Project report

MM Aqua Technologies Ltd Page 1
PROJECT REPORT ON INVESTMENT PLAN
OF 2014-15 AND 2015-16
FOR
MM AQUA TECHNOLOGIES LIMITED
Behrampur Road, Khandsa, Gurgaon,
Haryana
India
Owners:
M/s MM AQUA TECHNOLOGIES LIMITED
Prepared by
S. S. Rawat President- Marketing
Dolly Roy CFO
Suprasana Dey Senior Accountant
for MM AQUA TECHNOLOGIES LIMITED
Behrampur Road, Khandsa, Gurgaon, Haryana, India
April 2014

Table of Contents
Chapter No. Topic Page No
A Objective and Investment Plan 3-4
B Capacity enhancement and projection completion date 5
C Industry Background 6-7
D Market Potential and action taken 8-10
E Company Profile 11-24
F New Products 25-27
G Competitors 25-29
H SWOT Analysis 30
I Project Details 30-38
J Risk Assessment 39
K Projected Balance Sheet till 2020 40
L Detailed Break up of investment plan 41

OBJECTIVE :
1. Behaviour of Industry
Developments in the area of infrastructure particularly electricity and water shall remain to be a
focus of the government in coming years as population grow and the demand for energy
increases. It is very obvious from the present budget. Focus of the government to provide round
the clock electricity and potable water would demand for investment in these basic necessities.
In past years business potential for Cooling tower & Water treatment company in country has
grown many folds. It is expected to grow further in next decade. Demand of energy i.e.
electricity power & refinery products is forecasted to grow by 25% (Details attached). Therefore
industries like manufacturing and electric power generation will require expansion and hence
more Cooling Towers.
Following needs of the market induce further demand of cooling tower products with improved
efficiency.
- Large size of turbine units needs very big cooling tower & hence make size more
compact and efficient fill design needs to be improved.
- Low clog fill - larger water flow requirement is more difficult to treat and thus industry
needs fill media that can operate with poor quality water.
- Efficient fill design for reduction in auxiliary power consumption.
- Large volume to be supplied in short duration to reduce escalation of project cost and
save penalty.
- ICB demanding competitive price & higher quality standard at par with European &
American companies.
2. Entry of Competitor
Worldwide manufacturers like Brentwood Industries, USA starting manufacturing facility in
India. Brentwood is a market leader in USA and Europe for cooling Tower Components. It is
expected to be change in the market as improved international quality will be available in India.
To sustain in the market against competition and in an effort to maintain high standards and to
meet the ever-increasing demands of cooling tower technology, MM Aqua has decided to go
for improvement in existing products range and manufacturing process and development of new
designs fills and profiles and product enhancements. Focus on cost effectiveness to remain cost
competitive.
MM Aqua has made ambitious plans to meet all demand of the domestic market with new
efficient design & export market demand to grow to 100 Cr in next 5 years. MM Aqua shall be
taking various projects and investment to:
.
a) Development of existing & new product in our own R&D department
b) Establishment of Test Cooling Tower.
To market new or developed fill designs calls for necessity of a full-fledged, very accurate
testing cell to develop complete performance parameters i.e. Heat transfer capabilities and
pressure drop values. With availability of test cells, MM Aqua will not only be able to carry out

performance testing and development of new/ improvised fill design, but also will be able to test
competitor fill and prove to consultants and end user about performance of our
products as against competitors product. New developed products and improved products can
only be manufactured through Vacuum forming process.
c) Thermoforming Machine
Thermoforming is a manufacturing process in which plastic is heated until it reaches a pliable
temperature and is formed into a shape by a mold using a combination of vacuum pressure and
mechanical assistance. This process offers fast and inexpensive prototyping, tooling, production
lead times, design modifications, demand flexibility, and large part geometries.
To be par with high and international quality and manufacture new and improved fill designs
MM Aqua decided to adopt new manufacturing process i.e. vacuum forming process. We need
to invest in Thermoforming Machine to cater to specific requirements of new products. Benefits
and details are mentioned in chapter no-J project details.
d) Calendering Line
Presently, MM aqua imports semi finished product i.e. PVC sheet for its flute forming process
but these sheets are not superior enough to process in Vacuum forming. With instability in
dollar imported sheet proves expensive and to meet demand of various customers we need to
keep high inventory. To have advantage over high inventory turnover and to produce required
quality of PVC sheet for vacuum forming process call for new Calendering line. Details
working is shown in chapter no-J project details.
e) Cutting system for existing flute forming machines
MM Aqua is a manufacturer of different designs of Rigid PVC corrugated film sheet through
Calendering and flute forming process in continuation. Sheets are formed at speed of 12 to 16
Mtr/Min of finished corrugated length. Formed corrugated sheets travels on conveyor to cutting
unit. Length of the sheet is set by moving assembly having infra red sensors, that senses the
sheet approaching a particular length and to actuate clamps and cutter. Cutting system does not
have accuracy to cut in desired size therefore we need to keep 100mm extra which is around 10-
12%. In next process we cut the extra length sheet to make it required length. Cutting wastes are
grinded to powder to reuse. To avoid further cutting and save in operating cost, MM aqua
decided to go for imported cutting system which will cut the sheet in desired length. Detail
working shown in chapter no-J project details.
Investment Plan Rs/cr.
S.no Description 2014-15 2015-16
1 4 Roll Calender line 7.47
2 Downstream of profile line 1.59
4 Vacuum Forming Machine 0.70
4 Cutting Machine 0.25
Total investment 20.53

Detail project cost (Break-up in FY15 and FY16) into break-up into land, machinery, building,
other expenses etc attached as Annexure 1 and 2.
Detail of CAPACITY ENHANCEMENT
S.no Description Existing
Proposed with
investment
a) Fill Forming line 4500 tons 8800 tons
b) Extrusion Line 1800 tons 1800 tons
c) Injection Moulding 1500 tons
Expected dated of completion of each of the project
Sr
N
o. Particulars
4 Roll
Calender
Downstre
am for
New
profile
line
Vacuum
Forming
Machine
Test
Cooling
Tower
Cutting
system
1
Expecteddate of
Machine ordering 29-Mar-14 31-Jul-14 31-Jul-14 1-May-14 31-Aug-15
2
Completionof Civil
Work 20-Sep-14 30-Oct-14 18-Oct-14 31-Jan-15 -
3
ExpectedDate of
Machine
Installation 31-Oct-14 30-Nov-14 26-Dec-14 1-Mar-15 15-Dec-15
4
Commercial
Production 15-Nov-14 15-Dec-14 31-Jan-15 1-May-15 20-Dec-15

INDUSTRY BACKGROUND
MM Aqua is manufacturer of components for cooling tower, water and waste water treatment
plants. Cooling tower is part of industry like Power plant and refinery however water and waste
water treatment plants are constructed by PHE/water boards. Please find below brief about the
future market scenario for Power, refinery and water treatment plants in India.
Indian Power Scenario
India is presently 65% electrified and Opportunity is coming up in power generation. Govt is
promoting private sector participation in power sector. Power Sector Overview is as below
1. Electricity demand is growing by 10-12% per annum.
2. Power deficit range is 9-13%.
3. 72339 MW is planned to be added in 12th
Plan (2012-2017) and 75500 MW is to be
added in 13th
Plan (2017-2022).
4. Amendment in Mega Power policy 2009 is made to facilitate immediate progress in 25
provisional mega power projects totaling to 32300 MW.
Above reference is taken from :
1. list of 25 power projects cleared by Ministry of Power for mega power status.
Annexure-3
2. List of Power projects listed by CEA and are under construction between 2012-2017.
Annexure -4
3. IBIS data of power plants updated as on 12/10/13. Annexure - 5
Refinery
Over the last several decades India has been among the world’s fastest growing economies,
with GDP more than tripling between 2002 and 2012. However, with the country’s expanding
economy comes an increasing demand for energy and, if current trends continue, India will be
the world’s third largest energy consumer by 2020. The government put in place an ambitious
plan that called for the country to produce 206.8 million tons of crude oil over the five-year
period ending in 2012
Demand for petroleum product of 215 MMT in 2012 will increase to 302 MMT in 2017. Country
is expanding its refining capacity by 87 MMTPA by 2017 in 11 expansion and 4 New green field
projects.
Please find attached Annexure-5 on refining capacity from website of Ministry of
Petroleumand Natural gas. www.petroleum.nic.in
Water treatment
MM aqua technologies limited manufacture components (in environment divison) which are
used in municipal and industrial sewerage treatment and municipal water treatment plants. The
growth for water and sewage treatment can be seen as an upheading graph due to numerous
investments coming up under JNNURM scheme of GOI the details are briefed as under:
As per strategic plan 2011- 2021 of Department of Drinking Water and Sanitation – Rural
Drinking Water under Ministry of Rural Development, GOI: NSSO 65th round survey shows
that 8 States of Bihar, Uttar Pradesh, Jharkhand, Orissa, Assam, Chhattisgarh, West Bengal
and Madhya Pradesh have less than 10% of piped water coverage at present.
As per the plan total fund of Rs 3,40,928 Crore shall be required to provide piped water system
to uncovered population with 70lwater per capita per day.

