVC is very easy to install, remove, repair and reinstall, and all this
can be done without causing any structural damage to your walls or
columns.
3. When combined with the right noise-cancelling door or window glass,
UPVC is highly effective in providing acoustic insulation to your retail
store.
4. UPVC as a material is extremely efficient at keeping external heat at
bay, providing a strong insulating layer between the outdoors and the
indoors.

Types of Product Manufactured

1. UPVC Doors
2. UPVC Windows

Manufacturing process of UPVC Doors and Windows

Process Flow:

The raw material is procured from the authorized vendor and stored in the
inventory. At first, the PVC resin, stabilizer, lubricant, and coloring pigment
is added to the Pellet mixer in the required ratio. The mixer rotates at high
speed to spread the pellets evenly. The profile dies are mounted at the
end of the extruder to give the desired shape of the UPVC structure profile;
after approval from the production department. After this, the barrel
heaters are started and brought to the desired temperature and pressure.

The raw material is fed into the hopper of the extruder. From the hopper,
these plastic pellets come into the feed section of the barrel. There is a
screw inside the barrel which rotates about the vertical axis and
compresses the pellets along its length. Pellets get melts down and flown
plastically out through the extruder. This molten plastic is fed into shaped
and drawn dies having the desired profile of the structure. After this,
cooling and solidification of the molten plastic are performed using
suitable cooling arrangements. After this, the solidified UPVC structures
are fed into a cutting machine where these structures are cut down as per
the desired length with allowable tolerance and stored in the inventory.

In the next step, the sheet metal roll is brought from the inventory and fed
into the sheet metal slitting machine. The sheet roll is arranged in such a
way that one end of sheet roll is fed through the machine and the
remaining coil set will unfold as the sheet fed through the machine.

This machine cuts the sheet into fine strips along its length as per the
desired width. Rotary cutters are arranged at precise locations to perform
slitting operation. These fine strips of slitting sheets are winded over rolls
using sheet winding machine.
In the next step, these slitting sheets are fed into the Automatic roll forming
machine. There is an arrangement of a series of rollers, with each of these
rollers adding shape to the metal. The rolls work together and precisely
produce very high volumes of the reinforced sheets of the desired cross-
section. After this finished MS sheets are fed into cutting machine where
the rotary cutter cuts the sheets as per the desired length. In the next step,
these reinforced sheets are fed into punching the press to punch the
desired slots at the required location.

In the next step, drilling is performed as per the desired profile over the
surface of the UPVC structure for routing and drainage. This helps the
removal of rainwater from the surface. Automatic Multi-axis drilling
machines are used to perform these operations.

In the next step, these reinforced sheets are inserted into UPVC structures
and fixed firmly with screws. Torque guns are used at sufficient speed to
impart the desired momentum in the screws. After this, welding of the
reinforcement sheets is performed using the UPVC welding machine as
per the desired profile of windows and doors. The welding machine holds
the parts to be weld and uses high-frequency acoustic vibrations to
produce dynamic shear stress with frictional heat generation. This leads
to plastic deformation and weld formation.

After this, these welded sheets are fed into the UPVC profile cleaning
machine to trims off the burr, weld slag, and excess material. In the next
step, an oil gasket is pasted firmly at the corners and faces assembled
sheets using a gasket tool. The gasket acts as a seal to make the doors
and windows sound and waterproof.

In the next step, door and window handles, latches, locks are assembled
using screw and torque gun. After this glass cutting is performed as per
the desired profile of the doors and windows using a glass cutting tool.
The glass beads are cut at an angle of 45° using a glass beading cutting
machine. These glass and glass beads are assembled to the doors and
windows using suitable glazing and gasket seals.

In the next step, these doors and windows are precisely checked as per
the desired quality standards. After this, they are safely packed and
dispatched in the required quantity.
UPVC Doors and Windows Market analysis

The Indian uPVC doors and windows market is expected to grow at a

CAGR of 7.0% during 2015-2020. The major drivers of the Indian uPVC
doors and windows market are increasing new housing construction and
replacement activities, which have contributed to the growth of this market.
Another important factor that drives this market is their tangible and
intangible benefiting features, such as the uPVC doors and windows are
thermal, and water- and wind-resistant. They are corrosion-free. These
doors and windows are termite free, highly sound insulated, dustproof,
highly durable, and need no maintenance. They are energy efficient and
could save energy up to 25% to 30%.

