Injection Moulded Shoes

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Product Code 291101003
Quality and Standards There is no specific BIS specification for Injection Moulded Shoes.
Production Capacity Quantity: 6,00,000 pairs shoes (per annum)
Value: Rs. 199800000
Uploaded on March 2007


Injection moulding is one of the many processes adopted for shoe manufacture. Injection moulding of shoes with rubber as soling material by vulcanization process is very popular. It attained popularity during the early 1960's when PVC followed by PU were developed for use as soling materials. Injection moulded shoes has certain advantages over other shoes and is still one of the preferred methods for manufacture of shoes.

Market Potential

The international market for shoes is dominated by Italy, China, Thailand, Indonesia, India and some other South East Asian countries. The footwear industry in all major developed countries is showing a decreased trend due to a rise in the cost of production. Shoes being a low technology and high labour intensive product, India stands a favourable chance to be the largest exporter of footwear. The Indian domestic market is also huge and there is a lot of scope for setting up units manufacturing injection moulded shoes.

Basis and Presumptions

Working Hours Double shift of 8 hours each i.e 16 hours a day for 300 working days in a year
Capacity Utilisation 60% during first year
70% during second year
80% during 3rd year and onwards
Entrepreneur Preferably by one or group of promoters having knowledge/experience in shoes and footwear field and /or venturing to start Injection based units.
Location Any where in India, preferably near any township.
Land and Building Cost is calculated as per prevailing market rates
Important Raw Materials Chrome tanned cow softy upper leather, lining leather,toe puff, insole and PVC.
Salary and Wages All the employees are paid on monthly the prevailing market rates
Transportation and Taxes on Purchase Not Included in purchase price
Power Charges Rs.4.5 per KWH from power supply source
Depreciation 5% on building and civil construction
10% on plant and machinery
20% on furniture and fixture
Margin Money 30% of total capital investment
Interest Charges 12% has been calculated on total capital investment.
Fixed Cost For BEP Analysis 100% insurance, interest and depreciation
40% of total salary and wages
40% of total utilities and other Contingent expenses excluding insurance

Implementation Schedule


Period (In months)

Registration and other formalities 2
Land acquisition 3
Construction of shed, office etc. 8
Machinery purchasing and installation 4
Trial production 1
Total 18

Technical Aspects

Process of Manufacture

The graded patterns of the components of the selected design are clicked for upper and lining materials and passed on to closing section for making the upper. In closing section, the edges are skived and components stitched and eyelets fixed as per buyers specification. In the making section, the insole is stapled to the making last, shank attached, the upper is then lasted over the last either by adhesive or tacks. Bottom roughing of the lasting allowance is done which can be a little over the lasting edge. The shank is attached securely by tacks and heel filler is attached in seat area to cut down PVC around the heel, shorten cooling time and prevents distortion of head shape. A one part or two part polyurethane adhesive is applied by machine or hand brush over the whole bottom only in case of PVC and not required for PU and is completely dried. The shoe is slipped from the making last and put on to alloy last mould. The shoe in the inverted position is then slid into the injection moulding machine. The side and sole moulds close and lock into position. Molten PVC is then injected into the mould, cutting off supply when full. It is then cooled by refrigeration chamber and moulds unlock after cooling time and shoe unloaded. The spue is then removed. Shoe is then send for finishing and then checked and packed. For PU injection moulding a different kind of injection moulding machine is used which is more critical. Expanded PVC is now a days popular as soling material. Vulcanized rubber soles are still in use.

Quality Control and Standards

The quality of footwear is guided by the physical and chemical properties of the material, destructive test on footwear and wear trials. Various organizations like SATRA, BLMRA, SLTC (UK), CTC (France), TNO (Netherlands), PFI (Germany), VESLIC (Switzerland), ALCA, ASTM (USA) and CLRI(India) have contributed to achieve quality standards for footwear and footwear materials. Test procedures and testing equipments of Bally (Switzerland) and SATRA (UK) and specification of British Standard (BS), German Standards (DIN) and international standards (ISO) are widely used. In India BIS (Bureau of Indian Standards) have worked out specifications for various footwear and footwear materials. Shoes are to be manufactured as per the buyer's specification.

Production Capacity

Quantity 6,00,000 pairs injection moulded shoes (per annum)
Value 199800000

Motive Power

The proposed unit will consume 20,000 kWH units of electricity per month.

Pollution Control

There is no pollution in the manufacture of injection moulded shoes.

Energy Conservation

Workers should be properly trained to minimize wastage of electrical energy by proper running and maintenance of the machines.

