What is a pressure die casting project report?
A pressure die casting project report is a detailed project report (DPR) for a plant that injects molten aluminium alloy into steel dies under high pressure to make near-net-shape components. It sets out the process, die casting machines, alloy, buyers, project cost, means of finance, five-year projections, DSCR and break-even a lender needs.
Promoters use it to size the plant and raise a term loan; banks and investors use it to judge whether the castings business can carry its debt.
Also known as: project report on pressure die casting, aluminium die casting plant DPR, HPDC project report, pressure die casting business plan.
Pressure die casting manufacturing plant cost in India
Our sample report models an aluminium die casting plant with 2,800 kg per day of good castings over 330 working days, or 9,24,000 kg a year. Output starts at 60% of capacity and reaches 80% in Year 5, at an average selling price of ₹345 per kg.
A smaller job unit with one or two machines up to about 250 tonne, in a rented shed and without CNC machining, needs roughly ₹2–4 crore (indicative). The sample plant is larger because it runs three to four machines and machines castings before dispatch.
| Land and site development | 79.83 |
|---|---|
| Building and civil works | 359.10 |
| Plant and machinery | 773.59 |
| Other fixed assets | 97.70 |
| Contingencies | 56.63 |
| Preliminary and pre-operative | 34.17 |
| Working capital margin | 77.69 |
| Total | 1,478.71 |
| Promoter's contribution (25%) | 369.68 |
|---|---|
| Term loan from bank (75%) | 1,109.03 |
| Cash credit limit (separate) | 233.06 |
| Total project cost | 1,478.71 |
Why the DSCR is tight: plant and machinery is over half the project cost, so loan instalments are heavy. The sample's lowest DSCR (debt service coverage ratio, cash available per rupee of instalment) is 1.22 in Year 2, when full repayments start and output is still at 65%.
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. Sample figures are illustrative; the job-unit range is indicative.
Pressure die casting manufacturing process
A casting cycle on a cold chamber machine takes from under a minute for small parts to a few minutes for large housings. Most quality problems start in the furnace, not at the machine.
- Melting
Alloy ingots and clean in-house returns are melted in a central furnace at about 680–720°C, with returns kept to a fixed share of each charge.
- Degassing and fluxing
The melt is treated with nitrogen or degassing tablets and flux to remove dissolved hydrogen and oxide skins, which cause gas porosity.
- Die preparation
The steel die is preheated and sprayed with release agent before each shot so the casting ejects cleanly and the die surface lasts longer.
- Injection
Metal is ladled into the shot sleeve and the plunger drives it into the die cavity at high speed, then holds pressure while it freezes.
- Trimming
A trimming press removes the biscuit, runners, overflows and flash; this scrap goes back to the furnace.
- Shot blasting and machining
Castings are shot blasted for an even surface, and sealing faces, bores and threads are machined on CNC centres.
- Inspection and dispatch
Parts are checked for dimensions, porosity and leak tightness where specified, then packed in trays or bins for the customer.
Pressure die casting or gravity die casting: which route fits?
The route decides the machines, die cost and buyers. Aluminium parts are made on cold chamber machines because molten aluminium attacks an injection system that sits inside the melt, as it does on hot chamber machines.
| Cold chamber pressure die casting | Aluminium and magnesium; thin-walled housings, covers and brackets in high volumes. The route modelled in our sample report. |
|---|---|
| Hot chamber pressure die casting | Zinc alloys; small hardware, fittings and lock parts with very short cycles. |
| Gravity die casting | Aluminium poured into a permanent mould without pressure; denser parts such as wheels, pistons and cylinder heads that need heat treatment. |
| Low pressure die casting | Aluminium pushed up into the die by gas pressure; alloy wheels and larger structural parts with low porosity. |
Many units add gravity casting later to serve parts that pressure casting cannot make sound enough.
