|
Crockery (Bone China)
| Product Code
|
: |
94326 and 94389
|
| Quality and
Standards |
: |
As per Customers
Specification |
| Uploaded
on |
: |
May
2007 |
Introduction
Mankind has a natural liking and
inclination towards clay made utensils/crockery. Though
a number of substitute items appeared in the market
ultimately the clay crockery has sustained. The fancy
items of bone china like tableware, crockery, decorative
items, lamp shades etc. is finding a good domestic
as well as export market.
Market Potential
The decorative items made of bone
china are elegant for while there is a customer preference.
The demand of bone china crockery and decorative item
in urban areas is gradually increasing. There is a
good scope of export to Gulf countries.
Basis and Presumptions
The unit will run on single shift
basis in 300 working days in a year. There will be
a 8 hours shift in a day. Furnance will work on three
shifts basis.
Full production capacity will be achieved in 3 years.
Wages are taken as per the minimum wages of the Government.
Rate of interest on borrowings- 13%.
Life of plant and machinery-10 years.
Life of furnace-5 years.
Cost of plant and machinery as
per latest quotations.
Implementation Schedule
| Sl.No. |
Activity
|
Period
(in months) |
| 1. |
Possession of
land |
2 |
| 2. |
Construction
of building |
5 |
| 3. |
Purchase of
machinery |
8 |
| 4. |
Installation
of machinery |
12 |
| 5. |
Trial production
|
14 |
Technical Aspects
Process of Manufacture
China clay powder, calcined quartz
powder, potash felspar, bone ash and other raw materials
are weighed proportionately and fed in to ball mill
for fine grinding. This mixture is ground to 300 mesh
and sieved after passing through magnetic separator.
The slurry is placed in agitator. This slurry is again
pumped in to filter press, cake received from filter
press is mixed with water and electrolyte to make
casting slip. Now desired items are cast in Plaster
of Paris moulds. Articles are taken out from moulds
and dried. These articles are finished. After finishing
and drying articles are biscuit fired. Articles are
glazed by dipping or spraying and again after drying
these articles are gloss fired. At last ready articles
are decorated by transfer papers, ceramic colour or
gold. These decorated articles are fired at 650ºC
in electrical furnace. Thus ready articles are sorted
and packed for despatch.
Quality
Control and Standards
As per customer's specification.
Production Capacity (per annum)
Bone China Crockery and Art ware
| Quantity |
: 130 MT |
| Value |
: |
Pollution Control
Bone China unit has to take no
objection certificate from the State Pollution Control
Board as per rule.
Financial Aspects
A Fixed Capital
| (i) Land
and Building |
(Rs.) |
| Land 2000 sq.
mtr @ Rs.2 000sq . mtr. |
4000000 |
| Building |
|
| Work shed 500
sq. mtr. @ Rs. 5 000 sq. mtr. |
2500000 |
| Office Store
100 sq. mtr. @ Rs. 7000 sq. mtr. |
700000 |
|
Total
|
7200000
|
(ii) Machinery and Equipments
| Particulars
|
Quantity (Nos.)
|
Value (Rs.)
|
| Ball mill 5'
x 5 1/2' with motor and other accessories |
3 |
120000 |
| Ball mill 3'
x 3' with 7 HP motor and other accessories |
1 |
50000 |
| Blunger 10'
with 5 HP motor |
1 |
80000 |
| Agitator with
3 HP motor |
1 |
48500 |
| Vibrating screen
with magnetic separator |
2 |
60000 |
| Filter press
44'' dia, 30 plates |
1 |
100000 |
| De-airing pug
mills with 5 HP motor |
1 |
80000 |
| Saggar press
hand operated |
1 |
30000 |
| Pot mills 2
HP motor |
1 |
10000 |
| Shuttle kiln
6 Cubic meter |
2 |
2400000 |
| Muffle electric
furnace |
1 |
400000 |
| Installation,
electrification expenditure |
L.S. |
300000 |
| Plaster of Paris
moulds |
L.S. |
60000 |
| Rack, panels
etc. |
L.S. |
25000 |
| Testing equipments
|
L.S. |
20000 |
| Office furniture
|
L.S. |
100000 |
|
Total
|
3883500 |
| (iii) Pre-operative
Expenses |
80000 |
| Total Fixed
Capital |
(Rs.) |
| Land |
4000000 |
| Building |
3200000 |
| Plant and Machinery
|
3883500 |
| Preliminary
Expenses |
80000 |
|
Total
|
11163500 |
B. Working Capital (per month)
(i) Salary and Wages
| Particulars
|
Nos. |
Salary / (Rs.)
|
Total (Rs.)
|
| Manager |
1 |
16000 |
16000 |
| Production Manager
|
1 |
10000 |
10000 |
| Supervisors
|
3 |
7000 |
21000 |
| Accountant/Clerk
|
1 |
7000 |
7000 |
| Firemen |
4 |
7000 |
28000 |
| Moulders |
2 |
6500 |
13000 |
| Skilled Workers
|
25 |
5000 |
125000 |
| Un-skilled Workers
|
15 |
3500 |
525000 |
| Decorators |
2 |
4000 |
8000 |
| Peons |
2 |
3000 |
6000 |
| Electrician
|
1 |
4000 |
4000 |
|
Total
|
763000 |
| Add
Perquisites @ 10 % |
76300 |
|
Total
|
839300 |
(ii) Raw Material
| Particulars
|
Quantity |
Rate (Rs.)
