What is a aluminium collapsible tubes project report?
An aluminium collapsible tubes project report is a detailed project report (DPR) for a unit that impact-extrudes aluminium slugs into thin tubes, then lacquers, prints, caps and lines them for ointment and cream makers. It sets out the process, machinery, raw materials, market, project cost, five-year projections, DSCR and break-even that a bank needs.
Entrepreneurs and packaging firms use it to size a tube line and raise a term loan; lenders use it to judge whether the unit can repay.
Also known as: aluminium tube manufacturing project report, aluminium collapsible tubes business plan, DPR for aluminium tube plant, pharmaceutical aluminium tube project report.
What a bank checks in an aluminium collapsible tubes project report
A tube line is capital heavy for the sales it makes, so lenders look hard at material cost, cash cover for the loan and how long pharma buyers take to pay. These are the values in our sample report and why each one matters.
Slugs, caps, lacquer and inks take about half of every rupee of sales. A report showing much less is usually pricing aluminium too low.
Slug prices move with primary aluminium. The report should show what a rise in slug price does to profit and loan cover.
DSCR (debt service coverage ratio) is cash available divided by loan instalments plus interest. The sample's lowest year is 1.21, so there is little room for slippage.
Pharma companies and contract makers pay on credit. Debtors are the largest part of working capital in the sample.
Values are the assumptions in our illustrative sample. Your report uses figures for your line, suppliers and buyers.
How much does an aluminium tube manufacturing unit cost?
Cost depends on press speed and on whether you lacquer and print in-house. The middle tier is the unit in our sample report; the other two are indicative ranges.
Small line
₹1.2–2 crore
About 15,000–25,000 tubes per day, semi-automatic
- Machinery₹60–100 lakh
- Shed and fit-out₹25–50 lakh
- Working capital margin₹8–15 lakh
MSME term loan; suits plain or one-colour tubes
Mid-size line
₹391 lakh
68,000 tubes per day, 2,04,00,000 tubes per year
- Plant and machinery₹190 lakh
- Land and building₹129 lakh
- Working capital margin₹22 lakh
Term loan ₹293 lakh (75%), promoter ₹98 lakh
High-speed line
₹7–12 crore
About 1.5–2 lakh tubes per day, automatic
- Machinery₹4–7 crore
- Land and building₹1.5–3 crore
- Working capital margin₹40–80 lakh
Term loan for an established packaging firm
Small and high-speed ranges are indicative. Costs vary with press make, number of print colours, location and automation.
Aluminium collapsible tubes plant economics
The sample report models a 68,000 tubes per day line running 300 days a year, starting at 60% capacity and reaching 80% in Year 5. The average selling price is taken at ₹3.52 per tube, ex-GST.
| Land and site development | 41.19 |
|---|---|
| Building and civil works | 88.05 |
| Plant and machinery | 189.64 |
| Other fixed assets | 27.56 |
| Contingencies | 13.88 |
| Preliminary and pre-operative | 9.01 |
| Working capital margin | 21.98 |
| Total | 391.31 |
| Promoter's contribution (25%) | 97.83 |
|---|---|
| Term loan from bank (75%) | 293.48 |
| Cash credit limit (separate) | 65.92 |
| Total project cost | 391.31 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. The line needs 21 people. All figures are illustrative.
Aluminium collapsible tubes manufacturing process
Tubes are made cold from a disc-shaped aluminium slug in a single high-speed stroke, then finished on a connected line. Most units run all eight stages so that lacquer and print quality stay under their own control.
- Slug lubrication
Slugs are tumbled with zinc stearate powder so the metal flows evenly around the punch.
- Impact extrusion
A punch strikes the slug in a die and the metal flows up to form the wall, shoulder and nozzle in a fraction of a second.
- Trimming and threading
The ragged open end is cut to length and the nozzle is threaded for the cap; trimmed rings go back as scrap.
- Annealing
Extrusion work-hardens the metal, so tubes pass through a furnace that softens them and burns off the lubricant.
- Internal lacquering
An epoxy-phenolic lacquer is sprayed inside and oven-cured so acidic or reactive contents never touch bare aluminium.
- Base coat and printing
A white enamel base coat is rolled on and dried, then the brand design is printed by dry offset in up to several colours.
- Capping and latex lining
Caps are screwed on and a latex band is laid inside the open end so the crimp seals airtight after filling.
- Inspection and packing
Tubes are checked for pinholes, lacquer cover, print register and cap torque, then packed in cartons by batch.
