PROJECT REPORT

ON

MANUFACTURING UNIT

OF

 KLOCKNER LPG GAS CONVERTER KIT

 FOR

OUTBOARD ENGINES, SPEED BOATS, FISHING BOATS

& ADVENTURE SPORTS CRAFT

0
 FROM 8 BHP TO 40 BHP
(2 Stroke /4 Stroke)

 

Engines 8 to 40 BHP Boat Engine Boat Converter Kit
     
 

BOON TO MARINE ECO SYSTEM

 

KLOCKNER Gas Technology is a state of art technology and developed first time in the world solely for small engines: air cooled, single cylinder 2 stroke as well 4 stroke engines.


Sole Objective to introduce Klockner Gas Technology, is to declare liquid fuel (Petrol) Carburetor based technology as obsolete, used presently world wide on all outboard marine engines.


World’s scientific community and marine engineers must discard this carburetor device, as it is impractical for carburetor to mix air and petrol in accurate and in metered quantity to suit the ever changing and variable engine requirements.


Carburetor technology has failed to control the uneven supply of petrol with the incoming air stream to engine at various levels.


It is inbuilt and inherent draw back that in some circumstances the sucking air stream sucks excess petrol at carburetor ventury, resulting in petrol wastage and marine pollution.


Now let us replace this redundant carburetor technology with new revolutionary klockner gas technology, which promises: -

  • Cent % fuel efficiency.

  • With clean exhaust and Zero Pollution.

    If the world’s whole fleet of boats / speed boats using outboard engine (8 BHP to 40 BHP) are made to run on klockner revolutionary gas technology then the world will save:
     

  • 1 Billion US$ worth of gasoline / kerosene per day.

  • Or 365 Billion US$ worth of gasoline / kerosene per year.

  • Even more importantly this will prevent 200 million tons of carbon and NOx pollutant from entering into sea & air per day

Klockner Project will drastically improve marine life. Diseases due to aquatic life poisoning this subsequently will also reduce human sufferings globally.
Even lot more saving will be on a/c of engine life & maintenance.

 

Performance of Klockner kit on 2 Stroke 9 BHP outboard engine at 7000 RPM.

 
  Petrol /hr Rs. / hr. LPG ./hr. Rs. / hr.

Remarks

9 BHP outboard engine 9 Ltrs. Rs.400/- 4 Ltrs. Rs.108/-

* LPG/Ltr. Cost calculated on

* commercial /Auto LPG

* Rates

Ltrs of Fuel Saved 200% to 225%.
Cost Saving 500% (Calculated at current LPG & Petrol prices applicable in India.)

 

MARKET POTENTIAL

To date No Proven Gas Technology available world wide to run gasoline marine engines on LPG.

Klockner LPG converter provides complete solution and cent % performance of outboard engines on LPG Fuel.

Approximately 120 million speed boats / fishing boats / utility crafts and adventure sports crafts exists worldwide.

And every year another 12 million outboard engines / speedboats are added to the existing population.

If every year 10% of these Boat Engines population if converted to LPG system then we have an existing market of kits worth 1500 million US$.

Converter kits can be supplied as OEM to boat engine manufacturers (After all types of Govt. Approval and certification).

Market Viability

As a low polluting, LPG Auto Fuel is on promotional list of most Govts., in the world.

Besides in India alone State Governments of Gujarat, Kerela, Maharastra etc., are offering special subsidies for use of LPG fuel to their fishermen

ALL KLOCKNER GAS MODELS FOLLOWS THIS THUMB RULE FOR GAS AVERAGE:

2 Stroke Engines - * 5 Times The Petrol Average.


4 Stroke Engines - 4 Times The Petrol Average.


(LPG Cost: - all calculated on domestic LPG Rates preventing in India)

LPG is a clean burning fuel and reduces clogging of spark plug as well as carburetor and piston block, whereby you save on maintenance cost also.