Under JNNURM some of the PROJECTS IMPLEMENTATION STATUS UNDER UIG :
TRANSITION PHASE is as under:
 Water supply scheme for Bhadreswar Municipality, Kolkata Rs 88.77 Cr
 Providing Sewerage network and sewerage treatment plant for South East Zone,
Amritsar Rs 89.27 Cr
 Construction of 500 MLD water treatment plant and clear water pumping station and
recycling plant in Pune Rs 171.08 Cr
 Water treatment plant & raw water pumping station at Wadgoan (Budruk), Pune under
PMC Rs 118.07 Cr
 Construction of New Water Treatment Plant in lieu of existing for Cauvery Water Supply
Scheme (CWSS) at T.K.Halli, Bangalore Rs 102.70 Cr
 Capacity Expension for Sewage Treatment Plant (STP) in Vadodara City (Zone-II) Rs
72.26 Cr
 WTP, Transmission line and storage reservoir for water supply system of east zone of
Surat Rs 49.13 Cr
 Water Recycling & Reuse project- Providing 60 MLD secondary & tertiary treatment
plant at Old Pirana, Ahmedabad Rs 58.75 Cr
 Water Recycling & Reuse project- Providing 60 MLD secondary & tertiary treatment
plant near Bhavan’s college, Ahmedabad, Rs 91.51 Cr
 Water recycling and reuse project for Ahmedabad City Providing 60 MLD tertiary
treatment plant for Narol Industries, Ahmedabad Rs 96.37 Cr
List of approved projects in Transition Phase under UIDSSMT for various state
 West Bengal water supply projects- Rs 247.56 Cr
 Tamil nadu water supply and sewerage project- Rs 899.31 Cr
 Uttarakhand water supply project – Rs 35.87 Cr
 Uttar Pradesh water supply projects- Rs 323.67 Cr
 Rajasthan water supply and sewerage projects- rs 1887.82 Cr
 Punducherry water supply project 161.439 Cr
 Punjab sewerage project Rs 112.90 Cr
 Orrisa water supply project Rs 347.14 Cr
 Maharashtra water supply and sewerage project Rs 2 746.834 Cr
 Kerala water supply project Rs 20 Cr
 Bihar water supply and sewerage projects Rs 918.60 Cr
 Chattisgarh water supply projects Rs 232.96 Cr
 Himachal Pradesh water supply and sewerage projects Rs 254.26 Cr
 Haryana water supply and sewerage projects Rs 61.09 cr
 Jammu & Kashmir water supply and sewerage projects Rs 129.87 Cr
 Karnataka water supply and sewerage projects Rs 1016.99 Cr
 Kerala water supply projects Rs 20 Cr
 Madhya Pradesh water supply and sewerage projects Rs 1705.8 Cr

MARKET POTENTIAL
Based on above data future demand of the products is forecasted as below:
A) Power Projects balance of 12th
plan( 2012- 2017) as per CEA report
Total MW to be Commissioned : 89976
No of Projects : 153
No of Cooling Tower : 188
Approximate Quality of Cooling tower product required
plasDEK : 647,000 CuM Rs 194,10,00,000
Splash fill V bar : 4,19,82,801 Mtr Rs 83,96,56,032
Splash Fill Grid : 1,49,90,000 Nos Rs 2,32,34,50,248
Splash fill trickle : 179952 CuM Rs 1,07,97,12,000
B) Power Projects in 13th
plan 2017- 2022 as per CEA report
Total MW to be Commissioned : 75500 MW
No of Projects : 129
Approximate Qualtity of Cooling tower product required
plasDEK : 543,600 CuM Rs 163,08,00,000
Splash fill V bar : 352,28,300 Mtr Rs 70,45,66,000
Splash Fill Grid : 12578300 Nos Rs 1,94,96,36,500
Splash fill trickle : 1,43,450 cuM Rs 8,60,70,00,000
C) Business Opportunity in refinery Expansions
Total MMTPA to be added : 89 MMTPA
No of Projects : 15
Approximate Qualtity of Cooling tower product required
plasDEK : 47,452 Rs 14,23,64,400
Splash fill : 71182 CuM Rs 4270932000
D) Business Opportunity in replacement requirement
Presently large industrial cooling towers installed in country are as below.
1 Power Plant : 50000 MW ~ 8,50,000 CuM of fill,
2 Refinery : 215MM TPA ~ 30,000 CuM of fill
3 CPP : 10000MW ~ 50,000 CuM of fill
Total Market size for replacement fill is : 75000 CuM/Year i.e. Rs.26,25,00,000.00
MM Aqua’s Share is 12-15% due to following market trends and actions taken:
A. Market Trends for Cooling Tower Products
i. Film fill has clogged in NTPC talcher which has raised concern and after a detailed survey,
NTPC engineering has decided to opt for Splash fill instead of film fill media. Various other
organizations like, Reliance, UPRVNL, APGENCO, RRVUNL and consultants opting for
Spalsh fill taking NTPC experience as example.

ii. Large number of Power Projects has moved to splash fill design from Film fill design. Three
designs of fill are presently used, namely GRID, Trickle block and V bar. We have
production facility for V Bar only. Splash fills design namely Turbo splash is still not
preferred by OEM’s due to its cost comparison. We need to develop capability for
manufacturing of trickle and Grid fill design.
iii. PCT has an edge over other cooling tower manufacturers in film fill tower and thus has
major share in business.
iv. From past 3 years, HSC designs tower either with GRID (we do not make) or with Film fill
of their Belgium collaboration which they import form their factory at China.
v. Fans Asia, NBCC etc bag orders with Splash fill design preferably GRID and thus have
only one source of supply i.e. Neel kamal.
vi. SBR and MBBR technologies are taking preference over Bio tower in waste water
treatment, which has reduced requirement of Biodek We are also now into manufacturing
MBBR media to capture the loosing Tubedek which earlier used to go with Biodek.
vii. Power projects that are awarded to Chinese companies on EPC basis and in such case, all
components are imported from China.
B. Strategic Actions – Following strategy is planned to ensure growth in above market
change.
i. Develop and produce higher efficiency cross corrugated fill to meet up gradation and
replacement market. VF fill sheets with better micro structure and higher surface area
would be required.
ii. Develop Straight fluted fill design to meet low clog requirement. Straight fluted sheets and
vertical offset fluted sheets production is possible in VF machine. Test cell would be
required to develop performance data.
iii. Increase export Market with Vacuum formed fill sheets quality that are required in
Australian, south Africa, Middle east, Thailand, Iran, Indonesia etc.
iv. Develop Tube settler with VF sheets to increase profit margin.
v. Develop exclusive manufacturing arrangement with Paharpur, SPX.
vi. Include Grid fill and Trickle fill media into product range. – Needs injection molding
machine.
vii. Develop exclusive manufacturing arrangement with GEA, SPX for injection molded
products.
A. Market Trends for water treatment products
viii. Due to higher surface area of product and requirement of lesser tank size clients started
opting tubesettlers in place of lamella plates.
ix. Recently the demand has moved to tubesettler media suitable for drinking water application
which MM aqua also offer.
x. Few consultants prefer a media with higher surface area for applications like rainwater
harvesting and thus opt for V shape tubesettlers.
xi. The products made from square shape tubes come in module form and offer higher span of
beams due to higher thickness of product and are preferred by clients like thermax.

