What is a double single wall vacuum steel bottles project report?
A double single wall vacuum steel bottles project report is a detailed project report (DPR) for a plant that forms SS 304 stainless steel into insulated double wall and plain single wall bottles. It sets out the process, machinery, raw materials, BIS certification, project cost, means of finance, five-year projections, DSCR and break-even that a lender reviews.
Promoters use it to size the plant and raise a term loan; banks use it to judge whether bottle sales can carry the repayments.
Also known as: vacuum flask project report, stainless steel water bottle business plan, project report on double single wall vacuum steel bottles, insulated steel bottle plant DPR.
Double single wall vacuum steel bottles project report: plant cost and returns
Our sample report models a plant making 3,900 bottles per day, or 12,87,000 bottles a year over 330 working days. It starts at 60% capacity and reaches 80% in Year 5, with an average ex-factory price of ₹224 per bottle across double wall and single wall sizes.
| Land and site development | 102.56 |
|---|---|
| Building and civil works | 318.53 |
| Plant and machinery | 753.56 |
| Other fixed assets | 93.89 |
| Contingencies | 53.60 |
| Preliminary and pre-operative | 33.05 |
| Working capital margin | 68.76 |
| Total | 1,423.95 |
| Promoter's contribution (25%) | 355.99 |
|---|---|
| Term loan from bank (75%) | 1,067.96 |
| Cash credit limit (separate) | 206.27 |
| Total project cost | 1,423.95 |
Plant and machinery is more than half the project cost, which is typical of a vacuum bottle line. DSCR (debt service coverage ratio, the cash available to pay each year's loan instalments) is lowest in Year 2, at 1.49, when full principal repayments begin.
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. All figures are illustrative.
Double single wall vacuum steel bottles manufacturing process
A vacuum bottle is two steel bottles, one inside the other, with the air pumped out of the gap. Single wall bottles go through the same forming, welding, finishing and packing stages but skip vacuum brazing and the heat retention test.
- Tube making and cutting
SS 304 strip is roll formed and seam welded into tube, then cut to length for the inner and outer bodies.
- Bulging and necking
Hydraulic presses expand each tube to the bottle profile, and spinning machines form the neck and shoulder.
- Body welding
Bottoms are laser welded to both bodies, then the inner body is fitted inside the outer and welded at the mouth.
- Leak testing
Every welded body is pressure or water tested, so no leaking piece takes up space in the furnace.
- Vacuum brazing
Bottles are loaded with a getter and brazing solder and heated in a vacuum furnace, which evacuates the gap and seals it.
- Heat retention test
Bottles are filled with hot water and checked after a set time; any that lost vacuum are rejected.
- Polishing and coating
Outer bodies are polished, powder coated and cured, then printed or laser engraved with the buyer's brand.
- Assembly and packing
Moulded lids with silicone seals are fitted, and each bottle is inspected and packed in a colour box.
Where yield is lost: a weld that passes the leak test can still let air back into the gap after brazing. That is why every double wall bottle gets a heat retention check, and why the reject rate at this stage drives real cost per bottle.
Double wall vacuum or single wall: which line to set up?
The product name covers two different lines. Most plants make both, because single wall bottles use the same forming, welding and finishing machines and fill spare capacity at a lower price point.
| Point | Double wall vacuum | Single wall |
|---|---|---|
| Construction | Inner and outer body with vacuum gap | One steel body |
| Keeps drinks hot or cold | Yes, for hours | No insulation |
| Extra machines | Vacuum brazing furnace, heat retention test | None beyond forming, welding and finishing |
| Steel per bottle | Two bodies, so more steel | One body |
| BIS standard | IS 17526 under the QCO | Check scope with BIS before launch |
Our sample report models a mixed plant. Your report sets the double wall and single wall split from your buyers' orders.
