Power Pack/Battery Eliminators

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Product Code (ASICC) 77606
Quality and Standards As per customers specification
Production Capacity Qty. : 120,000 Nos./ an
Value : Rs. 2,25,00,000
Uploaded on March 2007


Battery eliminator is used in place of ordinary dry batteries as power source for equipments like radio receivers AM/FM, tape recorders, calculators etc. and other low power operated equipments. Battery eliminator's output is DC voltage which usually varies from 1.5 V / 3 V to 12 Volts / upto 500 mA. This item is reserved for manufacture in the small scale sector.

Market Potential

There are large number of units in Small Scale Sector in the country manufacturing Battery Eliminators. Since they are used with radio receivers, tape recorders, calculators and other low power operated equipments/appliances, the demand of Battery Eliminator is also in proportional to their use. The Battery Eliminators are available in the range of 1.5V/3V/6V/9V/12V at 500 mA between Rs. 40 to Rs. 170 depending upon the transformers using CRGO sheets and good quality components.

The consumer electronics sector continues to consolidate its production base and has achieved a production level of Rs. 12700 Crores during 2001 and which achieved a growth rate of 10% in 2001 over 2000. The production of Battery Eliminators in 2001 was to the tune of Rs. 18.03 Millions.

Basis and Presumptions

  • The basis for calculation of production capacity has been taken on single shift basis on 75% efficiency.
  • The maximum capacity utilization on single shift basis for 300 days a year. During first year and second year of operations the capacity utilization is 60% and 80% respectively. The unit is expected to achieve full capacity utilization from the third year onwards.
  • The salaries and wages, cost of raw materials, utilities, are based on the prevailing rates. These cost factors are likely to vary with time and location .
  • Interest on term loan and working capital loan has been taken at the rate of 12% on an average. This rate may vary depending upon the policy of the financial institutions/agencies from time to time.
  • The cost of machinery and equipments refer to a particular make/model and prices are approximate.
  • The break-even point percentage indicated is of full capacity utilization.
  • The project preparation cost etc. whenever required could be considered under pre-operative expenses.
  • The essential production machinery and test equipment required for the project have been indicated. The unit may also utilize common test facilities available at Electronics Test and Development Centres (ETDCs) and Electronic Regional Test Laboratories (ERTLs) set up by the State Governments and STQC Directorate of the department of Information Technology, Ministry of Communication and Information Technology, to manufacture products conforming to Bureau of Indian Standards.

Implementation Schedule

The major activities in the implementation of the project has been listed and the average time for implementation of the project is estimated at 12 months

Name of Activity

Period in Months (Estimated)

Preparation of project report 1
Registration and other formalities 1
Sanction of loan by financial institutions 3
Plant and Machinery  
(i) Placement of orders 1
(ii) Procurement 2
(iii) Power connection/ Electrification 2
(iv) Installation/Erection of machinery/Test Equipment 2
Procurement of Raw materials 2
Recruitment of Technical Personnel etc. 2
Trial Production 11
Commercial Production 12


  • Many of the above activities shall be initiated concurrently.
  • Procurement of raw materials commences from the 8th month onwards.
  • When imported plant and machinery are required the implementation period of project may vary from 12 months to 15 months.

Technical Aspects

Process of Manufacture

The battery eliminator consists of a transformer (using CRGO sheets), rectifying circuit and a filter. The output AC Voltage is stepped down and rectified and filtered. The components after checking to its value are assembled and soldered on the terminal strip/PCB. The PCB is mounted in the cabinet along with the transformer. Electro-mechanical components are fixed. After the wiring is completed the product is finally tested for its output voltage/current.

Quality Control and Standards

Input Voltage 220 Volts AC, 50 Hz.
Output Voltage 1.5 to 12 Volts DC
Load 500 mA
Ripple Less than 2 mV

Production Capacity


Value (Rs.)

1,20,000 Nos per annum 2,25,00,000
Motive Power 5 KVA

Pollution Control

The Govt. accords utmost importance to control environmental pollution. The small-scale entrepreneurs should have an environmental friendly attitude and adopt pollution control measures by process modification and technology substitution.

India having acceded to the Montreal Protocol in Sept. 1992, the production and use of Ozone Depleting Substances (ODS) like Chlorofluoro Carbon (CFC), Carbon Tetrachloride, Halons and Methyl Chloroform etc. need to be phased out immediately with alternative chemicals/solvents. A notification for detailed Rules to regulate ODS phase out under the Environment Protection Act, 1986 have been put in place with effect from 19th July 2000.

The following steps are suggested which may help to control pollution in electronics industry wherever applicable

  • In electronic industry fumes and gases are released during hand soldering/wave soldering/Dip soldering, which are harmful to people as well as environment and the end products. Alternate technologies may be used to phase out the existing polluting technologies. Numerous new fluxes have been developed containing 2-10% solids as opposed to the traditional 15-35% solids.
  • Electronic industry uses CFC, Carbon Tetrachloride and Methyl Chloroform for cleaning of printed circuit boards after assembly to remove flux residues left after soldering, and various kinds of foams for packaging.

