PROJECT REPORT

ON

MANUFACTURING UNIT

OF

 KLOCKNER LPG GAS CONVERTER KIT

FOR

MOTORCYCLES/ SCOOTERS

THREEWHEELERS
(4 Stroke and 2 Stroke)

 

Bajaj Pulsar 180 cc Average 165 KM

Honda Eterno Average 185 KM

 

LET US SHAKE HANDS

FOR GREEN REVELUTION

 

Introduction

 

KLOCKNER Gas Technology is a state of Art Technology and developed first time in the world solely for small engines 50 cc to 375 cc air cooled, single cylinder 2 stroke as well 4 stroke vehicles.

 

Sole Objective to introduce Klockner Gas Technology, is to declare liquid fuel (Petrol) Carburetor based technology as obsolete, used presently world wide on 2 Wheelers and 3 wheelers.

 

World’s scientific community and automobile 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 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 this new technology is implemented with right spirit in India alone, on in-use vehicles (Existing Vehicles) plus new vehicles added during the year.,

 

New KLOCKNER gas technology will save fuel worth Rs.200 crores per day.

or

73000 Crore rupees (Seven Kharab Thirty Arab Rupees) annually in foreign exchange only.

 

Even more importantly this will prevent entry of 1.5 crore tons of carbon and NOx pollutant from Air per day in India alone

 

Klockner Project will Drastically improve Air quality, crores of urban people suffering from Air Born dieses will breathe in Fresh Air. (Which will help our urban citizens to breathe in fresh Air), even lot more saving will be on a/c of engine life & maintenance.

 

 

 

MARKET POTENTIAL


To date No Proven Gas Technology available world wide to run two wheelers & single cylinder small engine on LPG.

 

Klockner LPG converter provides complete solution and 110% performance of petrol engine on Auto LPG Fuel.

 

In India alone we have an existing population of 90 million 2 wheelers

 

And every year another 9 Million new 2 wheelers are added to this existing population.

 

If every year 10% of this vehicle population if converted to LPG system then in India alone we have an existing market of kits worth 4000/- crores Rupees.

 

Converter kits can be supplied as OEM to 2 wheeler giants (After all types of Govt. Approval and certification).

 

Tremendous export potential, as there is a growing demand of LPG based products in ASIAN countries like Philippine, Indonesia, Malaysia etc.,

 

Market Viability

 

LPG as Auto fuel is gaining popularity day by day. LPG dispensing Units/ Pumps are opening up in all major cities of the country in another 2 years time another additional 20new cities will be having LPG Pumps.

 

Major car manufacturers like Maruti Suzuki , GM etc., are already offering cars on only LPG Fuel.

 

As a low polluting, LPG Auto Fuel is on promotional list of Govt.

 

Performance of Klockner kit on 4 Stroke Motorcycle/ Scooter

 

Petrol Km / Ltr

Rs. / Km.

 LPG Km./Ltr.

Rs. /Km.

Remarks

100 cc to 125 cc M/Cycles

60 Km/ Ltr.

Rs.0.75 /Km

72 Km/ Ltr

* Rs.0.37 /Km

* LPG/Ltr. Cost

* calculated on

* commercial/Auto

* LPG Rates

350 cc M/Cycle
( Bullet )

40 Km/Ltr

Rs.1.13 /Km

50 Km/Ltr

Rs.0.53/Km

 - Do-

Fuel Saved 50% to 75%.

       
 

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

2 Stroke Engines - * 4 Times The Petrol Average.


4 Stroke Engines - 3.5 Times The Petrol Average.


(LPG Cost :- all calculated on domestic LPG Rates)

 

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.

 

PROJECT AT A GLANCE

 

UNIT CAPACITY

:

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

Total Investment

:

20 Crores

Plant & Machinery

:

6 Crores

Land Building

:

3.7 Crores

Power Required

:

300 K. Watt

Utility & Allied Services 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

:

 0.5 Crore

Govt. Approvals

:

1 Crore

Patent of all systems
Approval by explosive Nagpur

Approval by ARAI, Pune

Marketing Budget Ist year

:

5 Crores

Manpower required

:

90 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. 2500 / Unit

Rs. 2,000 / Unit

Rs. 1800 / Unit

 

Pay back period

:

The pay back period for the project shall be one year

Gestation period

:

Six to Eight Months

Working Capital Requirement

:

3 Crores (0.3 Crore Promoters + Balance Financial Institution).

Consultancy Charges

:

0.5 Crore

PP Expanses

:

0.3 Crore

Unit Ex- Factory Price

:

Rs.3000 per unit.

Yearly Turn Over

:

60 Crores (Double shift basis)

Net Profit before taxes

:

20 Crores.

 

DESIRED LOCATION


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).