Land &Building required:

Land required 3,000 square feet

Approximate rent for the same is Rs. 35,000 per month.

Machinery & Equipment’s required:

Name Cost (Rs.)

Double head cutting machine 480000

Glazing bead Cutting saw 80000

Manual end Milling Machine 55000

Upvc window 2 head seamless welding machine 460000

Portable Copy Router 45000

Manual tool for cleaning pneumatic 17500

Manual tool for water slot 10500

Manual V Welding tool 18000

Sub total 1166000

GST @ 18% 209880

Total Machine cost 1375880

 Cost of the machine is other than transportation cost.

Raw Material Requirement

Following raw material is required as the major raw material for the UPVC
Doors and Windows Manufacturing process.

a) Reinforcement steel
b) Screws & Hooks
c) Glass
d) Rubber Gasket
e) Mosquito mesh
f) Wheel for smooth sliding
g) Lockers etc.

This project report is prepared on the basis of average size of upvc doors
and windows, which are as follows:

 Average Window size is 4*4 sq ft = 16 sq ft.

 Average Door size is 6*4 sq ft = 24 sq ft.
 Average Raw Material Cost Per square Feet is approx. Rs.150.

Labour & Staff Requirement:

8 Manpower are required for the UPVC Doors and Windows unit.

Includes:

4 Skilled Labour
2 Unskilled Labour

2 Helper

UPVC Doors and Windows License & registration

For Proprietor:
 Obtain the GST registration.
 Additionally, obtain the Udyog Aadhar registration Number.
 Fire/pollution license as required.
 Choice of a Brand Name of the product and secure the name with
Trademark if required.

Implementation Schedule

S.N. Activity Time Required

(in Months)
1 Acquisition Of premises 1
2 Construction (if Applicable) 1- 2 Months
3 Procurement & installation of Plant & 2
Machinery
4 Arrangement of Finance 1
5 Requirement of required Manpower 1
Total time Required (some activities shall run 3-4 Months
concurrently)
 FINANCIAL ASSISTANCE REQUIRED

Term Loan of Rs. 13.5 lakh and Working Capital limit of Rs. 5 Lacs
(in Lacs)

Own Bank
COST OF PROJECT PARTICULARS Amount Contribution Finance
10.00% 90.00%
Building Civil Work
Plant & Machinery 13.76 1.38 12.38
Furniture & Fixtures and Other
Assets 1.24 0.12 1.12
Working capital 5.55 0.56 5.00
Total 20.55 2.05 19.52

MEANS OF
FINANCE PARTICULARS AMOUNT
Own Contribution 2.05
Bank Loan 13.50
Working capital Limit 5.00

Total 20.55
COMPUTATION OF PRODUCTION OF UPVC DOORS AND WINDOWS

Items to be Manufactured

UPVC Doors and Windows

Machine capacity Day 200 Square Feet

working Days in a month 25

Working Days per annum 300

Production capacity per Annum 60,000 Square feet

Production of UPVC Doors and Windows

Production Capacity Square Feet

1st year 50% 30,000

2nd year 55% 33,000

3rd year 60% 36,000

4th year 65% 39,000

5th year 70% 42,000

Raw Material Cost

Year Capacity Rate Amount

Utilisation (Per Square Feet) (Rs. in lacs)

1st year 50% 150.00 45.00

2nd year 55% 155.00 51.15

3rd year 60% 160.00 57.60

4th year 65% 165.00 64.35

5th year 70% 170.00 71.40

 COMPUTATION OF SALE OF UPVC DOORS AND
WINDOWS (In Lacs)

Particulars 1st year 2nd year 3rd year 4th year 5th year
Op Stock - 1,000 1,100 1,200 1,300

Production 30,000 33,000 36,000 39,000 42,000

Less : Closing Stock 1,000 1,100 1,200 1,300 1,400

Net Sale 29,000 32,900 35,900 38,900 41,900

sale price per Square Feet 250.00 257.50 265.23 273.18 281.38
Sales (in Lacs) 72.50 84.72 95.22 106.27 117.90