Raw materials for aluminium collapsible tubes
Slugs of high-purity aluminium are bought from slug makers who punch them from cast or rolled strip. Their price follows primary aluminium: NALCO's basic ex-works ingot price was about ₹3.55 lakh per tonne on 29 July 2026, before the slug maker's conversion charge.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Aluminium slugs (99.7% purity) | 72% | 187.59 |
| HDPE caps | 9% | 23.45 |
| Internal epoxy-phenolic lacquer | 8% | 20.84 |
| White enamel base coat and printing inks | 8% | 20.84 |
| Latex sealant | 3% | 7.82 |
| Total | 100% | 260.54 |
Machinery for aluminium tube manufacturing
The machines run as one connected line, so the slowest station sets output. The impact extrusion press is the largest single item in the sample.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Impact extrusion press | Forms the tube from a slug in one stroke | 56.89 |
| Trimming and threading machine | Cuts tubes to length and threads the nozzle | 18.97 |
| Continuous annealing furnace | Softens the tube and removes lubricant | 18.96 |
| Internal lacquering machine with curing oven | Sprays and cures the inner coating | 26.55 |
| Base coating machine with drying oven | Applies the white enamel ground | 18.96 |
| Offset dry printing machine with drying oven | Prints the brand design and cures it | 26.55 |
| Capping and latex lining machine | Fits caps and lays the sealing band | 13.28 |
| Slug tumbler and lubrication unit | Coats slugs before pressing | 3.79 |
| Tube testing and inspection equipment | Checks pinholes, coating and dimensions | 5.69 |
| Total plant and machinery | 189.64 | |
Costs are the sample report's estimates for a 68,000 tubes per day line. Get current quotations, including tooling for each tube diameter, before you finalise.
Who buys aluminium collapsible tubes in India?
Demand comes mostly from medicines that must be kept away from air, light and moisture. Aluminium is a full barrier and stays collapsed after each squeeze, so no air is drawn back onto the ointment. Plastic and laminated tubes have taken toothpaste and most cosmetics, but antibiotic, steroid, antifungal and eye ointments largely stay in aluminium.
- Pharmaceutical companies and loan licensees packing ointments and creams
- Contract manufacturers in pharma clusters
- Ayurvedic and herbal product makers
- Hair colour and dye cream brands
- Adhesive, sealant and artist colour makers
Where a new unit wins: pharma buyers change tube suppliers slowly, after vendor audits and stability trials. A unit near a pharma cluster that can deliver short runs of printed tubes quickly gets its first orders from contract manufacturers.
Licences and standards for an aluminium tube unit
A tube unit needs the usual factory approvals plus attention to the Indian Standards that pharma buyers write into their purchase specifications.
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Product standard | IS 3101:1995, the BIS specification for aluminium collapsible tubes |
| Test methods | IS 7182:1973 sets the methods of test for aluminium collapsible tubes |
| Eye ointment tubes | IS 7852:1975 covers small eye ointment tubes, if you supply them |
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. Maharashtra's White list (June 2025) covers metal containers only without surface treatment and painting, so a unit that lacquers and prints should expect a higher category |
| Factory licence and fire NOC | Under the Factories Act and local fire rules; solvent-based lacquers and inks need safe storage |
Requirements vary by state. Confirm the pollution category and any BIS certification requirement with the authorities before you apply.
Mistakes that weaken an aluminium tube project report
- One price for every tube size
A 5 gram eye ointment tube and a 100 gram cream tube sell at very different prices. Revenue should follow the size and print mix you expect to sell.
- Ignoring trim scrap and rejects
Trimmed ends and tubes rejected for pinholes or print faults go back as scrap at a discount. Slug use per good tube must allow for them.
- Full sales from the first month
Pharma vendor approval can take months of audits and stability trials. A first year at full capacity overstates cash flow and DSCR.
- No budget for tooling and print plates
Each diameter needs its own punch and die, and each design its own plates. Short runs and frequent changeovers cut real output below rated speed.
How NPCS helps you set up an aluminium tube unit
- Line size and tube mixChoose diameters, print colours and daily output to suit your buyers and budget.
- Machinery and toolingCompare extrusion, lacquering and printing lines and collect quotations.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender wants.
- Approvals and layoutLine layout, solvent storage, power load and the approvals list for your state.
NPCS's client list includes 2 assignments on aluminium collapsible tubes and 35 in engineering and metal fabrication. The work is done by the NPCS project team, led by founder Ajay Kumar Gupta.