Marketing NOTES

 

After initial approvals from explosives dept. Nagpur & ARAI, Pune. Following marketing practices may be adopted: -

  1. Electronic Media.(TV Channels / News Channel etc.,)

  2. Print Media.(All National Dailies & Regional Papers)

  3. Demo Vehicles for live demo’s
    Participation at all local trade fares with live demo.


Glimpses: Klockner gas Converter technology

It is impossible to have successful running of 2 Wheelers, specially new generation 4 stroke motorcycles on LPG gas fuel with a help of High Pressure Italian Gas Technology, which is currently in use to run car and heavy automobiles all over world for last 25 years.

 

Activa

Exploded View Activa Rear Fitting

Bajaj Chetak

 

 

Let us have Arial view on Klockner Gas Technology

 

Klockner gas technology is a amalgamation of a seven new principles and technologies, which we have discovered first time in the world and applied for successfully running of all types of 2 wheelers on LPG Fuel. It is not the all, bike fitted with Klockner gas kit system beats petrol run original Models in terms of power developed, cold starting, fuel efficiency, pick up, pollution, maintenance and engine life.

 

a) EMR Single kick starting technology

This system ensures first kick-start of engine without touching the Accelerator. In this starting technique Air& Fuel are pre mixed in explosive ratio & fed directly to intake manifold facilitating instant starting.
 

b) 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 100 Km./hour on petrol then on klockner gas system with this device, ensures that the engine will give a top speed of 105 Km/hour.


Emitting pollution levels also comes to near zero.

 

Power Enhancer Device

   

c) Low Pressure Klockner Gassifire

All klockner gas system works on low-pressure systems i.e., Gas cylinder by design, supplies gas fuel at a pressure as low as 0.5 PSI.


KLOCKNER Gassifire is a single stage suction based, twin diaphragm operated precision gas to gas control valve, specially designed to run air cooled single cylinder engines 50 cc to 375 cc 4 stroke as well 2 stroke

Klockner Gassfire

   
d) MVLPO Gas Container
       
Gas Containers, Capacities 2.5 kg, 2.2 kg & 2 kg Gas Meter

 

 

MVLPO Gas Container is a specially designed system for safe handling & storage of Liquid Gas. MVLPO Gas cylinder are available of capacities 2.5 Kg. (4 Ltr. LPG capacity), 2.2 Kg (3.52 Ltr. LPG capacity) having inbuilt functions like a) Fuel level meter which indicates gas in Kg scale b) Excess pressure release valve / safety valve c) Filler valve (To fill gas from Auto LPG Station/ dispensing units) d) Low pressure gas Output at 0.5 PSI (with double locking valve) installed with a low pressure rugged output regulator, with flow adjustment facility.


(ALL THESE SYSTEMS ARE DESIGNED TO WITH STAND 5 TIMES THE WORKING PRESSURE)

     

e) Oil And Dirt Separator

 

All klockner kits consist of a special filtration system, which enhances the performance of the total system. Protect system from all metallic impurities / rust particle in fuel., Increases the life of the gas cylinder and the total system.

 

It Prevents any fuel Line choking, Meter Jamming etc. This system also separates the wax

 

(Scent chemical: - ethyl me captor, C2H5SH) - out of gas  hence increasing the life of gassfire components manifolds (no periodic cleaning) of vaporizer necessary as in case of all other vapourisers available for cars.

 

f) SSJ Ideal Speed control

 

It is impractical to have constant ideal running of a single cylinder 4 stroke engine with the help of Diaphragm Based Vaporizer, specially in cold conditions. To overcome this problem Solenoid based slow jet speed control technique has been developed.

 

g) i) 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.

Power Based Electronic 2-T Oil Pump

   

ii) GTP Mechanical Oil Pump
 

This is a mechanical vacuum operated 2T-Oil Pump and is a alternate, direct replacement to electronic PWR 2T oil system. Safest gas system of the world.


h) 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 vehicle generates a stroke, as soon as engines stops for any reason the gas supply to engine cuts of automatically.

Mech. Oil Pump

     

OTHER APPLICATIONS : A BRIEF VIEW

Klockner gas technology finds endless applications and is extremely useful for applications like:

  1. Outboard engines / Fishing Boats / Speed Boats etc.

  2. Petrol and kerosene run multipurpose engines used for miscellaneous applications.

  3. Petrol and kerosene run water pump sets.

  4. Petrol and kerosene run Portable Generators unto 500 VA to 7 KVA

Yamaha Water Pump 3" x 3"

 
Honda Elemax 7000 Yamaha LG 700 K Honda EM-650
     
 
Yamaha LG 2000 Honda E-650 K Yamaha LG 2800 

 

Popular Models of Portable Generator running on Klockner Gas System

 

Constitution of Klockner LPG Converter kits: -


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

 

a.