BREAK UP OF LABOUR CHARGES

Particulars Wages No of Total

Rs. per Month Employees Salary

Skilled (in thousand rupees) 18,000 4 72,000

Unskilled (in thousand rupees) 10,000 2 20,000

Helper 8,000 2 16,000

Total salary per month 108,000

Total annual labour charges (in lacs) 12.96

Utility Charges at 100% capacity (per month)

Particulars value Description
Power connection required 12.5 KWH
consumption per day 100 units

Consumption per month 2,500 units

Rate per Unit 7 Rs.
power Bill per month 17,500 Rs.
PROJECTED PROFITABILITY STATEMENT (In Lacs)

PARTICULARS 1st year 2nd year 3rd year 4th year 5th year

Capacity Utilisation % 50% 55% 60% 65% 70%

SALES

Gross Sale

UPVC Doors & Windows 72.50 84.72 95.22 106.27 117.90

Total 72.50 84.72 95.22 106.27 117.90

COST OF SALES

Raw Material Consumed 45.00 51.15 57.60 64.35 71.40

Electricity Expenses 1.05 1.16 1.26 1.37 1.47

Depreciation 2.19 1.87 1.59 1.36 1.16

Labour 12.96 13.61 14.29 15.00 15.90

Repair & maintenance 1.81 2.54 2.86 3.19 3.54

consumables 1.31 1.52 1.71 1.91 2.24

other direct expenses 0.73 1.02 1.14 1.28 1.41

Cost of Production 65.04 72.86 80.45 88.45 97.12

Add: Opening Stock /WIP - 2.17 2.43 2.68 2.95

Less: Closing Stock /WIP 2.17 2.43 2.68 2.95 3.24

Cost of Sales 62.87 72.60 80.20 88.19 96.83

GROSS PROFIT 9.63 12.12 15.02 18.08 21.06

Gross PROFIT % 13% 14% 16% 17% 18%

Interest on Term Loan 1.21 1.06 0.76 0.46 0.16

Interest on working Capital 0.50 0.50 0.50 0.50 0.50

Selling & distribution Expenses 0.73 1.02 1.19 1.59 1.77

Rent 4.20 4.62 5.08 5.59 6.15

TOTAL 6.63 7.20 7.53 8.15 8.58

NET PROFIT 3.00 4.92 7.48 9.94 12.48

Taxation 0.26 0.64 1.69

PROFIT (After Tax) 3.00 4.92 7.22 9.30 10.80

PROJECTED BALANCE SHEET (In Lacs)

PARTICULARS 1st year 2nd year 3rd year 4th year 5th year

Liabilities

Capital

opening balance 2.05 3.46 6.69 9.48

Add:- Own Capital 2.05

Add:- Retained Profit 3.00 4.92 7.22 9.30 10.80

Less:- Drawings 3.00 3.50 4.00 6.50 8.00

Closing Blance 2.05 3.46 6.69 9.48 12.28

Term Loan 12.00 9.00 6.00 3.00 -

Working Capital Limit 5.00 5.00 5.00 5.00 5.00

Sundry Creditors 1.50 1.71 1.92 2.15 2.38

Provisions & Other Liab 0.20 0.30 0.45 0.54 0.68

TOTAL : 20.75 19.47 20.06 20.17 20.33

Assets

Fixed Assets ( Gross) 15.00 15.00 15.00 15.00 15.00

Gross Dep. 2.19 4.05 5.65 7.00 8.16

Net Fixed Assets 12.81 10.95 9.35 8.00 6.84

Current Assets

Sundry Debtors 3.63 4.24 5.71 6.38 7.07

Stock in Hand 3.67 4.13 4.60 5.09 5.62

Cash and Bank 0.64 0.15 0.39 0.70 0.81

TOTAL : 20.75 19.47 20.06 20.17 20.33

PROJECTED CASH FLOW STATEMENT (In Lacs)