Raw materials for vacuum steel bottles
SS 304, the food-grade 18/8 stainless steel, is bought as coil or ready welded tube. In our sample, raw materials are 48.5% of sales in Year 3, and steel is 62% of that bill.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| SS 304 coil or welded tube | 62% | 606.44 |
| PP and silicone for lids and seals | 18% | 176.06 |
| Powder coating paint | 8% | 78.25 |
| Getter and brazing solder | 4% | 39.13 |
| Argon gas and polishing consumables | 8% | 78.25 |
| Total | 100% | 978.13 |
Lids are moulded in-house in the sample. Units that buy finished lids move that cost from raw materials to bought-out parts.
Machinery for a vacuum steel bottle plant
The vacuum brazing furnace is the single biggest machine, at 20% of the machinery cost in our sample. Its batch size sets how many double wall bottles the plant can finish each day.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Tube welding and cutting line | Makes and cuts body tubes | 75.36 |
| Hydraulic bulging presses | Expand tube to bottle shape | 105.50 |
| Necking and spinning machines | Form neck and shoulder | 75.36 |
| Laser welding machines | Weld bottoms and mouth joint | 105.50 |
| Vacuum brazing furnace | Evacuates and seals the gap | 150.71 |
| Leak and heat retention test equipment | Finds leaks and failed vacuum | 45.21 |
| Polishing and buffing machines | Finish the outer body | 60.28 |
| Powder coating line with curing oven | Colours and cures the body | 75.36 |
| Injection moulding machine for lids | Moulds PP lids and caps | 60.28 |
| Total plant and machinery | 753.56 | |
Costs are the sample report's estimates for a 3,900 bottles per day plant. Get current quotations before you finalise.
Manpower and power for a bottle plant
Welding, polishing and inspection still need many hands, so headcount is high for the output. Our sample plant employs 62 people, and power and fuel cost about 8.7% of sales, mainly for the furnace, curing oven and presses.
| Category | Number | Monthly wage (₹) | Year 1 cost (₹ lakh) |
|---|---|---|---|
| Management, supervision and administration | 9 | 30,500 | 32.94 |
| Skilled workers and operators | 22 | 19,500 | 51.48 |
| Semi-skilled and unskilled workers | 31 | 13,000 | 48.36 |
| Total | 62 | 132.78 |
Wages in the sample rise 5% a year. Skilled laser welders and furnace operators are the hardest roles to fill.
BIS certification and licences for steel vacuum bottles
Stainless steel vacuum bottles sold in India come under a Quality Control Order (QCO), a government notification that makes a BIS licence compulsory before goods are made, sold or imported.
| Product standard | IS 17526:2021, Domestic stainless steel vacuum flask/bottle |
|---|---|
| Quality Control Order | Insulated Flask, Bottles and Containers for Domestic Use (Quality Control) Order, 2024 (S.O. 1072(E), 5 March 2024), which replaced the 2023 order |
| Exemptions | Goods made for export, and Udyam units with plant and machinery up to ₹25 lakh and previous-year turnover up to ₹2 crore, certified by a CA |
| Business registration | Udyam (MSME) registration and GST registration |
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board; powder coating and any pickling decide the category in your state |
| Factory and fire | Factory licence under the Factories Act and fire NOC, as state rules require |
Checked against the BIS gazette copies in October 2026. QCOs are amended from time to time; confirm the current status with BIS before you apply.
Who buys vacuum steel bottles in India?
Demand comes from households, students and office workers replacing plastic bottles with reusable steel ones, and from companies that buy branded bottles for gifting. Sales peak before summer and around the festive gifting season, so stock planning matters.
- Kitchenware and houseware brands buying private label
- E-commerce and quick-commerce sellers
- Corporate gifting and promotional companies
- Distributors for modern retail and gift shops
- Schools, sports academies and institutions
Where a new plant wins: the QCO means uncertified bottles cannot be sold here. A BIS-licensed domestic plant that accepts short runs with custom colours and engraving can take orders that once went to importers.
Mistakes that weaken a vacuum steel bottle project report
- Counting every bottle as saleable
Some double wall bottles fail the heat retention test. A report that ignores this rejection overstates output and understates steel use per good bottle.