Financial Aspects

Fixed Capital

Land and Building
Land 2 acres @ Rs. 15,00,000 per acre 3000000
Building area for workshed of 10,000 Sq. ft. @ Rs. 500 per sq. ft (Factory, Test laboratory, Stores, rest room etc.) 5000000
Administrative Block of 5000 sq. ft. @ Rs. 700 per sq. ft. (Administration, Inspection, Guest Room etc.) 3500000
Compound wall, gate, road, water pump etc. 500000
Total 12000000

Machinery and Equipments


Imp./ Ind.

Qty. Nos.

Rate (Rs.)

Value (Rs.)

Computer with design and grading software and cutter Imp. 1 1200000 1200000
Swing beam hydraulic beam press 20 tonnes Ind. 4 250000 1000000
Band knife upper splitting machine Imp. 1 500000 500000
Upper perforating machine Ind. 1 150000 150000
Strap cutting machine Ind. 1 80000 80000
Stamping machine for upper and lining Ind. 1 50000 50000
Sock stamping machine Ind. 1 45000 45000
Upper skiving machine Ind. 4 80000 320000
Thermocementing folding and attaching machine Imp. 1 280000 280000
Rotary Ironing machine Imp. 1 150000 150000
Stitch marking machine Ind. 1 30,000 30,000
Flat bed single needle machine Imp. 4 38,000 152000
Post bed single needle machine Imp. 4 60,000 240000
Flat bed double needle machine Imp. 1 50,000 50,000
Post bed double needle machine Imp. 1 80,000 80,000
Flat bed zig-zag machine Imp. 1 55,000 55,000
Cylinder bed binding machine Imp. 1 75,000 75,000
Steam rubbing machine Ind. 1 45,000 45,000
Steam pressing machine Ind. 1 25,000 25,000
Punching and eyeleting machine Ind. 1 55,000 55,000
Conveyor (closing department) Ind. 4 30,000 120000
Insole moulding machine Ind. 1 90,000 90,000
Counter moulding machine Ind. 1 110000 110000
Insole stapling machine Ind. 1 45,000 45,000
Toe puff attaching machine Ind. 1 55,000 55,000
Forepart lasting machine Imp. 1 850000 850000
Seat and side lasting machine Imp. 1 1000000 1000000
Humidifier for seat lasting Ind. 1 30000 30000
Pounding and ironing machine Ind. 1 150000 150000
Moist wrinkle classer Ind. 4 10000 40000
Humid heat setting machine Imp. 1 300000 300000
Bottom toughing machine Ind. 1 60,000 60,000
Cementing machine Imp. 1 60,000 60,000
Last removing jack Ind. 1 25,000 25,000
Heat activator Ind. 1 50,000 50,000
4 station injection moulding machine Imp. 1 1600000 1600000
Finishing machine Ind. 1 100000 100000
Spray booth Ind. 1 22000 22000
Air compresser Ind. 1 50000 50000
Generator set Ind. 1 500000 500000
Testing equipments Ind. LS 300000 300000
Cost of power connection including transformer       350000
Total 10489000
Taxes ,Erection, Electrification and installation charges @ 40% of the cost of machinery and equipments       4195600
Hand tools Ind. LS   20000
Clicking dies Ind. LS   50000
Plastic lasts Ind. LS   120000
Metal Moulds Ind. LS   280000
Furniture and office equipments Ind. LS   500000
Total 15654600

Pre-operative Expenses



Project Cost -non-refundable deposits 400000

Total Fixed Capital


Land and Building 12000000
Machinery and Equipments 15654600
Pre-operative Expenses 400000
Total 28054600

B. Working Capital (per month)

(i) Raw Material (per month)



Salary (Rs.)

Total (Rs.)

Administrative and Supervisory Staff
General Manager 1 20000 20000
Manager (Administration) 1 18000 18000
Manager (Production) 2 14000 28000
Supervisor 10 6000 60000
Accountant 1 6000 6000
Clerk cum Typist 2 4000 8000
Storekeeper 1 5000 5000
Peon 1 3000 3000
Sweeper 3 3000 9000
Watchman 3 3000 9000
Technical Staff (Skilled and Unskilled)
Skilled worker 60 6000 360000
Semi-skilled worker 40 4500 180000
Helper 30 3000 90000
Mechanic 2 6000 12000
Electrician 2 6000 12000
Total 820000
Perquisites @ 22% of Salary 180400
Total 1000400

(ii) Raw Materials (per month) (50 thousand pairs per month)







Upper Leather @ 2.5 sq. ft./pair Ind. Sq. ft 125000 55 6875000
Lining Leather @ 1.25 sq. ft./pair Ind. Sq. ft 62500 30 1875000
Textile lining tape Ind. Pair 50000 2.4 120000
Self adhesive cloth tape, threads, foam, cushion, eyelets Ind Pair 50000 18 900000
Toe puff and stiffener Ind Pair 50000 15 750000
Insole shanks Ind Pair 50000 14 700000
PVC Ind Kgs 10000 60 600000
Shoe finishing chemicals (cleaner, filler, finish and wax) Imp. Pair 50000 15 750000
Shoe laces Ind. Pair 50000 7 350000
Packing (tissue papers, antifungal tablet, carton box) Ind. Pair 50000 14 700000
Total 13620000

(iii) Utilities (per month)


Amount (Rs.)

