Brake Drum Casting

Home » Technology » Project Profiles » Metallurgy » Brake Drum Casting
Product Code 374815003
Quality and Standards As Per Customers Specifications
Uploaded on February 2007


Brake drum castings are made up of S.G. cast iron which has high strength, ductility, shock and wear resistance, good castability, excellent machinability and overall durability of the component.

Market Potential

With the start of the automobile revolution in the country the brake drum castings are expected to increase manifold in future. The S.G. brake drum castings are replacing even forgings. The brake drum casting units have good scope in small scale industries due to the excellent technical base available at the small foundry units.

Basis and Presumptions

  • The scheme has been prepared on the basis of 75% efficiency on two shifts of 8 Hrs each considering 25 working days in a month.
  • The rate of interest in the scheme has been worked out on the basis of 12% on an average; however this figure is likely to vary depending on the financial outlay of the project as well as location of the unit.
  • The costs of machinery and equipment as indicated are approximate ruling locally at the time of preparation of the scheme.
  • The rates quoted in respect of salaries and wages for workers and others are the minimum rates in the state/neighbouring states.
  • Margin money required is minimum 25% of the projected investment.

Implementation Schedule

Preparation of the Project Report



(a) Calling quotations
(b) Preparation of report
1 month
2 weeks
Provisional registration as SSI Unit 2 weeks
Financial arrangement 3 months
Purchase and procurement of machinery and equipments 3 months
Installation of machines and Equipments 3 months
Electrification 1 month
Recruitment of staff and workers 1 month
N.O.C. from Pollution Control Board 1 month

Technical Aspects

Process of Manufacture

The scrap and pig-iron in the required proportion are melted in the electric induction furnace. When the molten metal attains the pouring temperature, the hot metal is transferred from furnace to the ladle and then poured in the mould already prepared and kept ready. After cooling, the castings are knocked out, fettled, inspected and despatched to the customer.

Quality Control and Standards

The Brake drum castings are manufactured under the following Indian specifications

  • IS-1865-1974 Indian standard specification for Iron Castings with spheroidal or nodular graphite.
  • IS-5789-1970 Indian standard specification for S.G. Iron Castings for low temperature use.
  • IS-5788-1970 Indian standard specification for Iron Castings with spheroidal or nodular graphite for use at elevated temperatures.

Production Capacity


Value (In Rs.)

600 MT Rs.

Pollution Control

The units manufacturing brake drum foundry comes under category of Government classification. Hence the pollution control clearance is a must for these units. The unit has to take care of all statutory regulations.

Financial Aspects

Fixed Capital

(i) Land and Building  

Land 1 acre

Factory shed, raw material and finished goods storage, 750 Sq. Mtr.@ Rs. 5000 Per Sq. Mtr. 37,50,000
Office, laboratory, workers room, Security room, DG set room with diesel storage, pollution control system area, raw water boring and storage maintenance room, general store room, area for the commercial and administrative staff 750 Sq. Mtr @ Rs. 6000 / Sq. Mtr. Add Rs. 8,00,000 for boundary wall, roads inside the factory and factory gates. 53,00,000
Total 1,05,50,000

(ii) Machinery and Equipment



Rate(In Rs.)

Amount (In Rs.)

Air compressor capacity with high pressure storage tank, air dryer, valves and fittings, bore well, raw water storage handling and distribution and pollution control systems 1   14,00,000
Bench drilling machine 20 mm Cap. with 1 HP motor and 1 20,000 20,000
Crane capacity 3 tonnes with 20 HP motor 1 7,00,000 7,00,000
Double-ended grinder with 2 HP motor 2 25,000 50,000
Drying oven oil fired 1 2,00,000 2,00,000
Electricity Transformer 11 KV/440 V/250 KVA 1 3,00,000 3,00,000
Generating set with oil storage tank, pumping etc. 1 6,00,000 6,00,000
Hand Trolleys etc.   LS  50,000
Hardness Tester (Brinell) 1 50,000 50,000
Heat Treatment Furnace (2m ×1.5m ×1.5 m) oil fired with 3 HP motor 1 4,00,000 4,00,000
Induction Melting Furnace 150 kg capacity and office furniture 2 10,00,000 20,00,000
Izod / charpy Impact Tester 1 1.00,000 1.00,000
Lab. Chemicals and Equipments   LS 5,00,000
Metallographic Metallurgical Microscope 1 50,000 50,000
Moulding Machine with 5 HP motor (L.S.) 1 3,00000 3,00000
Office equipments, tables, chairs, fans, typewriters, almirah etc.     5,00,000
Platform weighing machine 500 kg capacity (Ind.) 1 50,000 50,000
Sand mixer (100 kg cap.) with 5 HP motor 2 1,50,000 3,00,000
Sand testing machine 1 50,000 50,000
Specimen Polishing machine (Double dise-type) 1 50,000 50,000
Swing frame grinder with 10 HP motor (LS) 3 3,00,000 9,00,000
Tools, Dies and equipments     3,00,000
Weighing scale 500 kg. cap 2 50,000 1,00,000
Excise, sales tax, installation and electrification @ 35% of sum of 1 to 23 LS   31,94,000
Total 1,21,64,000

Working Capital (per month)

(i) Raw Material (per month)



Rate (In Rs.)