    Many alternative solvents could replace CFC-113 and Methyl Chloroform in electronics cleaning. Other Chlorinated solvents such as Trichloroethylene, Perchloroethylene and Methylene Chloride have been used as effective cleaners in electronics industry for many years. Other organic solvents such as Ketones and Alcohols are effective in removing both solder fluxes and many polar contaminants.

Energy Conservation

With the growing energy needs and shortage coupled with rising energy cost, a greater thrust in energy efficiency in industrial sector has been given by the Govt. of India since 1980s. The Energy Conservation Act, 2001, has been enacted on 18th August 2001, which provides for efficient use of energy, its conservation and capacity building of Bureau of Energy Efficiency created under the Act.

The following steps may help for conservation of electrical energy

  • Adoption of energy conserving technologies, production aids and testing facilities.
  • Efficient management of process/ manufacturing machineries and systems, QC and testing equipments for yielding maximum Energy Conservation.
  • Optimum use of electrical energy for heating during soldering process can be obtained by using efficient temperature controlled soldering and desoldering stations.
  • Periodical maintenance of motors, compressors etc.
  • Use of power factor correction capacitors. Proper selection and layout of lighting system; timely switching on-off of the lights; use of compact fluorescent lamps wherever possible etc.

Financial Aspects

Fixed Capital

Land and Building Rs.
Land : 500 Sq. Mtrs @ Rs. 4000 Sq. Mtr 20,00,000

Civil construction:
Boundary wall, gates, and road inside the factory premises

Built up area, office, stores, security room, workers room etc. 100 Sq. Mtr @ Rs. 7000 / sq. mtr 7,00,000
Working shed 300 Sq. Mtr @ Rs. 6000 / Sq. Mt 18,00,000
Total (i) = (a) + (b) = Rs. 20,00,000.00 + Rs. 30,00,000.00 Rs. 50,00,000.00

Machinery and Equipments


Qty. (Nos.)

Rate (Rs.)

Total (Rs.)

Oscilloscope 20 MHz 1 74,000 74,000
DC Regulated power supply 30V,5A 1 10,000 10,000
DC Regulated power supply 30V,2A 1 8,000 8,000
Insulator Tester, 1000V 1 15,000 15,000
Variac, 4 A 1 5,000 5,000
Digital true RMS Multimeter 3½ digits 1 3500 10,000
Digital Multimeter 4½ digits 2 20,000 40,000
Digital panel (Volt/Amp) meter 2 Sets 5000 10,000
Drilling machine,¼ 1 10000 10,000
Grinding m/c 100 mm 1 20,000 20,000
Temp, controlled soldering stn. 4 12,500 50,000
Total 2,43,000
Excise, sales tax, electrification and installation charges @ 40% of machinery and bore well and electrical connection     4,00,000
Tools, Jigs and Fixtures etc.     50,000
Office equipment/working tables and furniture etc.     5,00,000
Total plant and m/c cost = Rs. 11,93,000  
Pre-operative Expenses Rs. 1,00,000
Total Fixed Capital = (i) + (ii) + (iii) 50,00,000 + 11,93,000 + 1,00,000
  Rs. 61,93,000

B. Working Capital (per month)

(i) Staff and Labour


Strength (Nos.)

Salary (Rs.)

Total (Rs.)

Manager 1 20,000 20,000
Sales Manager and his team 3 8333 25,000
Peon/ Chowkidar 5 3,000 15,000
Skilled Workers 10 5000 50,000
Semi skilled workers 6 4000 24,000
Un skilled workers 3 3000 9,000
Total 1,43,000
Add Perquisites @ 22% of the salaries 31,000
Total 1,74,000

(ii) Raw Materials (per month)


Qty. (Nos.)

Rate (Rs.)

Total (Rs.)

Transformer,230V/12V,9V,6V 500 mA 1 55 55
IC's Voltage Regulator 1 8 8
Diodes 4 1 4
Electrolytic Capacitor 6 1.5 9
PCB (Glass Epoxy) (Rs. 0.25 per sq.cm.) 1 6.0 6
Single phase 8-Way Switches (Rotary) 1 8 8
Switch with Indicator, 5A 1 8 8
Mains Lead (1.5m) with 2-Pin Plug (Moulded) 1 8 8
Cabinet (Metallic) and Packaging 1 13 13
Miscellaneous hardware, insulated terminals, wires etc. L.S.   8
Total 127
Total Requirement of Raw Materials for 10000 Nos. (per month) Rs. 12,70,000
(iii) Utilities (per month)


Power 10,000
Water 2,000
Total 12,000

(iv) Other Contingent Expenses (per month)



Postage and stationery 5,000
Telephone 10,000
Consumable stores 5000
Repair and Maintenance 5000
Transport and Conveyance 15000
Advertisement and Publicity and marketing 30000
Insurance 3,000
Miscellaneous expenses 5,000
Total 78,000

Total Recurring Expenses(per month) (i+ii+iii+iv)