PARTICULARS 1st year 2nd year 3rd year 4th year 5th year

SOURCES OF FUND

Own Margin 2.05

Net Profit 3.00 4.92 7.48 9.94 12.48

Depreciation & Exp. W/off 2.19 1.87 1.59 1.36 1.16

Increase in Cash Credit 5.00 - - - -

Increase In Term Loan 13.50 - - - -

Increase in Creditors 1.50 0.21 0.22 0.23 0.24

Increase in Provisions & Oth lib 0.20 0.10 0.15 0.09 0.14

TOTAL : 27.43 7.09 9.44 11.61 14.01

APPLICATION OF FUND

Increase in Fixed Assets 15.00

Increase in Stock 3.67 0.47 0.47 0.49 0.52

Increase in Debtors 3.63 0.61 1.48 0.66 0.70

Repayment of Term Loan 1.50 3.00 3.00 3.00 3.00

Drawings 3.00 3.50 4.00 6.50 8.00

Taxation - - 0.26 0.64 1.69

TOTAL : 26.79 7.58 9.20 11.29 13.91

Opening Cash & Bank Balance - 0.64 0.15 0.39 0.70

Add : Surplus 0.64 (0.49) 0.23 0.31 0.10

Closing Cash & Bank Balance 0.64 0.15 0.39 0.70 0.81
COMPUTATION OF CLOSING STOCK & WORKING CAPITAL (In Lacs)

PARTICULARS 1st year 2nd year 3rd year 4th year 5th year

Finished Goods

2.17 2.43 2.68 2.95 3.24

Raw Material

1.50 1.71 1.92 2.15 2.38

Closing Stock 3.67 4.13 4.60 5.09 5.62

COMPUTATION OF WORKING CAPITAL REQUIREMENT (In Lacs)

TRADITIONAL METHOD

Particulars Amount Own contribution Bank Finance

Finished Goods & Raw Material 3.67 10% 0.37 90% 3.30

Less : Creditors 1.50 10% 0.15 90% 1.35

Paid stock 2.17 10% 0.22 90% 1.95

Sundry Debtors 3.63 10% 0.36 90% 3.26

5.79 10% 0.58 90% 5.21

Working Capital Required 5.00

COMPUTATION OF DEPRECIATION

Description Plant & Machinery Furniture TOTAL

Rate of Depreciation 15.00% 10.00%

Opening Balance - - -

Addition 13.76 1.24 15.00

Total 13.76 1.24 15.00

Less : Depreciation 2.06 0.12 2.19

WDV at end of Year 11.69 1.12 12.81

Additions During The Year - - -

Total 11.69 1.12 12.81

Less : Depreciation 1.75 0.11 1.87

WDV at end of Year 9.94 1.00 10.95

Additions During The Year - - -

Total 9.94 1.00 10.95

Less : Depreciation 1.49 0.10 1.59

WDV at end of Year 8.45 0.90 9.35

Additions During The Year - - -

Total 8.45 0.90 9.35

Less : Depreciation 1.27 0.09 1.36

WDV at end of Year 7.18 0.81 8.00

Additions During The Year - - -

Total 7.18 0.81 8.00

Less : Depreciation 1.08 0.08 1.16

WDV at end of Year 6.10 0.73 6.84

CALCULATION OF D.S.C.R

PARTICULARS 1st year 2nd year 3rd year 4th year 5th year

CASH ACCRUALS 5.18 6.78 8.81 10.65 11.95

Interest on Term Loan 1.21 1.06 0.76 0.46 0.16

Total 6.39 7.85 9.58 11.12 12.12

REPAYMENT

Instalment of Term Loan 1.50 3.00 3.00 3.00 3.00

Interest on Term Loan 1.21 1.06 0.76 0.46 0.16

Total 2.71 4.06 3.76 3.46 3.16

DEBT SERVICE COVERAGE RATIO 2.36 1.93 2.55 3.21 3.83

AVERAGE D.S.C.R. 2.78

 REPAYMENT SCHEDULE OF TERM LOAN
Interest 10%
Closing
Year Particulars Amount Addition Total Interest Repayment Balance
ist Opening Balance

