Cement
Paints
|
Product Code
|
:
|
312101007
|
|
Quality and Standards
|
:
|
As per requirements of customer
or as mutually agreed between the purchaser and the
seller.
|
|
Production Capacity
|
:
|
Qty.: Cement Paints in various
Shades 250 MT (per annum)
Value : Rs. 6750000
|
| Uploaded on |
: |
December 2007 |
Introduction
Cement paints are covered under Powder
Paints which are used for exterior cemented walls, all types
of masonry surfaces like Bungalows, Multistoried buildings,
Bridges, Dams, Houses, Buildings of General Public, etc.
and can also be used for Interior as well as exterior masonry
cemented surfaces. A wide range of colours and shades in
cement paints have been developed and manufactured to meet
various choices, moods, service conditions, and methods
of application, performance and economic requirements. Cement
paints are widely used by general public and Government
Departments, and establishments. Cement paints give following
excellent properties to any masonry surface:
1) Cement paint gives very good protection
to all kinds of masonry surfaces from Ultraviolet rays present
in sunrays.
2) It gives very good protection from
severe climatic conditions like rain, heat, water, humidity,
salt atmosphere near sea-shores, to all types of cemented
walls, surfaces.
3) It prevents growth of fungus and
bacteria on masonry surfaces.
4) It gives very good colour and pleasing
appearance to all types of masonry surfaces.
5) Cements paint hides out various surface
irregularities, hair lining, roughness etc. thereby giving
smooth and pleasing appearance to all cemented masonry surfaces
where it is applied. Cement paints normally give smooth
and matt finish. The machines and equipments for the manufacture
of cement paints are indigenously available and are not
very expensive also. The process and technology being simple,
this item is suitable for development in rural and backward
areas. Cement paint produces a smooth, matt finish, is strongly
water repellent and weather proof. It is hygienic and an
excellent light reflector, requires minimum curing with
water, without peelings, flaking or rubbing offs.
Market Potential
Since the cement paints gives high order
of protection, decoration, beautification and durable properties
than the normal whitewash. It is extensively used on all
types of emented masonry surrfaces like Bungalows, multi-storied
building, bridges, dams, general public buildings, houses
etc. The demand of cement paint is increasing with the general
requirement of human beings throughout the country. Cement
Paints have a very good market and a very promising future.
There is a substantial demand for Cement Paints from Government
sectors like DGS and D, State PWDs, CPWD, Railways, Defence,
State Electricity Boards, Govt. of India Enterprises, State
Govt. Enterprises, various contractors, architects and engineers.
Basis and Presumptions
1. The information supplied is based
on a standard type of manufacturing activity utilizing conventional
techniques of production and optimum levels of performance.
2. The estimates are drawn for a production
capacity generally considered techno-economically viable
for a model type of manufacturing activity.
3. Interest rate is taken as 14%
4. Operative period of the project is around 10 years considering
technology obsolescence rate and period of repayment of
loan.
5.The costs of land, construction charges, cost of machinery
and equipment, raw materials and consumables, salary and
wages, other expenses etc. indicated in the profile are
based on the prices prevailing at the time of preparation.
Therefore, there are subject to necessary changes from time
to time based on the local conditions.
Technical Aspects
Process of Manufacture
Cement paints are composed of the following
ingredients :
i) Pigments ii) Binder iii.) Additives
and iv) Solventswater, which is added before application.
The pigment portion consists of prime pigments like Titanium
Di Oxide, Carbon Black, Phthalocyanine blue, Phthalocyanine
Green, Red Oxide etc. with suitable quantity of extenders
like whiting, china clay etc. The binder is the white cement
or ordinary Portland cement-33 grade which acts as a film
former or pigment binder. Here water is used as solvent
which is generally, added before application of cement paint
to the masonry surface. Water is to be added in cement paint
to bring it to the desired consistency. Additives like wetting
and dispersing agents, antifungicidal agents etc. are added
in small percentage to impart specific properties to the
cement paint.
Cement Paints are made on the basis
of the above ingredients depending upon the formulations
used by individual manufacturers which is further based
on customer's requirements and specifications.
In the manufacturing of Cement Paints
Ball Mills and Edge Runner are used. All the pigments/extenders
and some portion of binder (e.g. White cement, Ordinary
Portland cement-33 grade etc.) with dispersing agents as
per formulation are charged in the Ball Mills and run till
the desired grinding/dispersion is achieved. The ground
material is taken out with the help of the rest portion
of binder to the Edge Runner machine. Again it is grinded
and mixed uniformly. Anti-fungicides and other required
additives as per formulation are added here. Again grinded
and mixed uniformly. Then shade matching is done in comparison
with the colour card of manufacturer or as per the requirements
of customers. Then quality control testing is done to achieve
the required properties. After quality control testing is
O.K. It is packed into containers or bags as per the requirements.
