Product Description: These are pipe fittings which are mainly used in kitchens bath rooms, toilets and other similar facilities. The fittings include basin valves, kitchen sink valves, shower/bath valves, and basin and kitchen sink drainage systems. The products are all chrome plated to protect them from rusting and to give them shinning and attractive appearance. The products intended to be produced in the project idea are chrome plated fittings to be used in showers, bath rooms and kitchens. The plant could also produce gate valves. The main types of products will include cocks, shower fittings, bath tub fittings, hand wash basin traps, bidet fittings and bidet traps.
Market Potential: Though the construction industry is expanding and growing at a rapid rate during the last ten years, many types of construction materials are imported. And metallic sanitary fittings are one of the groups of construction materials which are imported. Between 1980 and 1990 when imports were restricted by government policy, an annual average import of metallic fittings was about 269,000 kgs. The projected demand for these fittings in 2008 will be 2,895,000 kgs. Currently, there is a small plant with a production capacity of about 75,000 pieces of pipe fittings per year. The projected demand is much larger than the capacity of the domestic plant. Hence for the purpose of substituting imports, one or two plants have to be established to meet the current and future demand of metallic fittings. With the growth of the construction industry, it is inevitable that the demand for metallic fittings will also grow. The Amhara region can take advantage of this market opportunity by establishing a plant which will produce metallic fittings.
Source of Raw Materials: The major raw materials are brass scrap, copper ignots, brass bars and tubes, electroplating chemicals such as nicked chloride, nickel sulphate, chrome salt and sulphuric acid. Most of these of raw materials will be imported. Brass scrap could be collected locally.
Process and Technology: The production process can be classified into four stages-casting, machining, electroplating and assembling. Brass is used to produce the main component. Gravity die casting technique is employed to produce value body, bonnet and other parts that can be easily produced by casting. The die (mould) used in this case is made from cast-iron and is permanent. The casting process begins with melting the brass ignot and scrap in a furnace (induction furnace in this case). After melting the metal is tapped into a ladle and the ladle is carried to the pouring station where the molten brass is poured into a metal die (mould). After cooling, the die and the castings are separated by splitting apart the two parts of the mould. The castings separated from the die have spruces, runners, and gates which have to be removed and reclaimed for remelting for reuse. This operation is called fettling. It is done in various ways-hammering, tubing and grinding. After fettling, the castings are sent to the machine shop for machinery parts such as the tags body, handle, bounet, sleeve, shower-head and knob. The machining operation includes facing, chambering, boring, drilling, taping and threading on all openings and grinding and polishing on all lapped surfaces.
In addition to die cast components, there are other sanitary fitting parts which require machining. These are mechanical components from free cutting brass such as spindle, seal holder, connecting foods, tubes and nuts. Producing these parts requires cutting the brass bar, facing, chambering threading, grinding and polishing. The next major manufacturing stage is chrome plating. But before plating, the die cast components have to undergo physical and chemical cleaning. Physical cleaning is carried out by rough and smooth grinding accompanied by primary and fine polishing. Chemical cleaning removes lubrication oil, greases oxides, dirt, metallic particles and abrasives that might have contaminated the cast components during fabrication. Chemical cleaning involves primary degreasing, pickling in water solution of acids, chemical degreasing by water solutions of salts and alkalic and activation by dipping the components in 10 percent water solution of sulphuric acid. After the cleaning processes, decorative plating is applied directly by dipping the components into the proper electrolytic solution containing chromic anhydride and proper current density. Finally the components are assembled, tested for leakages and packed. Types of machinery and equipment required include molding and Core making, melting furnace, shot blasting, polishing and buffing equipment, machine shop, electroplating plant, assembling line and testing equipment.
Estimated Investment: For a plant that will produce 1000 tons of sanitary fittings per year ( working 300 days and operating eight hours a day) the estimated investment will be:-
Ø Building/Shade 6000m2 at Birr 1500/m2 = Birr 9,000,000
Ø Machinery ........................................... = Birr 16,400,000
Ø Working capital ................................... = Birr 4,000,000
Total = Birr 29,400,000
Benefits: Similar to other projects
Location: Combolcha, Bahir Dar......