 
PROJECT AT A GLANCE
 

UNIT CAPACITY

1,00,000 Units Per Annum (8 hours shift)

  (INR) Rs. ( US $ )

Total Investment

16 Crores

4 Million

Plant & Machinery

5 Crores

1.25 Million

Land Building

2.5 Crores

6,25,000-00

Power Required

150 K. Watt

Utility & Allied Services

0.35 Crores

87,500-00

Air Circulation (Like Air Ducts/Blowers, Fan, coolers etc)
Lighting,
Water Supply, Storage and disposal
Water Cooler
Drainage and sewerage
Canteen
Garbage Shed and disposal system
Scrap Collection & disposal system
Workshop Cleaning System
   

Govt. Approvals

0.5 Crore

1,25,000-00

Patent of all systems

Approval by ARAI, Pune

(or by any Govt. approved agency)

Marketing Budget Ist year

3.5 Crores

8,75,000-00

Manpower required

70 Nos. (Semi-skilled/Skilled Workers) Inclusive of Engineers Management Staff & Workers.

 
Unit Cost of Production Approx.
 

8 hour shift

 16 hour shift

24 hour shift

Product Capacity

1,00,000 Unit/ Annum

2,00,000 Unit/ Annum

3,00,000 Unit/ Annum

Unit Cost of Prod

Rs. 3500/ Unit

Rs. 3400/ Unit

Rs. 3300/ Unit

Pay back period: The pay back period for the project shall be six months.

Gestation period: Six to Eight Months

 
  ( INR) Rs. ( US$ )
Working Capital Requirement 3.35 Crores 8,37,500-00
Consultancy Charges 0.5 1,25,000-00
PP Expanses 0.3 75000-00
Unit Ex- Factory Price Rs. 5000/- per unit. (US$ 125)
Yearly Turn Over 100Crores (Double shift basis) 25 Million
Net Profit before taxes 32 Crores 8 Million
 

DESIRED LOCATION ( in India )

We suggest that the above plant be installed in the state of Uttarakhand or Himachal Pradesh in order to avail the following fiscal incentives.

 

1. Excise holiday for 10 Years.
2. Income Tax holiday for 5 Years. & thereafter 30% rebate for next 5 Years.
3. 15% Capital investment subsidy subject to a maximum limit of Rs. 30Lacs
(This amount would cover all PP expanses of initial setting up of plant).
4. Or in any SEZ Area near to any major port for easy transshipment to any part of world.
 

Marketing NOTES

After initial approvals from Govt., Marine Authorities, approved agency. Following marketing practices may be adopted: -
a) Electronic Media.(TV Channels / News Channel etc.,)
b) Print Media.(All National Dailies & Regional Papers)
c) Demo speed boats for live demo’s at all major fishing ports.
d) Participation at all local/ international boat shows with live demo.

 

Glimpses: Klockner gas Converter technology

 

Videos:

Video on Fitment & Working 

(Click here to download)

Video on Field Trial with Fishing Boat

(Click Here to download)

 

For any marine application, engine weight to Power Ratio is very important factor.

Most of engines used for outboards/ speed boats are 2 stroke, twin cylinder, high speed and water cooled engines. Two Stroke engines are powerful, light in weight but inefficient, wastes lot of fuel and Hence makes a lot of pollution.

For all Marine outboard 2 stroke high speed engines, 2T-Oil(engine lubricating Oil ) is a life line. While running on Petrol/Kerosene fuel 2T-oil is pre-mixed in a ratio of 5 to 10%.

But for Gas running pre-mixing of 2T-oil in gas cylinder is impossible , hence to over come this technical barrier Gas Tech Electronic Products (P) Ltd, has specially developed two types of oil systems for smooth and enhanced performance of all types of 2 Stroke marine engines:-
 

a) Electronic PWR 2-T oil system

 

Electronic pulse width regulation oil system is a specially developed 2-T Oil Pump meant for smooth supply of 2-T Oil to 2 Stroke engine and it ensures supply of 2T-Oil in proportion to engine RPM.

 

It enhances engine life & performance.

