SUPER EFFICIENT AIR CONDITIONER (ONLY INVERTER)

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An air conditioner is a machine which keeps the air in a building cool and dry.

The purpose of an air conditioner is to maintain a comfortable indoor environment. The comfort we are used is to determined by a combination of 3 factors.

• Temperature
• Humidity
• Air Distribution

For this reason, the main purposes of air conditioners are to:

• Control room temperatures (cooling/heating).
• Control room humidity levels (drying, humidifying).
• Optimize air flow (circulation, distribution).
• Clean the air (filtration)

Working principle

An air conditioner collects hot air from a given space, processes it within itself with the help of a refrigerant and a bunch of coils and then releases cool air into the same space where the hot air had originally been collected. This is essentially how all air conditioners work.

Many folks believe that an air conditioner produces chilled air with the help of machines installed inside it, allowing it to cool a room so quickly. That might also explain why it consumes so much electricity. In reality, however, that’s a misconception. An air conditioner is not a magical device; it just uses some physical and chemical phenomena very effectively to cool a given space.

When you switch an AC on and set your desired temperature (say, 20 degrees Celsius), the thermostat installed in it senses that there is a difference in the temperature of the room’s air and the temperature that you’ve chosen.

A thermostat constantly monitors the temperature of the system so that it’s maintained near a user’s desired point.

This warm air is drawn in through a grille at the base of the indoor unit, which then flows over some pipes through which the refrigerant (i.e., a coolant fluid) is flowing. The refrigerant liquid absorbs the heat and becomes a hot gas itself. This is how heat is removed from the air that falls on the evaporator coils. Note that the evaporator coil not only absorbs heat, but also wrings out moisture from the incoming air, which helps to dehumidify the room.

This hot refrigerant gas is then passed on to the compressor (located on the outside unit). Being true to its name, the compressor compresses the gas so that it becomes hot, since compressing a gas increases its temperature.

This hot, high-pressure gas then travels to the third component – the condenser. Again, the condenser remains true to its name, and condenses the hot gas so that it becomes a liquid.

The refrigerant reaches the condenser as a hot gas, but quickly becomes a cooler liquid because the heat of the ‘hot gas’ is dissipated to the surroundings through metal fins. So, as the refrigerant leaves the condenser, it loses its heat and becomes a cooler liquid. This flows through an expansion valve – a tiny hole in the system’s copper tubing – which controls the flow of cool liquid refrigerant into the evaporator, so the refrigerant arrives at the point where its journey started.

Here’s a simplified diagram of the air-conditioning process:

(Photo Credit : Ilmari Karonen/Wikipedia)

Although all the components involved in the air-conditioning process in window ACs are located inside the same metal box, the underlying process of cooling remains exactly the same.

Parts of a window air conditioner. (Photo Credit : Wikipedia)

The entire process is repeated over and over again until the desired temperature is attained. In a nutshell, an AC unit keeps drawing in warm air and expelling it back into the room until there’s no more warm air left to cool.

SPLIT AIR CONDITIONER

A split air conditioning imply means that the condenser (or sometimes referred to as the “outdoor unit”) is separated from the “indoor unit”, thus the term “split”.

The split air conditioning has at least one unit that sits inside your room. The compressor sits outside of the room, sometimes on the ground or on brackets hung to the wall. Some models come with multiple indoor units that will use one single compressor, this is known as the multisplit air conditioning system.

A split air conditioner consists of two main parts: the outdoor unit and the indoor unit. The outdoor unit is installed on or near the wall outside of the room or space that you wish to cool. The unit houses the compressor, condenser coil and the expansion coil or capillary tubing. The sleek-looking indoor unit contains the cooling coil, a long blower and an air filter.

A split air conditioner is a suitable alternative to wall, window, or centralized air conditioner systems. Often called mini-split, ductless split, or duct-free air conditioning, this system can adequately cool a standard-sized house without requiring extensive installation costs and efforts.

Split air conditioners are home appliances that do not require ductwork, which reduces energy expenditures. Still, many homeowners shy away from a split air conditioner system because they do not know how it works or why it is a viable option for cooling down.