Rs. 1,74,000 + Rs.12,70,000 + Rs.12,000 + Rs. 78,000

= Rs. 15,34,000

C. Total Capital Investment

Fixed Capital Rs. 61,93,000
Working Capital for 3 months Rs. 46,02,000
Total Rs. 1,07,95,000

Cost of Production (per annum)


Total recurring expenditure 1,84,08,000
Depreciation on machinery and equipment @ 10 % 24,000
Depreciation on tools/jigs/ fixtures and office equipments @ 20% 1,10,000
Depreciation on civil construction @ 05% 1,50,000
Interest on capital investment@ 12% 12,95,000
Total 1,99,87,000

Turnover (per annum)

Item Qty.(Nos.) Unit rate (Rs.) Value (Rs.)
Battery Eliminator Power Pack, 1.5/3V/6V/9V/12V/500mA 12,0,000 187.5 2,25,00,000

Profit (per annum) (Before Taxes)



  Rs. 2,25,00,000 – 1,99,87,000
  Rs. 25,13,000

Net Profit Ratio


Profit (per annum) × 100

Sales (per annum)

  25,13,000 × 100

Rate of Return


Profit (per annum) × 100

Total capital investment

  25,13,000 × 100

Break-even Point

Fixed Cost (per annum)


Total Depreciation 2,84,000
Interest on capital investment @12% 12,95,000
40% Salaries and wages 8,35,000
40% other contingent and utilities 4,32,000
Total 28,46,000
B.E.P Fixed cost × 100
Fixed Cost + Profit
  28,46,000 × 100
  28,46,000 + 25,13,000

Additional Information

  • The Project Profile may be modified/tailored to suit the individual entrepreneurship qualities/capacity, production programme and also to suit the locational characteristics, wherever applicable.
  • The Electronics Technology is undergoing rapid strides of change and there is need for regular monitoring of the national and international technology scenario. The unit may, therefore, keep abreast with the new technologies in order to keep them in pace with the developments for global competition.
  • Quality today is not only confined to the product or service alone. It also extends to the process and environment in which they are generated. The ISO 9000 defines standards for Quality Management Systems and ISO 14001 defines standards for Environmental Management System for acceptability at international level. The unit may therefore adopt these standards for global competition.
  • The margin money recommended is 25% of the working capital requirement at an average. However, the percentage of margin money may vary as per bank's discretion.

Addresses of Machinery and Equipment Suppliers

  • M/s. Aplab Limited
    3rd Floor, 310-313, Chandralok
    Complex, S.D. Road,
    (Oscilloscope, Power Supplies,
  • M/s. Systronics
    2-2-647/A/3, 11th Floor
    Karur Vysya Bank Building,
    Shivam Road, New Nallakunta,
    (Oscilloscope, Power Supplies,
  • M/s. Instrument Techniques Pvt. Ltd.
    B-2, Co-operative Estate, Balanagar,
    (Panel Meters, Insulation Power
    Supplies, Multimeters, Testers.)
  • M/s. Automatic Electric Limited
    108/117, Chandralok Complex,
    S. D. Road,
    Secunderabad - 500 003.
    (Panel Meters, Variac.)
  • M/s. Signetic Systems Pvt. Ltd.
    C-3/4-117, Mallapur,
    Hyderabad - 500 076.
    (Temp. controlled soldering/desoldering
  • M/s. Ralli Wolf Limited
    1-7-241/1, S.D. Road,
    (For m/c, hand tools and
  • M/s. Motor Industries Co. Ltd.
    (Bosch Group-Power Tools)
    1-7-241/11, S. D. Road,
    Secunderabad - 500 003.
    (M/c and Tools and accessories)
  • M/s. C I T D
    Hyderabad - 500 037.
    (For dies and other implements.)

  • Addresses of Raw Material Suppliers

  • M/s. BEL Abids
    Hyderabad - 500 001.
    (I.C'S Active, Passive components)
  • M/s. C D I L
    C-120, Naraina Industrial Area,
    New Delhi–110 028
    (I.C'S Active, Passive components)
  • M/s. Keltron
    Syndicate Bank Complex,
    (Registers and Capacitors.)
  • M/s. M. B. Electronics
    4-3-258/A/F/411, Ist Floor,
    Sri Electronics House,
    Giriraja Lane, Bank Street,
    (I.C'S Active, Passive Components.)
  • M/s. Saini Electronics
    Shree Electronics House,
    Giriraj Lane, Bank Street,
    (I.C'S Active and Passive components.)
  • M/s. Electronics Trade and
    Technology Dev. Corporation Ltd.
    15/48, Malcha Marg,
    New Delhi-110021.
  • M/s. Ogswal Industries
    1-1/10, Ferozguda,
    (Solder Wires.)
  • M/s. Cosmic Engineering Enterprises
    Plot. No.3, Electronics Complex
    (Ext.), Kushaiguda,
    Hyderabad-500 062
  • M/s. Electromagnetic Cores and Coils
    MIG-5, APIIC Colony Moulai Ali,
    (Transformer, Coils.)

For further information please contact

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com