Amount (In Rs.)

Ferro-silicon (60%)   LS 2,00,000
Furnace lining and other refractory   LS 2,00,000
Graphite   LS 50,000
Innoculating agents, fluxes bath conditioners etc.   LS 1,00,000
M.S. Plate covers for reduction Ladle 1 tonne   LS 1,50,000
Mild Steel scrap 52 20,000 10,40,000
Sand, Binder and other Moulding Materials   LS 1,00,000
Total     18,40,000

(ii) Salaries and Wages (per month)



Salary (In Rs.)

Amount (In Rs.)

Sales, marketing, purchase and administration staff 08   80,000
Production and maintenance engineers and staff 3   45,000
Laboratory chemists and Technician 4   30,000
Skilled Workers 15 5,000 75,000
Supervisor 3 6,000 18,000
Unskilled workers 15 3000 45,000
Works Manager/ metallurgist 1 30,000 30,000
Total 3,23,000
Perquisites @ 22% 71,000
Total 3,94,000

(iii) Utilities (per month)


Rate (In Rs.)

Amount (In Rs.)

Electricity and Power LS 3,00,000
Funace Oil and Fuel LS 2,00,000
Furnace lining Charges LS 40,000
Total 5,40,000

(iv) Other Contingent Expenses (per month)


Amt.(In Rs.)

Miscellaneous 50,000
Postage and Stationery 5,000
Repairs and maintenance 50,000
Transportation/Advt. 50,000
Travelling and Conveyance 2,00,000
Water 5,000
Total 3,60,000
Working Capital per Month : 18,40,000 + 3,94,000 + 5,40,000 + 3,60,000 = Rs. 31,34,000
(v) Working Capital for 3 Months
= Rs. 31,34,000 ×3 = Rs. 94,02,000

Total Capital Investment

Fixed Capital Rs. 2,27,14,000
Working capital (3 months) Rs. 94,02,000
Total Rs. 3,21,16,000

Financial Analysis

Cost of Production (per year)

(In Rs.)

Depreciation on furnace & office furniture @ 20% 4,80,000
Depreciation on Machinery and Equipments 9,46,000
Depreciation on civil construction @ 5% 4,53,000
Depreciation on Tools @ 20% 60,000
Recurring Expenditure 3,76,08,000
Interest on capital investment @ 12% 38,54,000
Total 4,34,01,000

Sales (per annum)

By Sale of 600 M.Ts of S.G. Iron Castings Value : Rs. 5,15,36,000
By Scrap 30 M. Tonnes of Castings and Rejects Value : Rs. 7,85,000

Profit (per annum)



Sales 5,23,21,000
Cost of Production 4,34,01,000
Total 89,20,000

Profitability Analysis

a) % of Profit on Sales

  Profit per annum ×100
  Sales per annum
  87,20,000 ×100
  = 17.04%

b) % of Profit on Investment

  Profit per annum ×100
  Total Capital investment
  89,20,000 ×100
  = 27.77%

Break-even Point

Fixed Cost (per annum)

(In Rs.)

Depreciation 19,39,000
Interest on investment 38,54,000
40% of salary and wages 18,91,000
40% of other expenses and Utilities 43,20,000
Total 1,20,04,000
(ii) Profit (per annum) Rs. 87,20,000

B.E.P Fixed Cost per annum ×100
  Fixed cost per annum + profit per annum
  1,20,04,000 ×100
  1,20,04,000 + 89,20,000
  = 57.37%

Addresses of Machinery and Equipment Suppliers

  • M/s. Beco Engineering Co.
    Agra Road, H.T. Mills Compound,
    Vikhroli, Mumbai-400 079.
  • M/s. Brady and Morris Engineering Co. Limited
    12/14, Veer Nariman Road,
    Brady House,
    Mumbai-400 023.
  • M/s. Commercial Engineering Works
    P-17, Benaras Road,
    Bamangachi, Salkia,
    Howrah - 700 006.
  • M/s. Federal Engineers,
    Plot No.: A-81, Road No.: 16-R,
    Thana-400 604.

Addresses of Raw Material Suppliers

  • M/s. National Iron Traders
    364 Kurichi Pirivu, Coimbatore-23
  • M/s. NR Traders
    Pollachi Road, Karumbukadai,
  • M/s. PA Ponnusamy and
    Chandran Co.
    P.N. Palayam,
    Coimbatore-641 020

For further information please contact

Information Manager
TIMEIS Project