The following information will fill you in on the function and installation of split air conditioner systems. They are uncommon, but not through any fault or flaw.

CONSTRUCTION

The split air conditioner comprises of two parts: the outdoor unit and the indoor unit. The outdoor unit, fitted outside the room, houses components like the compressor, condenser and the expansion valve. The indoor unit comprises the evaporator or cooling coil and the cooling fan. For this unit, you don’t have to make any slot in the wall of the room. Further, present day split units have aesthetic appeal and do not take up as much space as the window unit. A split air conditioner can be used to cool one or two rooms.

Description

INTRODUCTION
WORKING PRINCIPLE
HERE’S A SIMPLIFIED DIAGRAM OF THE AIR-CONDITIONING PROCESS:
SPLIT AIR CONDITIONER
CONSTRUCTION
PARTS OF SPLIT AIR-CONDITIONER:
WALL MOUNTED INDOOR UNIT:
1) EVAPORATOR COIL OR THE COOLING COIL:
2) AIR FILTER:
3) COOLING FAN OR BLOWER:
4) DRAIN PIPE:
5) LOUVERS OR FINS:
OUTDOOR UNIT
REFRIGERANT PIPING OR TUBING
ADVANTAGES
USES AND APPLICATION
B.I.S. SPECIFICATION
ENERGY EFFICIENT AIR CONDITIONER
OVERVIEW OF SUPER EFFICIENT AIR CONDITIONER
GOING STRONG
GROWTH STRATEGY
NEW LAUNCHES
MAKING A MARK
INVERTER AIR CONDITIONER AND ITS COMPONENTS
AC INDUCTION MOTOR
DC BRUSHLESS MOTOR
DC INVERTER CONTROL CIRCUITRY
THE FIRST SECTION CONSISTS OF A DC CONVERTER
THE SECOND SECTION BEING PFC OR POWER FACTOR CORRECTION
THE THIRD SECTION IS THE INVERTER CONSISTING OF IGBT TRANSISTORS
RAW MATERIALS
DESIGN OF AIR CONDITIONER
MARKET OVERVIEW OF AIR CONDITIONER IN INDIA
ENERGY EFFICIENCY
REFRIGERANTS
STRATEGIES TO EXPAND CLIMATEFRIENDLY ROOM AC MARKET SHARE
STRATEGY 1: OPPORTUNITIES THROUGH THE MONTREAL PROTOCOL
HCFC PHASE OUT MANAGEMENT PLANS (HPMPS)
THE HFC PHASE DOWN
FLAMMABILITY & SAFETY STANDARDS
THE ENERGY EFFICIENCY OPPORTUNITY
SUMMARY
STRATEGY 2: ENERGY EFFICIENCY AND LOW-GWP STANDARDS & LABELS
UPDATING THE STAR RATING SCALE
VARIABLE SPEED TECHNOLOGY
TEST PROCEDURE
THE BIG PICTURE
SUMMARY
STRATEGY 3: BULK PROCUREMENT PROGRAMS
PROGRAMS IN INDIA
SUMMARY
STRATEGY 4: RAISING CONSUMER AWARENESS
THE IMPORTANCE OF ENERGY LABELS
REFRIGERANT AWARENESS
REDUCING DEMAND
SUMMARY
STRATEGY 5: LOCALIZING SUPPLY CHAINS & RESEARCH & DEVELOPMENT
INCREASING DOMESTIC COMPONENT MANUFACTURING
RESEARCH & DEVELOPMENT
SUMMARY
STRATEGY 6: BRINGING IT ALL TOGETHER: NATIONAL COOLING
ACTION PLANS
SUMMARY
CONCLUSION
ROOM AIRCON INDUSTRY (INVERTER)
INVERTER ACS TO ACCOUNT FOR 30% OF INDUSTRY VOLUMES
IN FY18E AND 50% IN FY20E
VOLTAS MAY NOT SEE MEANINGFUL GAINS EVEN WITH LG’S
COMPLETE EXIT FROM FIXED-SPEED ACS
HIGH COMPETITIVE INTENSITY