- Pricing at retail or brand MRP
A plant selling private label gets an ex-factory price, far below shelf price. Revenue and DSCR come out too high if this is mixed up.
- Leaving out BIS time and cost
The licence, factory inspection and testing must be done before the first sale. Plan the time and fees into the pre-operative period.
- Sizing the furnace after the presses
Forming machines can outrun the furnace. Daily double wall output is set by furnace batches, so size the furnace first.
- Ignoring buyer credit
Brands and online sellers pay on credit. In our sample, 45 days of receivables are the largest part of working capital.
How NPCS helps you set up a vacuum steel bottle plant
- Product mix and capacitySet the double wall and single wall split, sizes and daily output for your buyers and budget.
- Machinery and furnace sizingMatch presses, welders and furnace batches, and compare supplier quotations.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender expects.
- BIS and approvals planThe IS 17526 licence steps, plant layout and the approvals list for your state.
NPCS's client list shows 3 assignments for vacuum steel bottle projects and 116 across metal products. The work is done by the NPCS project team, led by founder Ajay Kumar Gupta.
What's inside the double single wall vacuum steel bottles 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 |
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Double Single Wall Vacuum Steel Bottles project report: frequently asked questions
What is the manufacturing plant cost of a vacuum steel bottle unit in India?
A unit that only makes single wall bottles from bought-in tube can start at roughly ₹1.5–4 crore. A double wall vacuum line of 2,000–5,000 bottles per day needs about ₹10–18 crore with land and building. These are indicative ranges. Our sample report models a 3,900 bottles per day plant at ₹1,424 lakh, with plant and machinery at ₹754 lakh.
Is BIS certification compulsory for steel vacuum bottles?
Yes, for most makers. The Insulated Flask, Bottles and Containers for Domestic Use (Quality Control) Order, 2024 requires a BIS licence to IS 17526 for domestic stainless steel vacuum flasks and bottles. It exempts goods made for export and Udyam-registered units with plant and machinery up to ₹25 lakh and turnover up to ₹2 crore.
Is a vacuum steel bottle plant profitable?
In our illustrative sample, a 3,900 bottles per day plant earns a 19% return on investment in Year 3, breaks even at 38% of capacity and pays back in about 3.8 years. Real results depend on SS 304 prices, the share of bottles lost at the heat retention test, and how much you sell under your own brand.
Which machines are needed to make double wall vacuum bottles?
A tube welding and cutting line, hydraulic bulging presses, necking and spinning machines, laser welding machines, a vacuum brazing furnace, leak and heat retention test equipment, polishing machines, a powder coating line and an injection moulding machine for lids. A single wall line skips the furnace and the heat retention test.
Steel bottle manufacturing business kaise shuru kare?
Start by choosing between single wall only, or a full double wall vacuum line, since the vacuum furnace changes the budget. Then fix your bottle sizes and buyers, get machinery quotations, apply for the BIS licence to IS 17526, and have a project report prepared for the term loan. Udyam and GST registration come first.
Is the sample 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 capacity, location and lender.
Can I get a collateral-free loan for a steel bottle unit?
Possibly, if your unit is a micro or small enterprise. Since 1 April 2025, the CGTMSE credit guarantee scheme covers loans up to ₹10 crore per eligible micro or small enterprise, which reduces the collateral a bank asks for. The bank still decides, based on your project report, DSCR and promoter contribution.
Sources and references
- Insulated Flask, Bottles and Containers for Domestic Use (Quality Control) Order, 2024, S.O. 1072(E)Bureau of Indian Standards / DPIIT, Gazette of India, checked Oct 2026
- Insulated Flask, Bottles and Containers for Domestic Use (Quality Control) Order, 2023, S.O. 3140(E)Bureau of Indian Standards / DPIIT, Gazette of India, checked Oct 2026
- Credit Guarantee Scheme: scheme guidelinesOffice of the Development Commissioner (MSME), Ministry of MSME, 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.