|
Value (Rs.)
|
| Bone ash |
9 MT |
16000 |
144000 |
| China clay |
2.4 MT |
3000 |
7200 |
| Felspar |
6.1 MT |
1500 |
9150 |
| Frit |
1 MT |
19000 |
19000 |
| Plaster of Paris
|
2 MT |
2200 |
4400 |
| Fire clay |
3.0 MT |
2500 |
7500 |
| Sillimanite
|
0.18 MT |
5000 |
900 |
| Decoration paper
|
L.S. |
15000 |
15000 |
| Packing material
|
L.S. |
15000 |
15000 |
| Other Contingent
expenses |
L.S. |
10000 |
10000 |
|
Total
|
232150 |
| (iii) Utilities
|
(Rs.) |
| Power 48 HP
|
43200 |
| Diesel L.D.O.
12 KL @ Rs. 35,000 per K.L. |
420000 |
|
Total
|
463200 |
| (iv) Other
Contingent Expenses |
(Rs.) |
| Postage and
Stationery |
2000 |
| Advertisement
and publicity |
5000 |
| Insurance |
2500 |
| Telephone Bills
|
4000 |
| Consumables
|
10000 |
| Repair and Maintenance
|
5000 |
| Miscellaneous
Expenses |
5000 |
|
Total
|
33500 |
| (v) Total
Working Capital (per month) |
(Rs.) |
| Raw Materials
|
232150 |
| Salaries and
Wages |
839300 |
| Utilities |
463200 |
| Other Contingent
Expenses |
33500 |
| Total |
1568150 |
| Working Capital
for 2 months |
3136300 |
C. Total Capital Investment
| Fixed capital
|
11163500 |
| Working Capital
for 2 months |
3136300 |
|
Total
|
14299800
|
Financial Analysis
| (1) Cost
of Production (per annum) |
(Rs.) |
| Total recurring
cost |
18817800 |
| Depreciation
on building @ 5% |
160000 |
| Depreciation
on furnace @ 20% |
80000 |
| Depreciation
on Plant and Machinery @ 10% |
338350 |
| Depreciation
on Furniture and Fixtures @ 25% |
25000 |
| Interest on
Total Capital Investment @ 13% |
1858974 |
|
Total
|
21280124
|
(2) Turnover (per annum)
| Item |
Quantity |
Rate (Tonnes)
|
Value (Rs.)
|
| Bone
China Waxes and Art ware |
| Grade A |
50 M.T. |
195000 |
9750000 |
| Grade B |
80 M.T. |
160000 |
12800000 |
|
Total
|
22550000
|
| (3) Net Profit
(per annum) |
= |
Turnover – Cost
of Production |
| |
= |
22550000 – 21280124
|
| |
= |
1269876 |
| |
|
|
| (4) Net Profit
Ratio |
= |
Net Profit per
annum x 100
----------------------------- |
| |
|
Turn Over per
annum |
| |
|
|
| |
= |
5.63 |
| |
|
|
| (5) Rate of
Return |
= |
Net Profit per
annum x 100
--------------------------- |
| |
|
Total Capital
Investment |
| |
|
|
| |
= |
8.88 |
(6) Break-even Point
| Fixed Cost
|
(Rs.) |
| 1. Depreciation
on Building |
160000 |
| 2. Depreciation
on Plant and Machinery and Furnace |
418350 |
| 3. Depreciation
on Furniture and Fixture |
25000 |
| 4. Interest
on Borrowings @ 13% |
1858974 |
| 5. 40% of Salary
and Wages |
4028640 |
| 6. 40% of Other
Contingent Expenses |
13400 |
| 7. Insurance
|
30000 |
|
Total
|
6534364
|
| B.E.P |
= |
Fixed Cost ×
100
----------------------- |
| |
|
Fixed Cost +
Profit |
| |
|
|
| |
= |
6534364 x 100
----------------------- |
| |
|
6534364 + 1269876
|
| |
|
|
|
= |
83.72% |
Addresses
of Plant and Machinery/ Furnace Suppliers
1. M/s. Shiv Industries
206, Veena Dalvi Industrial Estate,
Oshiwara, Jogeshwari (W),
Mumbai - 400 102
2. M/s. Erich Magnetics
176/6B/10, Old Tijab Mill,
Bholanath Nagar, Shahadra,
Delhi - 110 032
3. M/s. Amic Industries Private Limited
10, B.T. Road, Kolkata - 700 056
4. M/s. Eleind Engineering Private Limited,
D-20/2, Okhla Industrial Area,
Phase - II, New Delhi - 110 020
Raw Material Suppliers
1. M/s. Alam Ji Plaster Udyog
Ramji Ki Gol,
Tehsil Gurmalani,
Barmer (Rajasthan)
2. M/s. Ceekay Plasters and Chemicals,
64, Industrial Area, Bikaner
(Rajasthan)
3. M/s. Tower Minerals
Post Office- Malpur,
Zenipur, (Rajasthan)
4. M/s. Mahavir Minerals Private Limited
Jautani Bazar,
Ajmer, (Rajasthan)
Contact for more information:
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