Alloy and consumables for pressure die casting
Most units buy secondary aluminium alloy ingots from alloy makers who remelt scrap. ADC12 and LM24 are common for thin-walled parts because they fill fine sections well. In our sample report raw materials are 57.0% of sales, and buyers often link casting prices to an alloy index.
| Input | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Aluminium alloy ingots (ADC12, LM24, LM6) | 87% | 1,107.49 |
| Die release agent and plunger lubricant | 6% | 76.38 |
| Fluxes and degassing chemicals | 3% | 38.19 |
| Shot blasting media | 4% | 50.92 |
| Total | 100% | 1,272.98 |
Runners, overflows and rejected castings are remelted, so metal bought per kg of good castings depends on your yield and melt loss.
Machinery for an aluminium die casting plant
Machine tonnage is set by the projected area of the largest part you plan to cast. The die casting machines are the biggest item in the sample, at 45% of plant and machinery.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Cold chamber die casting machines (250 to 800 tonne) | Inject and hold metal in the die | 348.12 |
| Initial die sets and fixtures | Form the part; dies are often customer-funded later | 92.83 |
| Central melting furnace | Melts ingots and returns | 77.36 |
| CNC machining centres | Machine faces, bores and threads | 77.36 |
| Hydraulic trimming presses | Remove runners and flash | 46.42 |
| Holding furnaces and ladles | Keep metal at pouring temperature beside each machine | 38.68 |
| Shot blasting machine | Cleans the casting surface | 30.94 |
| Spectrometer and quality lab | Checks alloy chemistry and part quality | 30.94 |
| Air compressor and cooling tower | Supply air and cool dies and hydraulics | 30.94 |
| Total plant and machinery | 773.59 | |
Sample estimates for a 2,800 kg per day plant. Get current quotations for your tonnage mix before you finalise.
Manpower for a die casting plant
Die casting runs on skilled machine operators, die setters and a toolroom hand who can repair dies quickly. The sample plant employs 50 people, and wages are a smaller cost than power and fuel, which takes 8.6% of sales for melting and the hydraulic machines.
| Role | Staff | Annual cost (₹ lakh) |
|---|---|---|
| Management, supervision and administration | 8 | 29.28 |
| Skilled workers and operators | 17 | 39.78 |
| Semi-skilled and unskilled workers | 25 | 39.00 |
| Total | 50 | 108.06 |
Licences and approvals for a pressure die casting unit
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. Several boards list foundry operations in the orange category; the category for your unit depends on your state and furnace fuel |
| Factory licence | Under the Factories Act, with approval of the plant layout, furnace area and fire safety arrangements as your state requires |
| Material standard | IS 617 covers cast aluminium alloys, ingots and castings for general engineering use; buyers usually specify an IS 617, ADC or LM grade on the drawing |
| Customer approvals | Automobile buyers audit the plant and approve first samples before orders; most expect a quality system such as IATF 16949 |
| Power | HT or LT industrial connection sized for melting furnaces, machines and compressors |
Approval rules vary by state and change over time. Check current requirements with your state's industry and pollution departments, as of October 2026.
Who buys pressure die castings?
Almost all pressure die castings are made to a customer's drawing, so a new plant sells capability, not a catalogue product. Two-wheeler and car parts form the core of demand, and lighter vehicles and electric motor and battery housings are adding aluminium content per vehicle.
- Two-wheeler and car component makers
- Automobile OEMs and tier 1 suppliers
- Electric motor and switchgear makers
- Fan and home appliance brands
- LED lighting and telecom equipment makers
- Pump and compressor manufacturers
Where a new plant wins: buyers stay with a die caster for the life of a part, so the first two or three anchor customers decide the project. Fans, lighting and pumps balance the swings in automobile schedules.
Mistakes that weaken a pressure die casting project report
- Counting poured metal as saleable output
Runners, overflows, melt loss and rejects mean far less good casting than metal melted; sales must be based on good parts only.
- Assuming machines run full from day one
Each new part needs a die, trials and customer approval, which takes months. Utilisation should build up, as the sample's 60% start does.
- Leaving out die maintenance
Dies crack from heat cycling and need polishing, welding and replacement inserts; this cost belongs in repairs and in the working plan.