xii. At locations where SS concentration increases more than 3000 ppm consultants opt for
lamella plates due to their higher capacities to handle SS loads.
xiii. As many of the upcoming projects of STP/ETP go with SBR technology which uses
conventional settling process, tube settler market share in ETP/STP ( <10MLD capacity)
has been reduced.
xiv. Many companies have emerged in past 3 years which have started copying hexagonal
chevron shape and V shape tubesettler in India.
xv. Tubesettler made from vacuum formed sheets are lighter in weight and easy to install as
comaped to extruded tubesettlers with tongue and groove arrangement.
xvi. Vaccum formed tubesettlers are cost effective in international market and thus prove an
edge above our FS 41.50.
B. Strategic Actions – Following strategy is planned to ensure growth in above market
change.
xvii. Number of competitors have stepped into the domestic market thereby making the
technology popular among industries and consultants. The local manufacturers have
captured an ample share of market (< 100 cum market). Therefore, we should have stocks
maintained for catering urgent requirements and viz-a-viz we should also develop a
product that has good efficiency and lower costs.
xviii. Develop Tube settler with VF sheets to increase profit margin.
xix. Increase export Market with Vacuum formed tubesettler quality that are required in
Australian, south Africa, Middle east, Thailand, Iran, Indonesia etc.
xx. Develop some more types of tubesetter to prove an edge over different tubesettler types
available in market and provide a solution based on the need.
xxi. Develop a testing cell for tubesettler length and loading rate to provide an optimum solution
to clients.

COMPANY PROFILE
MM Aqua is one of largest manufacturer of cooling tower fills and drift eliminators in India.
We started manufacturing in 1991 in technical and financial collaboration with Munters
Euroform Germany as Munters India Ltd. Fills design of Munters are tested and developed in
reputed test facility. It was Munters design, which facilitated and optimised the interaction of air
and water. These fill media meet the physical properties as recommended by Cooling Tower
Institute U.S.A.
MM Aqua adopted its current avatar on July 7, 1997 with the change in name not- withstanding,
the long-standing tradition of high technical proficiency and customer satisfaction continues to
be in focus. Its principal manufacturing facility is at Gurgaon, Haryana. The MM aqua factory is
an imposing 5000 square metres, state –of-the art factory on a well-landscaped, seven-acre
stretch of land. We are an ISO company and are committed to supply quality products as per
international standards.
MM Aqua Technologies Limited operates under the overall guidance and control of the
Chairman-cum-Managing Director Mr Madan Mohanka. Mr Mohanka is original promoter of
this venture.
Mr. Mohanka graduated in Civil Engineering from the Birla Institute of Technology, Ranchi
and obtained his Post Graduate Diploma in Management from Indian Institute of Management,
Ahmedabad.
Mr Mohanka has vast experience of running engineering business and managing high
technology products and services for mining and mineral processing, power and environmental
industries.
Mr.Mohanka is also Chairman of the following Group Companies :
Tega Industries Limited : The company is India’s pioneer manufacturer of Specialized
Wear Resistant Rubber Components for the Mining and Material Handling Industry,
and Mineral Processing Equipment.
Hosch Equipment (India) Ltd, which is a joint venture with Hosch Fordertechnik
GmbH, Recklinghausen, Germany.
Maple Orgtech (India) Limited, licensee of EMRO, Japan, for manufacture of EM
(Effective Microorganism).
He was also an agent for Mannesman Group for a period of 30 years for providing
technology to BHEL for critical piping for large power plants until till Mannesmann was
restructured and division was taken over by Technip..
He is Visiting Faculty at various Business Schools in India and abroad.
National Chairman : CII Mining & Construction Equipment Division.

SOCIAL SERVICE :
Mr.Mohanka has been instrumental in founding a school in the state of Rajasthan for
the education of the underprivileged. The school is a Non-Profit Organization
dedicated to the upliftment of the children in the region.
AWARDS RECEIVED :
 Samman Patra – From the Income Tax Department, India in 2002.
 Certificate of Honour from the Government of the Republic of Ghana in 2003.
 TiEGER Award for Entrepreneur of the Year 2006 by The Indus
Entrepreneurs, worldwide body of Entrepreneurs.
 Certificate for outstanding eminence and contribution to the profession of
Mineral Engineering from Indian Institute of Mineral Engineers – MPT 2008.
 Outstanding Entrepreneurship Award for 3rd Annual Asia Pacific
Entrepreneurship Awards 2011.
Hobbies : Teaching and Gardening.
The other members of the Board of Directors include :
- Mr Mehul Mohanka, who is MBA from Pittsburgh University, USA and M com from
Calcutta university and has several years of experience in managing business. His forte being
international marketing and finance.
- Mr A N Sadhu - after leaving Price Waterhouse Coopers where he was a partner for 30
years. He is now a Professor in Vinod Gupta School of Management at IIT, Kharagpur. He
provides guidelines and support, particularly in the financial and legal aspects of the Company’s
business.
- Mr B Bhalerao - He is renowned professional in the field of Environmental
Engineering. He renders significant advise and offers regular replies in the technical and
marketing aspects of our Environment Product Division.
- Mr Manoj Basu - He is Mechanical Engineer and has been associated with this project
from its inception and he has been a long standing colleague of Mr Mohanka.
- Mr. A.V.Iyengar – He is a Chartered Accountant and Company Secretary and Ex-
Managing Director of Organon India Ltd, Currently he is a Director of various
Companies. He renders significant advice, guidelines and support to develop overall and
managing control within the company. Renders consultancy in the financial aspects of the
company.

- Mr. R K Pal – He is B-Tech IIT Khanpur, FIIE. He has 15 years of experience in
precision light engineering industries and engineering based plastic industries. He has 16 years
in project engineering company and engineering project in construction industries. He is
beholding for total development of the company and provide engineering advices related to
production and equipments of manufacturing. He is responsible for operational cost reduction.
- Manish Mohanka – He is commerce graduate and active participant in review of internal
and statutory audit of the company.
The activities of the company are run from the factory located at Behrampur Road, Village
Khandsa, Dist. Gurgaon, Haryana . It has network of branch offices in Delhi, Mumbai,
Chennai, Hyderabad and Kolkata.
The Marketing operation are under control of President-Marketing Mr. S.S.Rawat, BE
Mechanical, PGDBA-Marketing, with an experience of 19 years. His core competences are in
sale, marketing product development. He is overall authority of marketing, sales, despatch and
PPC.
The organizational structure of the Company is enclosed separately.
The network of branches manned by experienced professional significantly contributes in the
development of marketing of the company’s products and subsequently realisation of
outstanding.