What's inside the aluminium collapsible tubes 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
19 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 aluminium collapsible tubes project reports
These are aluminium collapsible tubes 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 Collapsible Tubes (Printed) | Aluminium Collapsible Tubes (Printed): 2,00,000 Nos/Day | ₹11.58 crore | 28.4% | 41.6% | Get this report |
| Aluminium Collapsible Tubes | 300000 Nos./day | ₹100.12 crore | 10% | 46% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
What clients say about NPCS
4.7
264 Google reviews, as of 20 Oct 2026
Clients most often mention
- feasibility reports 18
- project report 16
- helpful for startups 15
- detailed reports 8
-
Excellent experience with Niir Project Consultancy Services. Their Techno-Economic Feasibility Reports are incredibly detailed and backed by solid market data.
Piyush Singh, Google review, 2026
-
Niir Project Consultancy Services offers excellent guidance for business setup. Their market survey and feasibility reports saved us a lot of time and helped us make informed decisions. Highly recommended
Saroj Yadav, Google review, 2026 View on Google
-
In an era of information overload, NIIR stands out for its precision. Their technical consultancy and market feasibility studies are world-class.
Shrishti Gautam, Google review, 2026
-
NIIR Project Consultancy Services provides useful books and reports for students, entrepreneurs, and small businesses. Their content is easy to understand and focuses on practical ideas for starting and managing industries. Overall, NIIR is helpful for learning about business and project planning.
Raj Yadav, Google review, 2026
Aluminium Collapsible Tubes project report: frequently asked questions
What is the cost of an aluminium collapsible tubes manufacturing plant in India?
A semi-automatic line making 15,000–25,000 tubes a day needs roughly ₹1.2–2 crore, and a high-speed line of 1.5–2 lakh tubes a day about ₹7–12 crore. Our sample report models a 68,000 tubes per day unit at ₹391 lakh, including land, building and working capital margin. These are indicative figures; your report works out the cost for your line and location.
Which raw material is used to make aluminium collapsible tubes?
High-purity aluminium slugs are the main input. In our sample report they make up 72% of raw material cost. The rest is HDPE caps, epoxy-phenolic lacquer for the inside, white enamel and printing inks for the outside, and latex sealant for the open end. Slug prices track primary aluminium, so the report tests how a price rise affects profit.
Which machines are needed for aluminium tube manufacturing?
The core line is an impact extrusion press, a trimming and threading machine and an annealing furnace. Finishing needs an internal lacquering machine with curing oven, a base coating machine, a dry offset printing machine and a capping and latex lining machine. A slug tumbler and testing equipment complete the line. In our sample the extrusion press is the largest single machinery cost.
Is aluminium collapsible tube manufacturing profitable?
In our illustrative sample, a 68,000 tubes per day unit earns a 14% return on investment in Year 3. It breaks even at 46% of capacity and pays back in about 4.6 years. The margin is thin for a capital-heavy line, so profit depends on slug buying, scrap recovery, print changeover time and how quickly pharma buyers approve you as a vendor.
Why do pharma companies still use aluminium tubes instead of plastic or laminated tubes?
Aluminium is a full barrier to air, light and moisture, and the tube stays collapsed after each squeeze, so air is not drawn back onto the product. That matters for antibiotic, steroid and eye ointments that degrade on exposure. Laminated and plastic tubes cost less and suit toothpaste and cosmetics, but many sensitive formulations stay in aluminium.
Can I get a PMEGP loan for an aluminium tube unit?
Only for a very small project. PMEGP covers manufacturing projects up to ₹50 lakh, which is too little for a full extrusion, lacquering and printing line. Most tube units are funded with an MSME term loan and a cash credit limit. Our sample assumes a 75% term loan of ₹293 lakh and a separate cash credit limit of ₹66 lakh.
Is the sample report free and can I use it for a 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. It should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, tube sizes, location and lender.
Sources and references
- IS 3101:1995 Aluminium collapsible tubes: Specification (second revision)Bureau of Indian Standards, checked Oct 2026
- IS 7182:1973 Methods of tests for aluminium collapsible tubesBureau of Indian Standards, checked Oct 2026
- IS 7852:1975 Specification for eye ointment tubes, smallBureau of Indian Standards, checked Oct 2026
- Aluminium ingot price list effective 29 July 2026National Aluminium Company Ltd (NALCO), checked Oct 2026
- Circular on White category industries, 16 June 2025Maharashtra Pollution Control Board, checked Oct 2026
- Prime Minister's Employment Generation Programme (PMEGP) guideDistrict Industries Centre, Ganjam, Government of 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.