Before painting new surfaces, it should
be thoroughly cleaned and free from efflorescence. Previously
painted surfaces should be washed out or brushed down. But
if the surface is in powdery or flaking condition, it should
be removed by scraping or wirebrushing, Cement Paint normally
should not be used on non-absorbent surfaces, such as glazed
bricks or neat cement finish or previously flat oil or enamel
painted work. Two coats of cement paint are usually sufficient
on a new surface. Cement Paint, in powder form, is to be
thinned with water for applying by brush or spray. Cement
paint is to be made into a creamy consistency by adding
three volumes of Cement Paint to one volume of water. Normally
cement paint must be added to water and not water to cement
paints. The above paste is diluted to a suitable paint consistency
by adding, while stirring, further 2-3 volumes of water.
Cement paint can be applied by either brushing or Roller
coating. According to the painting instructions, the surface
is to be prepared and saturated with water. Immediately
after the excess surface water disappears, one coat of Cement
paint thinned with water previously is to be applied. After
4-6 hours, the surface is to sprinkled again with water.
When dry, usually overnight, the surface is to be wet with
water as done earlier before first application and second
coat of Cement paint is to be applied in the same way and
water sprinkled after 4 to 6 hours.
Financial Aspects
A. Fixed Capital
|
(i) Land and Building
|
(Rs.)
|
|
Land 700 sq. mtr @ Rs.2000sq.
mtr.
|
1400000
|
|
Building
|
|
|
Work shed 300 sq. mtr. @ Rs. 5000
sq. mtr.
|
1500000
|
|
Office Store 100 sq. mtr. @ Rs.
6000 sq. mtr.
|
600000
|
|
Total
|
3500000
|
(ii) Machinery and Equipments
|
Sl. No.
|
Description
|
Qty.
|
Amount (Rs.)
|
|
1
|
Mild Steel Ball Mill size, 30
×36 with 5 H.P. Flame proof motor and other
accessories
|
3 Nos. @ 65,000 each
|
195000
|
|
2
|
Mild Steel ball Mill size 26
×30 with 3 H.P. flame proof motor and other
accessories
|
2 Nos. @ 55,000 each
|
110000
|
|
3
|
Edge runner (Bucket, sizes 48)
with reduction gear and other accessories
|
1 No.
|
90000
|
|
4
|
Weighing balance platform type
200 kg. Capacity
|
1 No.
|
20000
|
|
5
|
Testing Laboratory equipments
and chemical testing tables etc.
|
|
70000
|
|
6
|
Counter scale balance capacity
upto 10 kg. with weight
|
|
3000
|
|
7
|
Fire extinguisher
|
4 Nos. @ 2200 each
|
8800
|
|
8
|
Miscellaneous hand tools, fittings
and auxiliary equipments
|
|
15000
|
|
|
Total
|
511800
|
|
|
Electrification and installation
charges @ 10%
|
51180
|
|
|
Total
|
562980
|
|
|
Office Furniture and fixtures
|
80000
|
|
|
Pre-operative expenses
|
50000
|
|
|
Total
|
692980
|
(iii) Staff and Labour (per month)
|
Sl. No.
|
Designation
|
No.
|
Salary (Rs.)
|
|
1
|
Manager
|
1 No.
|
15000
|
|
2
|
Clerk-cum-Accountant
|
1 No.
|
6000
|
|
3
|
Manufacturing Chemist
|
1 No.
|
9000
|
|
4
|
Salesman
|
1 No.
|
9000
|
|
5
|
Skilled Workers
|
2 Nos. @ Rs.5000
|
10000
|
|
6
|
Unskilled workers
|
4 Nos. @ Rs. 2500
|
10000
|
|
7
|
Peon
|
1 No.
|
3000
|
|
8
|
Watchman
|
1 No.
|
2500
|
|
|
Total
|
|
64500
|
|
|
Perquisites @ 22%
|
|
14190
|
|
|
Total
|
|
78690
|
|
(iv)
|
Raw Materials(Per Month)
|
|
(Rs.)
|
|
1
|
White Cement/ O.P.C.-33
|
15 MT @ 10600 PMT
|
159000
|
|
2
|
Whiting
|
3 MT @ 3800 PMT
|
11400
|
|
3
|
Barytes
|
1.25 MT @ 4800 PMT
|
6000
|
|
4
|
China Clay
|
1.25 MT @ 4000 PMT
|
5000
|
|
5
|
Pigments (Titanium Di Oxide, Carbon
black, Phthalocyanine Blue, Red oxide, Phthalocyanine
green etc.)
|
0.8 MT @ 1,10,000 PMT
|
88000
|
|
6
|
Additives like brightening agent,
Anti-fungicide etc.
|
|
25000
|
|
|
Total
|
|
294400
|
|
(v)
|
Utilities (per month)
|
(Rs.)
|
|
1
|
Electric Power 2100 KWH @ Rs.