MAJOR EQUIPMENT INSTALLED
1. Heater Cooler Mixer - 3 Nos.
2. Calendaring Unit - 2 Nos.
3. Post Calendaring Unit - 1 Nos.
(For Sheet forming)
4. Flute former (for corrugated - 2 Nos.
Sheet)
5. Sheet forming line for D-15 - 1 Nos.
Drift Eliminator
6. Cutting Unit automatic Piling Unit - 1 Nos.
7. Profile lines with twin Screw Extruder - 7 Nos.
MAJOR EQUIPMENTS PROPOSED WITH INVESTMENT PLAN
1. Heater Cooler Mixer - 3 Nos. (1 is replaced with new)
2. New Calendaring-Line - 1 Nos.
3. New Post Calendaring Unit - 1 Nos.
4. Flute former (for corrugated - 3 Nos.
Sheet)
5. Sheet forming line for D-15 - 1 Nos.
Drift Eliminator
6. Vacuum Forming Machine -1 Nos.
7. Profile lines with twin Screw Extruder - 4 Nos.( 3 is replaced with1)
BALANCING EQUIPMENT
1. Sheet slitting Machine
2. Sheet cutting machines
3. Gluing Machines
4. Punching Machines - 5 Nos.
5. Band Saw Machines - 4 Nos.
6. Strapping Machine
7. Sheet wrapping machine
8. DG Sets: 2 Nos. 600KVA
9. Grinder, Hammer Mill and Granulator
10. Big and small Pulveriser machine
11. Air Compressor
12. Chilling Plant

MM AQUA BRANCHES & LOCATION
1. NORTHERN REGION: AT DELHI
2. SOUTHERN REGION: AT CHENNAI and HYDERABAD
3. WESTERN REGION: AT NAVI MUMBAI
4. EASTERN REGION: AT KOLKATA
5. FACTORY & HEAD OFFICE : AT GURGAON
PRODUCTS
Primarily, the products is divided in the following segments :-
1) Existing Cooling Tower Products include the following :-
(a) PlasDEK
(b) V-Bar
(c) D-15
(d) Spectra
2) Environmental Division includes the following :-
(a) TubeDEK
(b) BioDEK
(c) FAB Media
3) Air Conditioning :
(a) Mist Eliminator – T-100, T-200
(b) LTG Profile
COOLING TOWER DIVISION – Detailed description of products and advantages:
The Cooling Tower division consist of various products which are used in Cooling Tower/Air
Conditioning Division
1. PLASdek (Fill media)
2. Nozzle
3. V-Bar (Splashdek) (double deck)
4. Spectra
The description of each one is given in the enclosed Brochure.
PLASdek
Plasdek is the PVC Film type fill material used in cooling towers for heat and mass transfer.
The basic principle used is the effective air-water mixing by providing large surface area. MM
Aqua’s PVC film type fill media is cross fluted in construction which gives Criss-Cross water
and air passages, thus contributing to effective air-water mixing.

For various applications, the fill media is manufactured in five different sizes as under :
- Plasdek C 10.12 having 12 mm flute size (opening size). This is mostly used in package
towers where normally clear water is available.
(4)
- Plasdek C 10.19 having 19 mm flute size (opening size). This is basically used in
industrial Cooling towers, where water quality is reasonably good.
- Plasdek C 10.27 having 27 mm flute size (opening size). This is used if the water is
dirty i.e. TDS is between 200-250 ppm.
- FC 33 - Non clogging fill
Industrial Cooling Towers could be of natural drift type or induced drift type. It could also be
of counter-flow construction or cross-flow construction. PVC film type fill media can be very
effectively used in all counter-flow applications both for natural drift cooling tower and induced
draft cooling tower.
MM Aqua’s Plasdek media can also be used for cross-flow cooling towers. Some modifications
in the fill supporting structures are required to use the media effectively in cross-flow
construction. It has been tried in few installation and has given good performance.
Plasdek media has the advantage over other media manufactured in the following respects :
UNIFORM SHEET THICKNESS DUE TO CONTINUOUS FORMING PROCESS
A continuous forming process adopted by us one end of fill is always free and material supply
from other end is always available, as such at the time of formation of additional requirement of
raw material is met hence no thinning effect takes place at crests and troughs. Vacuum formed
sheets suffer from unpredictable thickness due to material stretching during process. Thickness
will diminish by an average of 30% making sheet weaker at crests and troughs.
DOUBLE EDGE FOLDING DURING MANUFACTURING TO PROVIDE EXTRA
STRENGTH
The primary cause of pack deterioration and ultimately of fill pack failure is abuse and
mechanical stress at the sheet ege. MM Aqua manufacturing technique has the ability to fold
the edges of the sheets providing stronger edges which give extra protection against rough
handling during installation and maintenance. It also act as protection against erosion from
constant pounding of water droplet resulting in increase of fill media life.
WHITE COLOUR FILL MEDIA SUITABLE FOR HIGHER AMBIENT TEMPERATURE
CONDITIONS. WHITE COLOUR REFLECTS HEAT AS SUCH ITS SURFACE TEMP
REMAINS LOW AS COMPARED TO GREY COLOUR.
MM Aqua’s continuous manufacturing technique can provide sheets of any length to suit
economic design of support bars. Optimum sheet lengths can be provided for fastest possible

gluing operation. Others who use Vacum forming or Therma forming case not give fill of any
length beyond the size of the table.
MM Aqua’s planetary extrusion technique provides high degree of homogeneity in raw material
and thus produces best sheets as compared to any other process.
MM Aqua products are UV stabilised. Physical and mechanical properties of our products meet
the requirement as laid down by Cooling Tower Institute, USA.
MM Aqua has in House capability to test the above properties on the manufactured products.
Use in Retrofitting of Cooling Tower
Plasdek can be used in retrofitting jobs of cooling towers also. In case of the old towers,
Plasdek can replace splash bars and the efficiency of the cooling tower will increase
considerably. Replacement of existing fill by Plasdek in a Counter flow Cooling Tower can
further reduce the temperature of cold water by 1º to 1.5º C. With this reduction, a 100 MW
power plant can generate 1 MW additional power. The cost of changing fills could be
approximately 35-40 Lac whereas, the revenue drawn from 1 MW is 3.5 Crore per annum.
With the increased power cost the demand of Retrofitting has become more. More & more
users of Cooling Tower are looking for improvement of performance of CT by way of change
of design of internal component to improve the performance.
V Bar
Most cross flow cooling towers designs used today, do a pretty good job in promoting the
removal of heat from cooloing water, but they are constrained by the limited availability of
good quality water. This shortage has forced industries to use sea water or turbid water for
cooling towers. Unfortunately the cost involved in treating such water to make it suitable for
film fill is very high. It has therefore become increasingly imperative that splash fills be used in
cooling towers.
Splash bar type cooling media promote liquid surface area by creating a multitude of fine
droplets as water falls through the cooling section. This is accomplished by placing the splash
bar in a staggered, spaced - apart pattern where falling liquid impacts and shatters on the surface
of splash bars. The heat transfer takes place on the surface of the droplets. The greater the
number and the smaller size of droplets, the better is the heat transfer efficiency.
MM Aqua’s specially designed splash fill, SPLASHdek offers high thermal efficiencies and a
minimal pressure drop. SPLASHdek is however available in two different hole shapes –
rhombus and circular. V bar offered by are
- designed to take advantage of mechanical dispersion and dry splash methods, there by
creating a abundance of fine droplets.
- Its unique notch size generates drops and ensures a relative clean surface for better
splash.
- The smooth edge rib at the vertex gives added strength to the bar, making it conductive
to the high water loading and relatively larger spacing.

DRIFT ELIMINATOR
Drift Eliminator is a device used to reduce drift from Cooling Tower. In the Cooling Tower,
evaporation of water takes place. Therefore, the exhaust air comes out from Cooling Tower is
normally laden with water droplets. These fine droplets of water mixed with air cause nuisance
to the neighborhood by causing damage to the other equipment in the plant. Besides that, more
make-up water is required in the Cooling Tower to substantiate the Drift loss.
Therefore, Drift Eliminators are provided in Cooling Towers to arrest the water droplets from
the humid air. Drift Eliminators are required both for Counter flow and Cross flow Cooling
Towers.
MM Aqua manufactures two types of Drift Eliminators. Details of these two types are as
below:
 D-31 Drift Eliminator
These are profile type eliminators arranged at a definite spacing by providing polypropylene
ABS spacers - catalogue enclosed.
Drift Eliminators D-31 are only suitable for Counter flow Cooling Towers. These are sturdy in
nature. D-31 Drift Eliminators are supplied in the profile form from the factory along with the
spacers. The assembly of the Drift Eliminators is done at site by means of a simply designed
assembly table.
D-31 Drift Eliminators are highly efficient and capable of limiting the drift to below 0.007 % of
Water Flow.
 D-15 Drift Eliminator
These Drift Eliminators are made out of Vacuum formed PVC sheets. In this Drift Eliminator,
air laden with water droplets changes the direction three times. In every obstruction, water
droplets are removed from humid air.
D – 15 Drift Eliminators are highly efficient in reducing Drifts from Cooling Tower. These
Drift Eliminators can be used in both Cross and Counter flow Cooling Towers.
D – 15 Drift Eliminators are supplied in nested form to the site for larger Cooling Towers.
After making blocks by gluing, D-15 Drift Eliminators are placed in Cooling Tower. D-15 is
probably the best Drift Eliminator available in the market and can reduce Drift to 0.005% of
water flow. Two layers of D – 15 can reduce drift upto 0.005% even. They are manufactured
in a special flute forming machine to any length.
 DekSPRAY NOZZLE
Dekspray ‘Solid Rectangle’ spray nozzles are used in Cooling towers for uniform distribution of
water over the fill area.
Dekspray consists of standard plastic body and a choice of four different turbulators and orifice
inserts. These turbulators and orifice inserts are used according to the difference water