1st month - 13.50 13.50 - - 13.50

2nd month 13.50 - 13.50 0.11 - 13.50
3rd month 13.50 - 13.50 0.11 - 13.50
4th month 13.50 - 13.50 0.11 13.50
5th month 13.50 - 13.50 0.11 13.50
6th month 13.50 - 13.50 0.11 13.50
7th month 13.50 - 13.50 0.11 0.25 13.25
8th month 13.25 - 13.25 0.11 0.25 13.00
9th month 13.00 - 13.00 0.11 0.25 12.75
10th month 12.75 - 12.75 0.11 0.25 12.50
11th month 12.50 - 12.50 0.10 0.25 12.25
12th month 12.25 - 12.25 0.10 0.25 12.00

1.21 1.50
2nd Opening Balance

1st month 12.00 - 12.00 0.10 0.25 11.75

2nd month 11.75 - 11.75 0.10 0.25 11.50
3rd month 11.50 - 11.50 0.10 0.25 11.25
4th month 11.25 - 11.25 0.09 0.25 11.00
5th month 11.00 - 11.00 0.09 0.25 10.75
6th month 10.75 - 10.75 0.09 0.25 10.50
7th month 10.50 - 10.50 0.09 0.25 10.25
8th month 10.25 - 10.25 0.09 0.25 10.00
9th month 10.00 - 10.00 0.08 0.25 9.75
10th month 9.75 - 9.75 0.08 0.25 9.50
11th month 9.50 - 9.50 0.08 0.25 9.25
12th month 9.25 - 9.25 0.08 0.25 9.00
1.06 3.00
3rd Opening Balance

1st month 9.00 - 9.00 0.07 0.25 8.75

2nd month 8.75 - 8.75 0.07 0.25 8.50
3rd month 8.50 - 8.50 0.07 0.25 8.25
4th month 8.25 - 8.25 0.07 0.25 8.00
5th month 8.00 - 8.00 0.07 0.25 7.75
6th month 7.75 - 7.75 0.06 0.25 7.50
 7th month 7.50 - 7.50 0.06 0.25 7.25
8th month 7.25 - 7.25 0.06 0.25 7.00
9th month 7.00 - 7.00 0.06 0.25 6.75
10th month 6.75 - 6.75 0.06 0.25 6.50
11th month 6.50 - 6.50 0.05 0.25 6.25
12th month 6.25 - 6.25 0.05 0.25 6.00
0.76 3.00
4th Opening Balance

1st month 6.00 - 6.00 0.05 0.25 5.75

2nd month 5.75 - 5.75 0.05 0.25 5.50
3rd month 5.50 - 5.50 0.05 0.25 5.25
4th month 5.25 - 5.25 0.04 0.25 5.00
5th month 5.00 - 5.00 0.04 0.25 4.75
6th month 4.75 - 4.75 0.04 0.25 4.50
7th month 4.50 - 4.50 0.04 0.25 4.25
8th month 4.25 - 4.25 0.04 0.25 4.00
9th month 4.00 - 4.00 0.03 0.25 3.75
10th month 3.75 - 3.75 0.03 0.25 3.50
11th month 3.50 - 3.50 0.03 0.25 3.25
12th month(Subsidy
adjusted) 3.25 - 3.25 0.03 0.25 3.00
0.46 3.00
5th Opening Balance
1st month 3.00 - 3.00 0.02 0.25 2.75
2nd month 2.75 - 2.75 0.02 0.25 2.50
3rd month 2.50 - 2.50 0.02 0.25 2.25
4th month 2.25 - 2.25 0.02 0.25 2.00
5th month 2.00 - 2.00 0.02 0.25 1.75
6th month 1.75 - 1.75 0.01 0.25 1.50
7th month 1.50 - 1.50 0.01 0.25 1.25
8th month 1.25 - 1.25 0.01 0.25 1.00
9th month 1.00 - 1.00 0.01 0.25 0.75
10th month 0.75 - 0.75 0.01 0.25 0.50
11th month 0.50 - 0.50 0.00 0.25 0.25
12th month 0.25 - 0.25 0.00 0.25 -

0.16 3.00

DOOR TO DOOR 60 MONTHS

MORATORIUM PERIOD 6 MONTHS
REPAYMENT PERIOD 54 MONTHS
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