Power 20,000 kWH units @ Rs. 4.50 per unit 90000
Fuel for Generator 15000
Total 105000

(iv) Other Contingent Expenses (per month)


Amount (Rs.)

Postage and Stationery 10000
Telephone 10000
Consumable Stores 30000
Repairs and Maintenance 25000
Transport charges 25000
Advertisement and Publicity 200000
Insurance 20000
Sales Expenses 30000
Miscellaneous Expenses 20000
Total 370000

(v) Total Recurring Expenditure (per month)


Amount (Rs.)

Personnel 1000400
Raw material 13620000
Utilities 105000
Other Contingent Expenses 370000
Total 15095400

(vi) Total Working Capital

Working capital is calculated for 1.5 months i.e. Total Recurring Expenditure x 1.5 ( 15095400 x 1.5) = 22643100

C. Total Capital Investment

Fixed Capital 28054600
Working Capital 22643100
Total 50697700

Financial Analysis

Cost of Production (per annum)

Amount (Rs.)

Total Recurring Cost 181144800
Depreciation on Building @ 5% 600000
Depreciation on Machinery and Equipments @ 10% 1515460
Depreciation on Office Equipments and Furniture @ 20% 100000
Interest on Total Capital Investment @ 12% 6083724
Total 189443984

Turnover (per year)


Quantity(in pairs)

Rate (Rs.)/pair

Value (Rs.)

Shoes Grade-I 570000 340 193800000
Shoes Grade-II 30000 200 6000000
Total     199800000

Net Profit (per year) (Before Income Tax)

  Turnover – Cost of Production
  Rs. 199800000 – 189443984
  = 10356016

Net Profit Ratio

  10356016 x 100

Rate of Return on Total Investment


Net Profit per year x 100

Total Investment

  10356016 x 100

Break-even Point

Fixed Cost (per annum)


Amount (Rs.)

Depreciation on Machinery 1515460
Depreciation on Office Equipments and Furniture 100000
Depreciation on Building 600000
Interest on Capital Investment 6083724
Insurance 240000
40% of salary and wages 4801920
40% of other contingent expenses 1680000
Total 15021104
B.E.P Fixed Cost x 100
Fixed Cost + Profit

Addresses of Machinery and Equipment Suppliers

  • M/s. Leather and Packaging Machinery Corporation,
    1/23-B, Asaf Ali Road,
    New Delhi-110 002.
  • M/s. Torielli
    1090, Periyar EVR High Road,
    Chennai-600 084.
  • M/s. Rakesh Sukhia and Company Limited,
    62-A, Wulhucattan Street, Periamet,
    Chennai-600 003.
  • M/s. Bensen Industries
    96, Sri Arobindo Road, Salkia,
  • M/s. Lefoot Machines,
    373, Sideo Industrial Estate,
    Chennai-600 098.

Footwear Components, Grinderies and Chemical Suppliers

  • M/s. Agra Leather Board,
    Nunhai Industrial Estate,
  • M/s. Flexole Raman Limited,
    Mysore Ooty Road, Tahandvapura,
  • M/s. Atlanta Trading Pvt. Company,
    Atur house, Worli Naka,
    Mumbai - 400 018.
  • M/s. Chandra Chemicals Enterprises Limited,
    P-35, CIT Road,
    Kolkata - 700 014.
  • M/s. Salma International
    Salma House, 142,
    Purasawalkam High Road,
    Chennai - 600 012.
  • M/s. Toscana Lasts Limited
    Thapar House,
    124, Janpath,
    New Delhi - 110 001.
  • M/s. Sanghavi Shoe Accessories
    3, Hari Krupa, 10th Road,
    Mumbai - 400 071.
  • M/s. Vardhman Threads Private Limited
    4/6, D.B. Gupta Road, Paharganj,
    New Delhi - 110 055.
  • M/s. Indian Eyelet Industries
    5, Dr. Rajendra Prasad Sarani,
    Kolkata - 700 001.
  • M/s. Skandia Cutting Dies Private Limited
    1-B, General Collin Road,
    Chennai - 600 122.
  • M/s. India Shoe Lace Works
    8/359, Hing Ki Mandi,
    Agra - 3.

For further information please contact

Information Manager
TIMEIS Project