capacities. In order of increasing capacity, the nozzles are 1-A, 1-B, 1-C and 1-D The 1-D
nozzle does not use an orifice insert but utilizes the full orifice of the nozzle body.
The standard plastic used for manufacturing the nozzle body is ABS, which is suitable for
service at temperature upto 180 F. Each nozzle is supplied with its own silicon gasket, plastic
turbulator and orifice insert, forming the nozzle assembly.
Dekspray nozzles are fitted with the header pipe with special type of ABS adaptor supplied by
MM Aqua. Dekspray nozzles have some distinct advantages over the other nozzles available in
the market. Those are as follows :
* Dekspray ensures uniform distribution of water over entire fill area
* Dekspray contributes to less weight and cost in piping system.
* One Dekspray nozzle does the job of 10-20 conventional nozzle.
* Dekspray reduces the frequency of nozzle clogging if the water quality is bad
* The body of Dekspray is made of corrosion resistant plastic.
* Dekspray provides wide spray angle.
* Installation of Dekspray is only by twist-lock and removal from header does
not require any special tools.
* Water capacity can be readily changed within single Dekspray nozzle body.
- For details please see overleaf catalogue.
SPECTRA
Spectra Drift Eliminators removes liquid droplets from Cooling Tower exhaust air. Spectra can
be used in both Cross flow and Counter flow Cooling Towers. Spectra drift eliminator design
rely on rapid changes in velocity and direction of air-droplet mixtures to remove drift by
impacting on eliminator passage surface. Spectra has edge over other cellular and blade type
drift eliminators by extending the third pass impact by over 35% and by adding a trailing edge
airfoil. This airfoil creates a stagnation region immediately upstream which the smallest
droplets enter and then eliminated by impacting the airfoil surface outside of the influence of
the main airflow.
MM Aqua’s Spectra drift eliminator provides outstanding performance in both Cross flow &
Counter flow applications. A number of operating Spectra installations have been
independently tested by various agencies and drift rate measured is 0.003 to 0.0005% of the
circulating water rate. This outstanding performance is attributable to Spectra’s unique and
patented blade design.
Spectra provide a useful air velocity operating range that is well beyond the limits of other
products. Spectra’s double wall construction, coupled with the exceptional physical properties
of PVC, assured structural integrity and dimensional stability for maximum service life.
With the new water treatment restrictions in cooling towers, biological fouling is becoming an
increasingly important concern. Spectra’s rugged, double wall construction allows pressure
washing without damage to eliminate any efficiency loss due to bio mass build-up.

Spectra made out of PVC which is specially formulated for it’s superior physical properties. It
includes Titanium Dioxide as a UV inhibitor to provide exceptional resistance to ultraviolet
radiation in outdoor weather exposures. It can stand up well to temperature variations, air
contamination and biological attack.
The unique design of Spectra drift eliminators allows shipment and storage in a compact, low
volume nest form. Spectra provide significantly lower shipping, handling and in-plant storage
costs. Spectra weighs only 6.59 kg./Cu.m. This is 1/2 to 1/3 lighter than most wood eliminator
and reduces the loads on tower structures. Dimensional accuracy and uniformity are assured on
every panel of Spectra since all interlocking elements are fabricated at the factory to close
tolerance. Please see enclosed Catalogue.
ENVIRONMENTAL DIVISION - Detailed description of products and advantages:
TUBEDEK
The long term market for TUBEdek and the customer profile is given below :
LONG TERM MARKET
The long term market for TUBEdek depends on the following:
a) Cities/Metros like Surat, Pune etc. getting convinced to use Tubedek for water
treatment. Presently efforts are being put in Rajasthan where Asian Development Bank has
come up with an investment of Rs.200 crores (for various Water Treatment Plants).
b) Capacity of existing Clarifiers will increase by providing tube settlers.
c) Power plants using sea-water, raw river water will require Tubedek for
clarification of water.
d) Other industrial application like Common Effluent Treatment Plant, Textile etc.
the potential is expected to grow by around Rs.70 crores.
NOTE 1: Enclosed is a detailed list of application of Tubedek.
TUBEdek
TUBEdek is a PVC Tube Settler for solid liquid separation in water clarification and in Primary
as well secondary sedimentation in wastewater treatment plants.
It is to be noted that Traditional Sedimentation Tanks are large structures occupying much
valuable space on site and are perceived as high investment cost items. The Tube Settlers are
installed within the Settling Tanks where an enhanced capacity for settling the suspended solids
is required in a fractional area. It increases the settlement surface in the tank by providing it
with many layers at a slope of say 60 degrees. This produces a very large number of SINK
PATHS that effectively divide the tank into numerous small settling basin. Thus allowing a
highly structured flow pattern.
The very large area provided by TUBEdek reduces the tank size to a fraction resulting in
significant savings in the construction costs. With the availabilityof land becoming a big
constraint in big cities and the premium on the land costs, it is becoming imperative for water
supply authorities to opt for the Tube Settlers. Upgrading the existing overloaded tanks is

another very cost effective application of TUBEdek since it can easily be adopted to any shape
of tank. After the installation of the TUBEdek, the settling capacity of the tank significantly
increases and the settling efficiency highly improved. TUBEdek has a small “Hydraulic
Radius” encouraging laminar flow that is essential for good sedimentation. It’s
Hexagonal/Chevron shaped cross section has been found to be ideal for most efficient solids
separation in the tests conducted by numerous independent agencies.
On the structural stability front, it needs to be emphasized that TUBEdek is made from Robust
PVC Profiles with a very smooth surface finish. For periodic maintenance it allows foot traffic
on the TUBEdek module itself. This is in contract to many other suppliers who supply very
think walled PVC Tubes as Tube Settlers and these lack the structural strength to last the life of
a Water Treatment Plant.
MM Aqua Technologies Ltd. (Formerly: Munters India Ltd.) is the largest producer of PVC
structural Fill Media and Tube Settlers in Asia. In India these state of art components are
manufactured strictly as per their technical and quality control parameters.
In past years MM Aqua have received orders/despatched the goods from India to USA, Canada,
brazil, Japan, Australia, Hong Kong, Singapore, South Korea, South Africa, Saudi Arabia,
U.A.E , Oman, Malaysia, Indonesia, Taiwan, Thailand, Phillippines, Vietnam, and other
countries. Our components have been identified as of very high standards in these countries and
we get regular repeat orders.
CUSTOMER PROFILE – TUBEdek
S.No. APPLICATION CUSTOMER PROFILE
1. RAW WTP - MUNICIPAL BODIES
CLARIFICATION
2. RAW WTP - LARGE INDUSTRIES:
CLARIFICATION 1. POWER PLANTS
2. FERTILISER PLANTS
3. REFINERIES
4. PETROCHEMICAL PLANTS
5. PULP & PAPER INDUSTRIES
3. SEWAGE TREATMENT 1. MUNICIPAL BODIES
PLANTS – PRIMARY 2. LARGE COLONIES ATTACHED TO
SETTLING INDUSTRIAL PLANTS
3. LARGE HOUSING COMPLEXES
4. INDUSTRIAL EFFLUENT * SUGAR
TREATMENT PLANTS - * PULP AND PAPER
PRIMARY SETTLING * DISTILLERY SECONDARY
* BREWERIES
* PETROCHEMICAL INDUSTRIES
* FERTILIZER
* DAIRY
* SOFT DRINKS