- Under-sizing working capital for OEM credit
Trade receivables are the largest current asset in the sample at 45 days; longer OEM payment terms need a bigger cash credit limit.
- No named customers or parts
Lenders look for letters of intent or part enquiries that match the machine tonnage being bought.
How NPCS helps you plan a pressure die casting plant
- Machine and tonnage mixMatch machine sizes, furnace capacity and machining to the parts and buyers you are targeting.
- Supplier quotationsCompare die casting machines, furnaces and CNC centres and build costs from current quotations.
- Bank-ready project reportProjections, DSCR, break-even and working capital in the format your lender or investor wants.
- Layout and approvalsPlant layout, furnace and power load, and the approvals list for your state.
NPCS's client list records 116 assignments in metal products, and the NPCS project team, led by founder Ajay Kumar Gupta, has prepared reports for entrepreneurs, banks and companies since 1994.
What's inside the pressure die casting sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
18 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
Real NPCS pressure die casting project reports
These are pressure die casting project reports NPCS has prepared, with the plant capacity, total capital investment, rate of return and break-even worked out in each. Costs have moved since some were written, so we bring any of them up to date for your capacity and location.
| Project report | Plant capacity | Total investment | Rate of return | Break-even | Action |
|---|---|---|---|---|---|
| Aluminium Pressure and Gravity Die-Casting | 1200 MT/Annum | ₹2.62 crore | 39% | 67% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
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Pressure Die Casting project report: frequently asked questions
What is the pressure die casting manufacturing plant cost in India?
It depends mainly on the number and tonnage of machines and whether you machine in-house. A one or two machine job unit in a rented shed needs roughly ₹2–4 crore, while a three to four machine plant with CNC machining needs about ₹12–16 crore. These are indicative ranges. Our sample report models a 2,800 kg per day plant at ₹1,479 lakh.
Which machines are needed for aluminium pressure die casting?
The core items are cold chamber die casting machines, usually 250 to 800 tonne, with a central melting furnace and holding furnaces. You also need die sets, trimming presses, a shot blasting machine, CNC machining centres and a spectrometer. In our sample report the die casting machines are the largest item at ₹348.12 lakh, or 45% of plant and machinery.
What raw material is used in pressure die casting?
Secondary aluminium alloy ingots such as ADC12 and LM24 are the main raw material, chosen for fluidity in thin walls. In our sample report alloy ingots make up 87% of raw material cost. Die release agent, plunger lubricant, fluxes, degassing chemicals and shot blasting media make up the rest. Runners and rejects are remelted in-house.
Is a pressure die casting business profitable?
It can be, once the machines are loaded with steady customer parts. Our illustrative sample shows a 13% return on investment in Year 3, break-even at about 44% of capacity and payback in about 4.6 years. Returns rise with machine utilisation and fall with high rejection, idle dies or slow payment from buyers.
What is the difference between pressure die casting and gravity die casting?
Pressure die casting forces metal into the die with a plunger in a cycle of seconds, so it suits thin-walled, high-volume parts with fine detail. Gravity die casting lets metal flow in under its own weight, giving denser castings that can be heat treated. Gravity dies cost less, but cycle times are much longer.
Who buys pressure die castings?
Most castings are made to drawing for two-wheeler and car component makers, tier 1 suppliers and automobile OEMs. Electric motor and switchgear makers, fan and appliance brands, LED lighting and telecom equipment makers and pump manufacturers are the other main buyers. Each buyer approves your die and first samples before regular orders begin.
Is the pressure die casting project report PDF free, and can I use it for a bank loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own machines, customers, location and lender.
Sources and references
- Project profile: Aluminium pressure die casting (December 2002)Small Industries Service Institute, Ludhiana, Office of the DC (MSME), Government of India, checked Oct 2026
- Draft Aluminium and Aluminium Alloys (Quality Control) Order, 2023, schedule of Indian Standards (WTO TBT notification)Government of India, notified to the World Trade Organization, checked Oct 2026
- Orange category industries listState Pollution Control Board, Odisha, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.