 

This system consisting of a solenoid, electronic control unit, oil and pump functioning indicator, 2T oil box with inbuilt electronic oil level sensor

 

With every Klockner converter kit twin electronic Oil solenoid is fitted with the gas system to support twin cylinder engine.

   

b) GTP Mechanical Oil Pump

 

This is a mechanical vacuum operated 2T-Oil Pump and is an alternate, direct replacement to electronic PWR 2T oil system.


Twin mechanical oil pumps are inbuilt with Klockner gas system consisting of one 2T-oil can with fuel level gauge

Mechanical Oil Pump

   
c) RVO Power Enhancer Technology

This supersaver Reed Valve Operated device specially developed to work in tandem with the gassifire does not allow any fuel wastage by the kit and enhances the power output of the engine, for example:- if an engine has a top speed of say 30 knots on petrol, then on klockner gas system with this device, ensures that the engine will give a top speed of 33 knots.

Emitting pollution levels also comes to near zero.

Power Enhancer

   

d) Low Pressure Klockner Gassifire:-

All klockner gas system works on low-pressure KLOCKNER Gassifire is a single stage suction based, twin diaphragm operated precision gas to gas control valve, specially designed to run air cooled 10 BHP to 40 BHP outboard engines ( 2 stroke / 4 stroke ). 

 

All klockner LPG Converter kits function on “ lean burn system” and operates at extremely low pressure. Thereby maximizing fuel efficiency and overall system safety. Gassifire releases gas only when the piston of the engine generates a stroke, as soon as engines stops for any reason the gas supply to engine cuts of automatically.

Exploded view boat kit

   
 

e) Regulator:-

A specially developed low pressure, high flow LPG output regulator to suit smooth running of engines up to 40 BHP specially at high speeds (6000 to 8000 RPM)
This rugged device is designed to with stand high suction of engine and to with stand rough sea conditions

 

f) Safest gas system of the world.

 

Constitution of Klockner LPG Converter kits:-


Klockner LPG Converter kit consists of the following Sub-Assys:-


a) Dikki /Housing.
b) Bracket Assy.
c) Gassifie Assy.
d) Solenoid
e) Control Circuit & Wiring.
f) Regulator Assy.
g) Pipe Assy. /.
h) Nozzle / Ventury Assy.
i) Economizer Assy.
j) Electronic PWR 2-T oil system
k) GTP Mechanical Oil Pump.

 

BRIEF SUMMERY OF PROJECT

    INR (Rs.)
( In Lacs)
US$
( In Million)

Total Area required

3000 Sq /Mtrs

70

0.175

Total Covered Area

1500 Sq/Mtrs

125

0-3125

Power required

150 K.Watt

25

0-0625

Manpower required

70 Nos. (Semi-skilled/Skilled Workers) Inclusive of Engineers Management Staff & Workers.

Unit Cost of Production

3400/- ( at i.e. to 16 hour shifts).

Office Building

(Double Story)

100 Sq/Mtrs

15

0-0375

Guest House

200 Sq/Mtrs

15

0-0375

Utility & Allied Services

35

0-0875

Air Circulation ( Like Air Ducts/Blowers, Fan, coolers etc) Lighting, Water Supply, Storage and disposal Water Cooler Drainage and sewerage Canteen Garbage Shed and disposal system Scrap Collection & disposal system Workshop Cleaning System

 

Provisions for Govt. Approvals   50 0-125

Patent of all systems

Approval by ARAI, Pune
Or by any approved Govt. organization.

Air Compressor ( 2 Stage Compressor ) (500 PSI Capacity) 1 No

2

 0-005

Air Compressor (100 PSI Capacity) 1 No. 
(100 Cubic Meter Storage capacity)

12

0-030

Generator Set (20 KVA) 1 No. 
(To maintain essential services)

1

0-0025

Security and Surveillance equipment 
Computers with Video Conferencing facility

3

0-0075

Through Broad Band Internet Connection 
Computer Plant Management (Including accounts
& Stores

5

0-0125

Furniture Fixture 

8

0-020

Material Handling system 
(MS cage bins, hand pallets, trolleys, forklift
Electric hoists (5 ton capacity)

50

0-125

Stores 
Raw materials stores, Finished products stores, Tool crib (Production), Tool crib (Machine Maintenance), Packing Area

10

0-025

Conveyer Line (for 3 to 4 Assy. Systems) 
(As per design)

12

0-03

Assy. Tools and hand tools

5

0-0125

Pneumatic Tools

10

0-025

Sheet Metal Press Shop ( 8 Nos.)