* FOOD INDUSTRIES
* TANNERIES
(15)
* TEXTILE
* DYE STUFF INDUSTRY
* PHARMACEUTICAL
* OTHER ELECTRONIC AND PCB
MANUFACTURING INDUSTRIES
* METAL FINISHING & PLATING INDUSTRY
* COAL WASHERIES
* HOTEL INDUSTRIES
* OTHER INDUSTRIAL UNITS
5. SECONDARY SETTLING * DEPENDING ON THE TECHNICAL
FEASIBILITY AND MERITS
6. THICKENING * DEPENDING ON THE TECHNICAL
FEASIBILITY AND MERITS
7. ANAEROBIC DIGESTION * MAINLY DISTILLERY UNITS
* UASB
It clearly indicates the wide application.
BIODEK
The long term market for BIOdek and the customer profile is given below :
LONG TERM MARKET
Long term market for Biodek depends on the following:
a) Converting the Suspended Growth System (Conventional) to Attached Growth
System using Fill Media (Biodek).
b) Switching to high application in distilleries both in primary and secondary
treatment producing methane gas for power generation.
c) With the growth of food processing industry, the application of Biodek comes in.
d) Industrial plant application for Trickling Filter and BOD reduction.
Presently, in India, about 95% of wastewater treatment facility is based on conventional system.
With the gradual conversion of conventional system to Attached Growth System and setting up
of additional facilities, potential market for Biodek is expected to grow to around Rs.140 crores.
BIOdek
Biodek is a media for aerobic and anaerobic application for BOD reduction and nitrification –
de-nitrification in industrial and domestic wastewater treatment plants.

It is to be noted that traditional treatment systems consume more space and power. With the
space constraints in major cities, industrial towns and industrial units and the cost of power
increasing every day, the system of MM Aqua is getting increasing popularity and acceptance
day by day.
THE ADVANTAGES OF THE SYSTEM ARE:
 Low operating costs.
 Low energy cost (acration by natural draft).
 Reliable performance.
 High resistance to hydraulic and organic shock loads.
 Low energy costs.
 Low initial capital cost.
 Low construction cost.
 Efficiency consistency in winter time and during ice formation.
THE APPLICATIONS ARE BROADLY:
 BOD reduction, nitrification and de-nitrification in trickling filter.
 Complete secondary treatment.
 Roughing of pretreatment.
 Upgrading existing rock filters.
 Anaerobic Treatment Reactors.
 Submerged Aerobic Fixed Film Reactors.
 Odour Scrubbing.
MM Aqua has spent the previous years in promotional activities and educating the consultants,
the original equipment manufacturers and the end users (comprising of industrial design
engineering departments, Government bodies in water and sewage treatment plants, pollution
control boards, industrial associations). This effort has resulted in very positive development in
domestic and international market. This has resulted in pull towards accepting this
process/technology from all corners (from consultants, original equipment manufacturers and
government institutions/organizations) to adopt and go in for the technology in their water and
sewage treatment plants.
The effort towards development of international markets in Asia, Australia, South Africa, North
and South America has already resulted in orders round the globe. The orders in exports have
grown more than two fold in the present year and expected to increase by over 25% every year
in the coming five to six years. During the last four years, MM Aqua has received
orders/despatched the goods from India to USA, Canada, Brazil, Japan, Australia, Hong Kong,
Singapore, South Korea, South Africa, Saudi Arabia, U.A.E., Oman, Malaysia, Indonesia,
Taiwan, Thailand, Philippines, Vietnam and other countries. Our components have been
identified as of very high standards in these countries and we get regular repeat orders.
In pioneering these state-of-art products, MM Aqua has contributed significantly to the
environmental protection and land savings.

CUSTOMER PROFILE – BIOdek / FAB Media
S.No. APPLICATION CUSTOMER PROFILE
1. SEWAGE TREATMENT - MUNICIPAL BODIES/COMMON
BOD REDUCTION EFFLUENT TREATMENT PLANTS/
LARGE HOUSING COMPLEXES/
LARGE INDUSTRIES HOUSING COLONIES
1. POWER PLANTS
3. REFINERIES.
2. SEWAGE TREATMENT - MUNICIPAL BODIES/COMMON
NITRIFICATION/ EFFLUENT TREATMENT PLANTS/
DENITRIFICATION LARGE HOUSING COMPLEXES/
STEEL PLANTS/LARGE INDUSTRIES
HOUSING COLONIES
1. POWER PLANTS
3. REFINERIES
3. INDUSTRIAL PLANTS - 1. SUGAR
TRICKLING FILTER FOR 2. PULP & PAPER
BOD REDUCTION 3. DISTILLERY SECONDARY
4. BREWERIES
5. PETROCHEMICAL INDUSTRIES
6. FERTILISER
7. DAIRY
4. SOFT DRINKS
9. FOOD INDUSTRIES
10.TANNERIES
11.TEXTILE
12.PHARMACEUTICAL
13.OTHER AGRO INDUSTRIES
5. ANAEROBIC DIGESTORS – 1. DISTILLERIES – PRIMARY INDUSTRIAL EFF
2.SEWAGE DIGESTORS TREATMENT PLANTS
3. BREWERIES
4. P.T.A. PLANTS
5. PHARMACEUTICALS
6. PULP & PAPER – BLACK LIQUOR
6. PHARMACEUTICAL INDUSTRY
*OIL-WATER SEPARATION
*AMMONIA STRIPPERS DEGASIFIERS

New Products under Cooling Tower Products range :-
1. GRID
Grid fill design is one of the options for counter flow cooling tower fill media. Yet another
design is Trickle fill which is a hybrid fill media and performs between splash and film fill
media. Both grid fill and trickle fill media needs to be added into product range to have
complete range of fill designs. These product additions will make presence of MM Aqua in all
range of water quality used in cooling tower application.
MM Aqua Grid fill is an efficient, non-clogging fill designed specifically for all counter flow
cooling tower applications to withstand a with range of water loading and offering a minimal
pressure drop. MM Aqua Grid fill is a true splash action fills designed to eliminating all
disadvantages and problems that are associated with other splash fill design. Structural stability
and firm fitment makes it a splash fill with practically no maintenance requirement. MM Aqua
Grid fill can be used for years offering consistent performance with any water quality including
sea water or brackish water. Grid fill is selected at different vertical pitch to offer different
thermal performance and allows the design engineer to offer an optimum cooling solution
meeting the clients need.
MM Aqua Grid fill performance is supplemented with a sturdy, quick fix and firm holding
clamping arrangement which holds the grid firmly to its location and ensures uniform pressure
drops.
In near future, other potential market for this product will be
1. Projects with GIL. - 700,000 Nos
2. Replacement requirement of PP Grid.
3. Projects with HSC where they consider above Grid ( HSC also uses another design
named Golden Grid)
4. SPIG – we need to develop another GRID to target their requirement. 18,00,000 Nos.
5. L&T – A new grid design is under discussion with Mr Ramsubramanian so that L&T can
quote projects specifying splash fill and counter flow.
Product :
1. 750x750x20mm grid as per sample available with us which is old Hammon design also
offered by Gammon
2. 750x750x20mm with frame of Hamon design and inner members of Opti Grid
A. Projects on going with PP Grid:
1. Fans a.s – 2 x 660 MW – Meja NTPC
2. Fans a.s – 2 x 660 MW – Nabinagar NTPC
3. NBCC - 2 x 600 MW – Singareni collieries
B. Projects where PP Grid would be optional in State Electricity are as below
1. APGENCO
2. RRVUNL
3. UPRVUNL
4. HPGCL, CSEB, NTPC and other electricity boards.
5. All projects with Sea Water Application

