§1What this business is
Stainless steel wire is wound on bobbins, twisted into a stranded cable, cut to length, one end dipped in molten zinc and a zinc stopper die-cast on the other end. Cables are packed by the dozen in printed poly bags and sold through auto-parts shops to mechanics and service stations.
Capacity: 60,000 dozen cables a year (200 dozen a day, 8 hours, 300 days).
§2Is it right for you?
Who it is for
Someone who knows the auto-parts trade and can build a dealer network.
Who it is not for
Someone who expects a few large buyers; sales come from many small shops.
Advantages
- Every two- and three-wheeler needs cable replacements — a never-ending spare-parts market
- Low machinery cost (₹4.31 L)
- Simple process that semi-skilled workers can run
- Small, light product that is easy to send to dealers
Drawbacks
- Low price per piece — you need large volumes and many dealers
- Competition from cheap unbranded cables
- Stainless steel wire price changes hit the margin
- Dealers often buy on credit
Skills you need
- Running wire twisting and die-casting machines
- Quality checks on length and stopper strength
- Dealer and mechanic sales
- Managing credit and collections
Why difficulty 2/5: Simple process and low machinery cost; the hard part is building a dealer network.
§3Market
Who buys
- Mechanics and two-wheeler service stations
- Owners of scooters, motorcycles, mopeds and auto-rickshaws
How it sells
- Auto-parts dealers and shops
- Dozen packs in printed poly bags
Good to know
- The report calls it a very wide, never-ending replacement market because control cables must be replaced on every scooter, motorcycle, auto-rickshaw and moped.
§4Raw material & machinery
| Item | Qty | Cost |
|---|---|---|
| Wire twisting machine (19 bobbins, 1 HP motor) | 4 | ₹1,60,000 (₹40,000 each) |
| Pressure die-casting machine | 1 | ₹70,000 |
| Compressor (1 HP motor) | 1 | ₹20,000 |
| Size cutter | 1 | ₹2,000 |
| Flower (end-forming) machine | 2 | ₹10,000 (₹5,000 each) |
| Hand press | 1 | ₹3,000 |
| Reel winder | 1 | ₹4,000 |
| Grinder | 1 | ₹5,000 |
| Hand cutter | 2 | ₹1,600 (₹800 each) |
| Dies for die-casting | 6 | ₹36,000 (₹6,000 each) |
| Shearing machine | 1 | ₹5,000 |
| Small bobbins | 100 | ₹2,500 (₹25 each) |
| Big bobbins | 20 | ₹3,000 (₹150 each) |
| Poly bag sealing machine | 2 | ₹2,000 (₹1,000 each) |
| Jigs, fixtures and other tools | lump sum | ₹35,000 |
| Installation and taxes (20%) | — | ₹71,820 (total plant and machinery ₹4,30,920) |
From: PMEGP sample project report — Automobile Control Cables (prepared by Udyami/Samadhan)
- Stainless steel wire21,600 kg a year at full capacity, ₹200 per kg
- Zinc alloy1,800 kg a year, ₹185 per kg (end dipping and stoppers)
- Printed poly bagsprinted outside to order (report's basis)
From: PMEGP sample project report — Automobile Control Cables (prepared by Udyami/Samadhan)
Suppliers in Building Business Bazaar
Ajit Wire Products · Amritsar →Lolita Manufacturing Works · Delhi →S. S. Sabharwal and Sons · Delhi →
§5Licences & registration
- Udyam registration
- GST registration
- BIS standard for auto control cables (the report cites IS 1978 — confirm the current standard with BIS)
- Trade licence from the local body
- State pollution board consent (zinc melting and die-casting)
§6Schemes & subsidies
- PMEGPCentralActive15–35% subsidy
- MudraCentralActiveLoan up to ₹20 lakh, no collateral
- CGTMSECentralActiveNo collateral, up to ₹10 crore
PMEGP (the report was prepared for it; own share 10% general, 5% special category), MUDRA up to ₹20 L, CGTMSE for a collateral-free loan.
§7Money
How the investment is worked out: Building and civil work (2,000 sq ft) ₹3.50 L + plant and machinery ₹4.31 L + furniture ₹0.75 L + pre-operative ₹0.35 L + working capital ₹6.59 L = ₹15.50 L.
Working capital: Working capital ₹6.59 L (bank finance ₹5.93 L): 15 days of wire and zinc and 15 days of finished cables.
Year not printed on the report — check current machinery and raw-material prices.
§8Export potential
Export council / board: EEPC India
- The project report prints no HS code; look up the 8-digit ITC(HS) line on the DGFT website or with a customs broker before exporting.
- You need an Import Export Code (IEC) from DGFT before the first shipment.
§9Risks — where people fail
- Price competition from unbranded cables
- Stainless steel wire price rise
- Cable failure in use leading to safety complaints
- Slow payments from dealers
§1030 / 60 / 90-day plan
A general plan that applies to any business. A plan for this business will be added after research.
- Days 1–30: Visit a working automobile control cables unit, ask 10 buyers about price and quantity, and get quotations from 3 suppliers.
- Days 31–60: Udyam and the licences you need (Udyam registration, GST registration), a project report (DPR), and the scheme or loan file.
- Days 61–90: Space and machines, trial production, and first deliveries to 10 customers.
§11Who to connect with
Associations, clusters and training institutes — the directory is being built. Connect
§12Watch
There is no episode on this business yet. Shows are coming soon on the Podcast page.
Want to start Automobile Control Cables?
DPR, loan file or registration — ask us on WhatsApp.
¶Sources
Data review: 6 October 2026. Spotted a mistake? Report it. For information only — not legal or financial advice.