BRAND, DISTRIBUTION, SERVICE CENTER NETWORK AND DEALER
MARGINS ARE KEY
SUMMER STRATEGIES OF AC MANUFACTURERS
BLUE STAR – IMPRESSIVE LINE-UP OF AC MODELS; MARKET
SHARE TARGET AT 13%
VOLTAS – TARGETING 15-20% GROWTH THIS SUMMER SEASON
LG INDIA – LOOKING FOR 30% GROWTH IN CY17
DAIKIN INDIA – TARGET TO EXPAND REACH AND MARKET SHARE;DOUBLING CAPACITY AT NEEMRANA TO 1.2M UNITS
PANASONIC – ‘A BETTER LIFE, A BETTER WORLD’ – AIMS FOR 30-35%
GROWTH IN FY18
GODREJ APPLIANCES – EYEING 20% SHARE IN INVERTER/5-STAR
AC SEGMENT
SAMSUNG – INVERTER RANGE LAUNCHED IN AFFORDABLE LUXURY
SEGMENT
VIDEOCON – TARGETS 13% SHARE AND TO INCREASE PRESENCE
IN TIER 2/3 CITIES
SWOT ANALYSIS
DETAILED EXPORT DATA OF SPLIT AC
DETAILED IMPORT DATA OF SPLIT AC
MANUFACTURERS/SUPPLIERS OF SPLIT AC
MANUFACTURING PROCESS OF AIR CONDITIONER
CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL
AND STRUCTURAL STEEL
PUNCH PRESSING THE SHEET METAL FORMS
CLEANING THE PARTS
POWDER COATING
BENDING THE TUBING FOR THE CONDENSER AND EVAPORATOR
JOINING THE COPPER TUBING WITH THE ALUMINUM PLATES
INSTALLING THE PUMP
QUALITY CONTROL
PROCESS FLOW CHART
PRODUCTION PROCESS
(1) PROCUREMENT OF RAW MATERIALS
THE MANUFACTURING PROCESS
(1) MAKING THE PARTS
(A) CONSTRUCTING THE CASING, BRACKETS, AND OTHER SUPPORTS
(B) PUNCH PRESSING THE SHEET METAL FORMS
(C) CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL
AND STRUCTURAL STEEL
(D) CLEANING THE PARTS
(E) POWDER COATING
(F) FABRICATION OF COIL
(G) FINISHING THE EVAPORATOR AND CONDENSER COILS
(2) ASSEMBLY
(3) CHARGING AND FINISHING
(4) QUALITY CONTROL
(A) PRODUCTION ROUTINE TESTS
(I) GENERAL RUNNING TEST —
(II) PRESSURE TEST OR LEAKAGE TEST —
(III) INSULATION RESISTANCE TEST —
(IV) HIGH VOLTAGE TEST —
(V) PERFORMANCE TEST —
(VI) LEAKAGE CURRENT TEST —
(VII) EARTHING RESISTANCE TEST —
(B) TYPE TESTS
(6) MARKING
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
ALUMINIUM FIN STOCK FOIL
COPPER TUBE
M.S SHEETS
ABS GRANULE
BRAZZING WIRE
MIG WELDING WIRE ELECTRODE
REFRIGERANT GASES
PICKLING CHEMICALS
SUPPLIERS OF AC COMPRESSOR
AIR CONDITIONER PARTS
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF FIN PRESS
SUPPLIERS OF FIN DIE
SUPPLIERS OF VERTICAL EXPANDER
SUPPLIERS OF HAIRPIN BENDER
CNC PRESS
POWDER COATING MACHINE
INJECTION MOLDING MACHINE
SUPPLIERS OF IDU ASSEMBLING LINE
SUPPLIERS OF BRAZING MACHINES
SUPPLIERS OF REFRIGERANT CHARGING UNIT
SUPPLIERS OF REFRIGERANT (HALIDE) LEAK DETECTOR
ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
AIR POLLUTION CONTROL EQUIPMENTS
AIR COMPRESSORS
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

333,3333 Nos

Land & Building

(4000 sq.mt.)

Plant & Machinery

US$ 518571

Rate of Return

48%

Break Even Point

30%