Dikki /Housing

b.

Bracket Assy

c.

Drainer Assy

d.

Gassifie Assy

e.

Solenoid

f.

Control Circuit & Wiring

g.

Container / Cylinder Assy

h.

Regulator Assy

i.

Pipe Assy. / Cylinder Belt

j.

 Nozzle / Ventury Assy

k.

Gas Filling Attachment Assy

l.

RVO Power Enhancer

m.

Electronic PWR 2T-Oil System

n.

GTP Mechanical Oil Pump
 

BRIEF SUMMERY OF PROJECT

 

 INR (Rs.) Lacs

Total Area required

5000 Sq /Mtrs.

100

Total Covered Area

2500 Sq/Mtrs.

190

Power required & Distributions

300 K.Watt

30

Manpower required

90 Nos. (Semi-skilled/Skilled Workers)

Inclusive of Engineers Management Staff & Workers.

Unit Cost of Production

2000 Rs./Unit ( at 50% capacity utilization i.e. TWO eight hour shifts).

Office Building

(Double Story)

200 Sq/Mtrs.

25

Guest House

300 Sq/Mtrs.

25

Utility & Allied Services

50

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

 

Patent of all systems

Approval by explosive Nagpur
Approval by ARAI, Pune

100

Air Compressor (2 Stage Compressor)

(500 PSI Capacity)

1 No

2

Air Compressor (100 PSI Capacity)
(100 Cubic Meter Storage capacity)

1 No

10

Generator Set (20 KVA)

(To maintain essential services)

1 No

1

Security and Surveillance equipment
Computers with Video Conferencing facility

3

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

7

Furniture Fixture

10

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

75

Stores
Raw materials stores,

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

6

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

15

Assy. Tools and hand tools

5

Pneumatic Tools

10

Sheet Metal Press Shop ( 18 Nos.)

75

(Presses from 5 ton to 50 ton capacity)
Sheet Cutter 2 Nos.

5

Semi Automatic Electrostatic Paint Shop
Plant & Machinery 

200

Maintenance Tool Room machinery

8

Special Purpose Machines

50

Welding Machines 15 Sets Tig Welding with special motorized welding fixtures etc., Automatic Winding Machine & Varnishing Plant

3

Packaging Machine & Dies

G N MOTa

10

QC Jigs & fixtures

15

QC Test benches

15

All type of Press Tools and Dies 

60

Forging Tool and dies

8

Rubber Molding Dies

3

Plastic Molding Dies

3

Special Pneumatic Tool Holders

1

CONSULTANCY CHARGES 

50

WORKING CAPITAL REQUIREMENT

A) Three weeks raw material of local purchase,

300

Publicity & Advertisement (Ist Year)

500

PP Expanses

30

Total Project

2000 Lacs

TOTAL YEARLY TURNOVER

60 Crore Per annum

RECOMMENDED EX FACTORY PRICE

3000 Rs/ Unit

RECOMMENDED CUSTOMER PRICE

4000 Rs. PER UNIT

 

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

2500 Rs./ Unit

2000 Rs./ Unit

1800 Rs./ Unit

TOTAL PROJECT COST

 

20 Crores

 

ANNEXURE-I

List of In-hose production items

1) Dickey / Kit hosing
2) Bracket Assy
3) Drainer Assy
4) Gassifire Assy
5) Solenoid
6) Control Circuit & wiring
7) Cylinder / Container
8) Regulator Assy
9) Testing, Assy. and Packing
   

ANNEXURE-II
Vender Components

1) Dikki Locks
2) Diaphragms Gassifire
3) Diaphragm Regulator
4) Traub Items for cylinders, Gassifire and regulator
5) Meter Assy. (Inclusive of Brass forging base plate)
6) Solenoid core and bobbin
7) All Type of Special Rubber ‘O” Ring Washers and components
8) Filler Valve
9) Safety Release Valves
10) Economizer
11) Gas filling Attachment Assy
   
LIST OF LOCAL PURCHASE ITEMS
a) Pipe Roll
b) Hinges
c) Fasteners etc.,
   
LIST OF RAW MATERIALS
a) MS Sheet
b) Copper Wire
c) Packing Material etc.,
   
STORE CONSUMABLES
a) Welding Wire & Welding Rods
b) Carbon dioxide 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 Electronic Products (P) Ltd.

28, Mohini Road, Dehradun-248001

Ph. 0135-2672540

e-mail : info@gastechproducts.com


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