(Presses from 5 ton to 50 ton capacity)

70

0-175

Sheet Cutter 2 Nos. 
Paint Shop

5

0-0125

Plant & Machinery

100

0-250

Maintenance Tool Room machinery

10

 0-025

Special Purpose Machines

Welding Machines 5 Sets, Tig Welding with special motorized welding fixtures etc.,

60

0-15

Automatic Winding Machine & Varnishing Plant

3

0-0075

Packaging Machine & Dies

15

0-0375

QC Jigs & fixtures

23

0-0575

QC Test benches

25

0-0625

All type of Press Tools and Dies

60

0-15

Rubber Molding Dies

5

0-0125

Plastic Molding Dies

5

0-0125

Special Pneumatic Tool Holders

1

0-0025

CONSULTANCY CHARGES

50

0-125

PP Expanses

30

0-075

WORKING CAPITAL REQUIREMENT

A) Three weeks raw material of local purchase, months imported components stock,

335

0.8375

Publicity & Advertisement (Ist Year)

350

0-875

TOTAL YEARLY TURNOVER

RECOMMENDED EX FACTORY PRICE

100 Crore Per annum

Rs5000/-/ Unit (US$ 125-00)

25-00

RECOMMENDED CUSTOMER PRICE

Rs.8000/- PER UNIT (US$ 200)

 
UNIT COST OF PRODUCTION
  8 Hour Shift 16 Hour Shift 24 Hour Shift
Production Capacity 100,000 Unit P. Annum 200,000 Unit P. Annum 300,000 Unit P. Annum
Unit Cost of Production Rs3500/ Unit(US$ 87.5) Rs.3400/ Unit( US$ 85) Rs.3300/ Unit(US$ 82.5)
 

ANNEXURE-I


List of In-hose production items


1) Dickey / Kit hosing
2) Mounting & Holding Bracket.
3) Gassifire Assy.
4) Solenoid
5) Control Circuit & wiring
6) Regulator Assy.
7) Testing, Assy. and Packing
8) GTP Mechanical Oil Pump.

 

ANNEXURE-II

Vender Components

1) Dikki Locks
2) Diaphragms Gassifire
3) Diaphragm Regulator
4) Traub Items for Gassifire and regulator
5) Solenoid core and bobbin
6) All Type of Special Rubber ‘O” Ring Washers and components
7) RVO Power Enhancer.
8) Oil Can.
9) Gas & Oil Nozzles.
10) Gas output adopter.

 

LIST OF LOCAL PURCHASE ITEMS: -

a) Pipe Roll
b) Hinges
c) Nut Bolts & Fasteners etc.,
d) List of discreet electronic components.

 

LIST OF RAW MATERIALS: -

a) Stainless steel Sheet.
b) Copper Wire
c) Packing Material etc.,
d) Aluminum Sheet

 

STORE CONSUMABLES:

a) Welding Wire & Welding Rods.
b) Carbon dioxide & Argon Gas.
c) Paints, Primer & Thinner.
d) Varnish.
e) Cutting Tools etc.,

 

Klockner gas technology is latest R & D work by professionals of Research & Analysis Alternate Energy Resources. Hence it is strongly recommended before going for bulk productions, Entering party must obtain patent & legal rights so as to safeguard his business interest and monopolized market potential

 

By:

Gas Tech Electronics Products (P) Ltd.

28, Mohini Road, Dehradun-248001

Ph. 0135-2672540

e-mail : info@gastechproducts.com


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