C. Replacement requirements in Projects already Commissioned with PP Grid In India
1. NTPC Jhajjar, NTPC Simhadri, NBCC Mouda
2. CSEB Marwah
3. Balco Korba
4. Export business Potential in Thailand, South Africa.
Price: The PP Grid is sold at Rs 135 per no, when raw material price is Rs 105 per Kg
2.Trickle Fill Media
It is an injection molded, counter flow PP fill. These provide large surface area for heat
exchange with both film fill and droplet generation. Water trickles over thin members and falls
from one member to another generating splash actions. Surface area produced through droplets
is far more as compared to conventional design of splash fill media. These fill have low
clogging tendency are very suitable for use for applications where the circulating water has very
high levels of suspended solids.
Features
Click lock assembly and thus not glue or solvent is used.
Can be used for high temperature applications. Maximum continuous operation up to 75°C
Can be cleaned and reused.
Can be used in combination of film fill to avoid clogging situations or to improve performance
of splash fill cooling tower.
Can be stored for long period without damage or deforming.
In near future, other potential market for this product will be
1. Projects with Gammon India Limited for RAPP Kota Expansion
2. Replacement requirement of PP Trickle Block Splash Fill
3. Projects with GEA where they consider above Trickle Block Splash Fill.
4. L&T – Trickle Block design is under discussion with L&T so that L&T can quote projects
specifying Trickle Block Fills.
A. Projects on going with Trickle Block Splash Fill
1. NPC Kakrapara – 2 x 18000 Cum
2. RAPP Kota – 2 x 18000 Cum
B. Projects /State electricity boards preferring Trickle Block Splash Fill as preferred
option.
1. APGENCO
2. RRVUNL
3. UPRVUNL
4. HPGCL
5. CSEB
6. All projects with Sea Water Application
C. Replacement requirements in Projects already Commissioned with trickle fill in India
1. Vijaywada Thermal – 18000 Cum
2. Kothagudem Thermal – 21000 Cum
3. Kalisingh Thermal – 44000 Cum
4. Krishnapatnam – 44000 Cum

5. NCC – 18000 Cum
6. Large no of projects in Europe / USA & South America.
Product: The size of the standard block is 300mm x 300mm x 1200mm. The tooling will be
single or double cavity for 300mm x 400mm piece.
Price : Trickle Block Fill is presently sold at Rs 6200/cum , When raw material price is Rs 120/
Kg.
Business Volume Expected:
Year 2015-2016 2016-2017 2017-2018 2018-2019 2019-20
Qty Cum/Year 7500 10000 12000 14000 160000

DETAILS OF COMPETITORS
1. Cooldeck - Has a manufacturing plant in Mumbai (Perfect converters) as well as in Daman.
Supplies the media based on the requirement from either of the units to save on the freight cost.
Strength and look of material is too bad but the dimensions are accurate and formation is good.
Limitations on the 10.27 range and cannot give higher thickness.
Also supplies Nozzles similar to our type. Price is Rs. 90/- per piece. Nozzle body has threads
instead of twist lock arrangement. Delivery is very prompt.
Alliance: Nil
Manufacturing Facility : Vacuum forming table and sheet feeding unit
Strength : Locally available in Mumbai and surrounding at Low price. Supplies all internals
for all types of CT. Sister concern M/s Melfrank undertakes retrofit as well new jobs using
cooldek spares. Very active in retrofit of wooden towers.
Weakness : Inadequate quality. Not technically sound. Small marketing set up. Caters only
smaller Cooling Tower.
2. Nilesh - Caters to small package tower industries. He even waives off the differential
amount cannot bother for the “C” form. Market info is that the quality of the product has
improved a bit in the past years. Prefers only cash business.
Alliance : Nil
Manufacturing Facility : Vacuum forming table.
Strength : Locally available in Gujrat at low price and immediate delivery. His man is
available for gluing work outside Gujrat for small quantities also.
Weakness : Poor Quality - No marketing set up
3. Brentwood industries - Has entered into Indian market with redg office in Ahmedabad.
Their manufacturing facility in ahmedabad is expected to be ready by next financial year i.e.
2015-16. Strength and look of material is good.
Alliance: has their own R&D department in USA
Manufacturing Facility : Vacuum forming machine and injection molding machines are
proposed to be installed in india.
Strength : expertise in manufacturing of cooling tower components, water treatment
components.

Weakness : Will be dependent on outsourced PVC sheets for production. High cost of
manufacturing. High over heads.
4.NILKAMAL LIMITED is the undisputed leader in the Indian market for Moulded Plastic
Furniture, Material Handling Solutions and offers a comprehensive product mix right from bins,
crates, pallets, Material Handling Equipment ranging from Pallet Trucks to Stackers, Forklifts,
Shelving and Racking plus all equipment required for every type of industry which is growing
at a rapid pace in India.
Manufacturing Facility : They have factory in different location to cater most part of India
from smallest distance. The Company has 7 large manufacturing plants in India
* North – Samba (Jammu & Kashmir) and Greater Noida (Uttar Pradesh)
* East - Barjora (West Bengal)
* West - Sinnar, Nashik (Maharashtra) and Silvassa (Union Territory of Dadra & Nagar Haveli)
(2 plants)
* South – Pondicherry (Union Territory)
Alliance : They are independent organization. NILKAMAL LIMITED has a Joint Venture in Sri
Lanka with a leader of Sri Lankan market for Moulded Furniture.
The Company also has a Joint Venture with BITO LagertechnikBittman GmbH for the manufacture of Material
Handling and Storage Systems in Metal, with a manufacturing plant at Samba, Jammu & Kashmir.
Nilkamal has exclusive tie ups with:
1.HanelBuro-Und
Lagersystems, Germany
For Automatic Storage and Retrieval Systems
2.ConTeyorMultibag
Systems NV of Belgium
For manufacture of Textile Partitions for Crates and Metal Racks to
provide valuable in-transit protection for scratch sensitive products.
3.Plastic Omnium Systems
Urbains, France
For supply of their International Standard Waste Bins of all sizes
conforming to EN/DIN Standards.
4.CAMBRO Manufacturing
Company, USA
For Hospitality Products suited for large Restaurants and Hotels. Now
further consolidated into a Joint Venture to market the entire range of
CAMBRO products throughout India,Sri Lanka, Bangladesh and Nepal.
Strength: Vast expertise into injection molding. They have their own tool development centre.
Some of their factories are in tax exemption zones. They can also meet demand of local tax in
states where they have factory.
Weakness: high cost due to high over heads. Cooling tower components is not their main focus,
thus give less preference to supplies. Thus customers are not happy.
B & C OEM’s with their own manufacturing set up for C.10.12 are Mihir and Himgiri.

SWOT ANALYSIS
STRENGTHS WEAKNESS
1. High Brand value
2. Good Quantity
3. All big OEM’s buy 100% from us.
4. High Quality of Technical services
5. 40% of business is form Export
6. Wide support base
7. Foreign collaboration
8. In-House Test capabilities
9. Wide product range
10. Competency to recommend improvement
and execute at site.
11. Big production facility and faster delivery.
1. Higher selling price
2. Overhead higher compared to competitor
3. 2% CST on product against NIL against
form C for competitor.
4. Higher Power cost due to Load shedding.
5. Higher wages in Haryana.
6. Monopoly supplier of main Raw material
i.e. PVC.
OPPORTUNITY THREATS
1. Untapped Export markets of New
developed products.
2. Alliance with Turbosplash, Italy to enter to
cater Turbid water Cooling Tower.
3. Large number of new projects in power,
refinery sector
4. Retrofit market – Large market size.
5. Wide product range to suit replacement
market.
6. Appointing agents in Thailand, Chilie will
generate more export business.
1. Competitors like Cooldek, Nilesh, sell
inferior material at lower price
2. Import of Recycle PVC is more difficult.
3. Duty free import in Mega Power making
competitor cheaper as they use recycled PVC.
4. EPC contracts bagged by Chinese
company. They import all items from China
only.
5. Big manufacturers are attracted towards
large upcoming projects.