4.00 per unit
|
8400
|
|
2
|
Water and others
|
2000
|
|
|
Total
|
10400
|
|
(vi)
|
Other Contingent Expenses (per
month)
|
(Rs.)
|
|
1
|
Postage and stationery
|
1000
|
|
2
|
Telephone
|
2000
|
|
3
|
Repair and maintenance
|
2000
|
|
4
|
Consumable stores
|
5000
|
|
5
|
Packing materials
|
12000
|
|
6
|
Advertisement and Publicity
|
10000
|
|
7
|
Transportation and Travelling
|
6000
|
|
8
|
Insurance
|
3000
|
|
9
|
Laboratory expenses
|
2500
|
|
|
Total
|
43500
|
B. Working Capital (per month)
|
1.
|
i) Raw materials
|
294400
|
|
|
ii) Staff and Labour
|
78690
|
|
|
iii) Utilities
|
10400
|
|
|
iv) Other expenses
|
43500
|
|
|
Total
|
426990
|
|
2.
|
Working Capital (for 2 months)
426990 ×2 =
|
853980
|
C. Total Capital Investment
|
1
|
Fixed Cost(Land +Machinery)
|
4192980
|
|
2
|
Working Capital (for 2 months)
|
853980
|
|
|
Total
|
5046960
|
Financial Analysis
|
(1)
|
Cost of Production (per annum)
|
(Rs.)
|
|
i)
|
Total Recurring Expenditure
|
5123880
|
|
ii)
|
Depreciation on Land and Building
@ 5 %
|
175000
|
|
iii)
|
Depreciation on machinery and
equipments @ 10%
|
56298
|
|
iv)
|
Depreciation on office equipments
@ 20%
|
16000
|
|
v)
|
Interest on total capital investment
@ 14%
|
706574
|
|
|
Total
|
6077752
|
|
(2) Total Sales Turnover (per
year)
|
(Rs.)
|
|
Cement Paint (water proofing)
250 M.T. @ Rs. 27000 per metric ton (27000 ×250)
|
6750000
|
|
(3) Profit (per year)
|
(Rs.)
|
|
6750000- 6077752
|
672248
|
|
(4) Rate of Profit on Sales
|
|
|
|
|
|
Net profit per year × 100
|
|
|
=
|
|
|
|
|
Total Turnover per year
|
|
|
|
|
|
|
=
|
9.96
|
|
|
|
|
|
(5) Rate of Return on Total Capital
Investment
|
|
|
|
Net Profit per year × 100
|
|
|
=
|
|
|
|
|
Total Capital Investment
|
|
|
|
|
|
|
=
|
13.32
|
(6) Break-even Point
|
(i)
|
Fixed Cost (per annum)
|
(Rs.)
|
|
a)
|
Depreciation on Machines, equipments
@ 10%
|
56298
|
|
b)
|
Depreciation on office equipments
@ 20% (25,000 ×0.2)
|
16000
|
|
c)
|
Depreciation on building @ 5 %
|
175000
|
|
d)
|
Interest on total capital Investment
@ 14%
|
706574
|
|
e)
|
Insurance ( 3,000 ×12)
|
36000
|
|
f)
|
40% of salary and wages
|
377712
|
|
g)
|
40% of other contingent expenses
(excluding Insurance, Utilities etc.)
|
194400
|
|
|
Total
|
1561984
|
|
(ii)
|
Net Profit (per year)
|
672248
|
|
B.E.P.
|
|
|
|
|
|
Total Fixed cost ×100
|
|
|
=
|
|
|
|
|
Total Fixed cost + Profit
|
|
|
|
|
|
|
|
1561984 ×100
|
|
|
=
|
|
|
|
|
1561984 + 672248
|
|
|
|
|
|
|
=
|
69.91
|
Addresses of Machinery and Equipment
Suppliers
1. M/s. Ahmedabad Victoria Iron Works
Co. Ltd.
Dhudherwal Road,
Ahmedabad.
2. M/s. Bakshi and Sons
G.T. Road, Millar Ganj,
Ludhiana, Punjab.
3. M/s. Standard Metal Fabricators
1/5, Kirti Nagar,
New Delhi-110001.
4. M/s. Kusum Engg. Works
25, Swallow Lane,
Kolkata-700001.
5. M/s. Devi Dayal and Co.
Lal Kuan,
Delhi- 110006.
6. M/s. Bhagsons Paint Industries
18, D.L.F, Industrial Area,
Najafgarh Road,
New Delhi-110001.
7. M/s. Telematrix Engineers Pvt. Ltd.
C-1, 404, Phase-IV, GIDC,
Vithal Udyog Nagar,
P.O. Vallabhvidya Nagar-388121
Gujarat.
Addresses of Raw Material Suppliers
a. M/s. Amar Minerals Pvt. Ltd.
Alic Building, Dr. D.N. Road,
Mumbai-400001.
b. M/s. Amar Dye Chemicals Ltd.
Rangh Udyan, Sitladevi Temple
Road, Melium,
Mumbai-400001.
c. M/s. Sudarshan Chemicals
162, Wellsely Road,
Pune-311001.
d. M/s. J.K. White Cement
Locally available in every district.
e. M/s. Birla White Cement
Locally available in every district.
f. M/s. R.N. Sahni and Sons
27/3, Shakti Nagar,
Delhi-110007.
g. M/s. Associated Pigments Ltd.
14, Netaji Subash Road,
Kolkata-700001.
h. M/s. Travancore Titanium
Products Limited
Kerala.
i. M/s. Colour Chem Ltd.
Fort House,
Dadabhai Naroji Road,
Mumbai-400001.