PROJECT DETAILS
PROJECT 1: Installation of 4 Roll Calender Line, make Rodolffo Comerio, Italian Calender.
Replacement Investment of Rs. 7.47 cr.
MM Aqua has 2 nos. old 2roll calendarite machine imported in the year 1991 from erstwhile
owner i.e. Munter Euroform Germany after the machines were used by them for more than 30
years. Both the machine is in operation at MM aqua for last 20 years. With present condition,
machine is not able to produce uniform thickness of PVC sheet, production of higher thickness
of PVC sheet, proper forming PVC sheet and thus high cost of operation. To meet the current
demand of the market and improve the quality of the products MM Aqua is procuring 4 roll
calendaring line which include heater cooler mixer, planetary extruder, 2 Roll mill, 4 Roll
calendar , Post calendar, beta gauge, winding machine to replace 2.nos old calendar machine.
Advantages of the 4 Roll Calenderer line :
1. Transferring of PVC compound from heater cooler mixer to
planetary is via root blower system which help in reduction of
fly loss and low cost of operation.
2. Planetary extruder has 6 big screw and 6 small screw which
help in good plasticization help in reduction of rejections.
3. Roll mill is an added advantage for PVC products.
4. 4 roll Calender will ensure uniform thickness, production of
higher thickness sheet with high production capacity i.e. 800
kgs/hr
5. Calendaring line is also very good at handling polymers that
are heat sensitive as it causes very little thermal degrading.
6. PVC sheet manufactured shall be used in existing sheet
feeding units and new Vacuum forming machine.
To install 4 roll calendaring line in existing plant requires modification in floor for foundation,
to make facility for 15 tons EOT crane- height of the shed to increase, make proper arrangement
of ventilation and replacement of roof.
To plan smooth unloading of 10 containers ( for 4 roll calendar) and other equipments at same
time and eventually making arrangement of loading of 6 -7 trucks and 3-4 containers daily i.e.
dispatch of 75 to 80 lacs, road is essential.
To Further reduction on cost of electricity, Thermal fluid heaters of 10 lac Kcal, coal based fuel
( make Thermax Ltd) is to be installed to generate 600KW every day.
BENEFITS EXPECTED FROM INVESTMENT
Replacement of Existing Calendar Machines whose residual value is zero has following
benefits:
1. Increase Production Capacity by 4000 p.a.
- reduction of overall cost of production by Rs.4/kg.
- reduction of raw material cost to avoid outsource semi-finished product by Rs.10.75/kg .
- reduction of high turnover of stock to 30 days leading to improved working capital and
generation of free cash flow.

2. Input Raw Material for Vacuum Forming Machine.
3. Reduction of power and Fuel Cost p.a. i.e.by Rs.2.42/kg
4. Reduction of repair and maintenance cost by 35% over 5 years.
Financial feasibility of this Project
Sales Graph
Cash outflow and free cash inflow
Pay Back Preiod- 1 Years 8 Months
Internal Rate of Return- 53%
Return On Investment- 43%

PROJECT 2: Downstream of profile line
Replacement Investment of Rs.1.59cr
Right now MM Aqua has 7 extrusion lines, 1 extrusion line is imported from Austria in year
2012 and balance 6 extrusion lines are locally procured from India. Results on performance and
output of European machine are outstanding and achieved its ROI as declared to the board of
directors. This extrusion line is equivalent to our existing 4 local machines. Therefore to reduce
further operational cost and increase output, company has decided to go for another equivalent
extrusion line to replace existing 3 lines. Company already has old Cincinnati extruder of
capacity 350kg/hr to be commission with new downstream to make a complete extrusion line.
Machine will manufacture profiles which are already in company’s portfolio.
Replacement of Existing 4 nos. Profile Line whose residual value is Nil has following benefits:
- Increase in contribution by 9.8 % i.e. Rs. 7.58/Kg on account of increase productivity,
substantial reduction of electrical cost and reduction of manpower cost.
- Reduction of Repair and Maintenance cost appox. Rs. 4.5 lacs p.a.
Financial feasibility of this Project
Sales Graph

Cash outflow and free cash inflow
Internal Rate of Return- 13%
Return On Investment- 37%

PROJECT 3 :Vacuum Forming Machine
As per the business plan submitted by President Marketing to stay ahead of competitions and to
avoid threats of new entrants and competitors and finally for own sustainable growth, MM
Aqua decided to have new products/designs in portfolio to have wide spread presence in
market. In past MM Aqua was dependent on technology providers / collaborators for any new
products and technologies. In such case all above inputs were available from the principle
company. To remain market leaders it has become eminent that MM Aqua carries out
improvements in their products and also innovates and develops new design to meet changing
market demands and remain at apr with other world leaders who have come up with various
new designs to suite bad water quality and clogging situations.
Marketing of any improved fill or new developed fill design calls for necessity of a full-fledged,
very accurate testing to develop complete performance parameters i.e. Heat transfer capabilities
and pressure drop values.
With availability of test cells, MM Aqua will not only be able to carry out performance testing
and development of new/ improvised fill design, but also will be able to test competitor fill and
prove to consultants and end user about inferior performance of copied products.
Initially targeted products are: improvised version of C10.19, internationally accepted
quality of D-15.
Therefore need arises to establish Fill Testing facility to test existing fills & new fills being
developed as any fills that is developed today or in the future needs to be tested and possibility
of testing such fills is almost non-existent in India. To established such facility at budgeted cost
of 2.34 Cr with overall area for the test facility is 36ft x 64ft.
IIT Delhi is appointed and contract is being signed for design of a test facility for performance
testing of fills with the objective “to design, fabricate, assemble, debug and commission a
cooling tower test facility for performance testing of various designs. The facility will enable
testing as per prevailing standards”.
Existing products and new products needs to be manufactured through Vacuum forming
machine to match the international quality and enter into entrapped export market.
Advantages of Vacuum Forming Machine :
1. Imported Vacuum forming machine has features of continuous forming , high quality of
shapes and designs of fills i.e. plasdek and online cutting of desired length which will
reduce existing cost of extra cutting, handling and grinding.
2. International Markets can be penetrated easily as sheets with better micro structure and
dimensions will have acceptability.
3. Freight cost per unit will reduce due to better nesting. Same can be marketed for better
selling price.
4. Non fouling and vertical flow designs can be added to product range easily.
To install Vacuum forming machine new Chillers and Compressors to purchase, existing plant
needs modifications for installing machine and its utilities

1. Installed capacity of Plant will be increased by 3800 Tons p.a. Capacity utilization is
indicated in sales Graph.
Financial feasibility of the Project
Sales Graph
Cash outflow and free cash flow

Internal Rate of Return- 51.59%
Return On Investment- 43.72%

PROJECT 4: Cutting system
Investment Rs. 1.52 cr
MM Aqua is a manufacturer of different designs of Rigid PVC corrugated film sheet through
Calendering and flute forming process in continuation. Sheets are formed at speed of 12 to 16
Mtr/Min of finished corrugated length. Formed corrugated sheets travels on conveyor to cutting
unit. Length of the sheet is set by moving assembly having infra red sensors, that senses the
sheet approaching a particular length and to actuate clamps and cutter. Cutting system does not
have accuracy to cut in desired size therefore we need to keep 100mm extra which is around 10-
12%. In next process we cut the extra length sheet to make it required length. Cutting wastes are
grinded to powder to reuse. To avoid further cutting and save in operating cost, MM aqua
decided to go for imported cutting system which will cut the sheet in desired length. Detail
working shown in chapter no-J project details.
Financial results:
Cash outflow and net free cash flow
Pay Back Period – 2years
Internal Rate of Return – 56%
Return on investment -63%

RISK ASSESSMENT
Financial Risk:
a. Delay in Sanction and allotment of funds to project authorities by Government.
b. Availability of Coal and Coal Prices
c. Increase in price of basic Raw material i.e. PVC
d. Change in Government policies and Taxes.
e. Completion of MM Aqua’s project work in time and as per the specifications required.
Operational Risk:
a. Labour availability in Haryana. Absence of experienced operators and Maintenance
staff.
b. Non-Availability of recycle material ( Domestic/import) as per the capacity.

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