|
Crockery Stone Ware
| Product Code |
: |
94389, 94330 and 94341
|
| Quality and Standards
|
: |
IS 11475:1985 Stoneware
Dinner ware
IS 2838:1984 Stoneware containers for
general purpose |
| Production
Capacity |
: |
Qty. : 600
M.T. (per annum) |
| Uploaded
on |
: |
May
2007 |
Introduction
Crockery ware are being manufactured in
earthenware, stoneware, vitreous china and bone china. This
project profile is prepared for the manufacture of tableware,
which comprises crockery items and some other articles made
of stoneware. Under the group of tableware cups, saucers,
plates, bowls, tea sets, dinner, sets jars, barnels etc. are
covered. They are impermeable to most of the liquids and water
absorption is less than 0.5%. Ceramic crockery ware have their
own place in the field of kitchenware due to their outstanding
properties over melamine and stainless steel wares, as these
are more hygienic, easily cleanable, heat resistant etc. The
main uses of these items are in houses, railway, defence,
canteens, restaurants, hotels etc.
Market Potential
Stoneware tableware and other items are
used in houses, hotels, restaurants, tea stalls, railway canteens,
defence canteens etc. The installed capacity of the industry
located mostly in the Northern parts of the country is estimated
around 1,40,000 M.T per annum. However, in the southern region,
production of these product is less than the demand. On the
national level demand of the product is greater than the supply.
This product has good scope in international markets, mainly
in Gulf and South African Countries. It is estimated that
demand of this item is increasing steadily at the rate of
10% per annum. The demand which was subdued in the past 3-4
years due to the use of substitute items made of melamine
and steel have again shifted to ceramic rockery. There is
a good scope for encouraging new units in this line of activity
especially in the southern part of the country.
Basis and Presumptions
Efficiency and working hours considered
for full capacity utilization:
(a) 80% efficiency.
(b) 8 working hours per day and 300 days in a year.
(c) Wages are taken as per the prevailing norms.
(d) Interest is taken @ 13% a nnum. It is expected that the
project can be implemented within one-year from the project
report stage.
Technical Aspects
Process of Manufacture
The raw materials like quartz, felspar,
ball clay, fire clay etc. are charged in ball mill in desired
proportion with 30- 40% water and ground to the fineness of
100-120 No. mesh. China clay and other plastic clays which
are white burning are blunged in blunger with 30- 40% water.
The slurry from ball mill and blunger is mixed and passed
through fine mesh and electromagnet in order to remove the
iron particles from the slurry. It is mixed properly in agitator
tank from where it is passed through filter press for dewatering
to make filter cakes. These cakes are fed into de-airing pug
mill to extrude the compact body. While the round shaped articles
are made by this body on Jigger and Jolly, other shapes are
made by slip casting process. For casting, slip is made and
poured into the moulds of plaster of paris. The articles are
finished, glazed, and fired at the temperature of 1250- 1280ºC.
Tunnel Kiln is proposed for firing in this project profile.
Use of D.D Kilns and shuttle Kilns is also in practice but
not economical. The articles taken out from the kiln are sorted
and packed for selling.
Quality Control
and Standards
The Bureau of Indian Standards has formulated and published
IS 11475:1985 Stoneware Dinnerware for carrying out
various tests and control of the quality of the product.
Production Capacity (per annum)
| Quantity |
: 600 MT |
| Value |
: Rs. |
Pollution Control
For the purpose of pollution control,
it is advisable to provide dust collecting system and necessary
retrofitting with the kiln to reduce waste gas pollution.
The unit may seek NOC from the concerned authority.
Energy Conservation
Crockery stoneware industry needs energy conservation in fuel
as well as electricity. Ceramic fiber lined tunnel Kiln is
proposed in the project profile which conserves around 30-35%
fuel when compared with conventional DD Kiln.
Financial Aspects
A Fixed Capital
| (i) Land and Building
|
(Rs.) |
| Land 3000 Sq. m.@ Rs.
2000 Sq.m Building |
6000000 |
| Machinery shed 300 Sq.
m Rs. 7000 Sq. m |
2100000 |
| Kiln shed 150 Sq. m.@
Rs. 8000 |
1200000 |
| Raw materials Materials
shed 100 Sq. M.@ Rs. 7000 Sq.m |
700000 |
| Finished goods godown
100 Sq. m. @ Rs. 7000 Sq. m |
700000 |
| Office 60 Sq. m. @ Rs.
5000 Sq. m |
300000 |
| Boundary walls etc. LS
@Rs.1000/m |
440000 |
|
Total
|
11440000 |
(ii) Machinery and Equipments
| Production Unit Description
|
Ind./ Imp |
Qty. |
Price (Rs.) |
| Ball Mills size 1800
x 1800 mm, with all accessories and 10 HP Motor each |
Ind. |
2 |
500000 |
| Ball Mills size 900 x
900 mm, with all accessories and 7.5 HP Motor |
Ind. |
1 |
90000 |
| Screw blunger, capacity
5000 Litre with 5 HP Motor and cemented Tank |
Ind. |
2 |
200000 |
| Vibrating screen size
900 mm x 900mm With all accessories and 1 HP Motor |
Ind. |
2 |
60000 |
| Electromagnet with rectifier
etc. |
Ind. |
1 |
40000 |
| Agitator with 3 HP Motor
and Cemented Tank |
Ind. |
1 |
70000 |
| Diaphragm pump, storke
225 mm suction 7.5 mm with 7.5 HP Motor |
Ind. |
1 |
95000 |
| Filter press chamber
dia 600 mm number of plates 50 No. |
Ind. |
1 |
200000 |
| De-airing pugmill with
vacuum pump etc. with 5 HP Motor |
Ind. |
1 |
350000 |
| Disintegrator size 550
cm with all accessories and 7.5 HP Motor |
Ind. |
1 |
90000 |
| Jigger and Jolly with
5 HP Electric Motor |
Ind. |
15 |
105000 |
| Sagger Press Power operated
with 5 HP Motor |
Ind. |
1 |
90000 |
| Water Pump set with 2
HP Motor |
Ind. |
1 |
30000 |
| Pot Mill, Pot No. 6 Pot
size 9" x 10" with Electric Motor of 2 HP |
Ind. |
1 |
30000 |
|
Total
|
1950000 |
| Electrification
and installation charges @ 10% on cost of machinery |
195000 |
| Testing equipments
|
140000 |
| Misc. tools,
Racks, Trolleys etc. |
90000 |
| Cost of office
equipments |
100000 |
|
Total
|
2475000 |
| Kilns |
(Rs.) |
| Ceramic fibre lined push
bat tunnel Kiln with control system oil storage tank,
combustion fan, hydraulic pusher and other equipments
Specifications |
3500000 |
| Length |
24000 mm |
| Setting width |
900 mm |
| No. of Burners |
4 Nos. |
| Power required for auxiliary
equipment |
10 HP |
| Capacity |
2 MT per day (Crockery
ware) |
| (iii) Pre-operative
Expenses |
300000 |
| Total fixed capital (i+ii+iii+Kiln)
|
17715000 |
B. Working Capital (per month)
(i) Personnel (per month)
| Designation |
Nos. |
Salary / (Rs.) |
Total (Rs.) |
| Manager-cum-ceramist
|
1 |
16000 |
16000 |
| Supervisors |
2 |
8000 |
16000 |
| Skilled workers |
15 |
6000 |
90000 |
| Semi-skilled workers
|
15 |
5000 |
75000 |
| Fitter |
1 |
6000 |
6000 |
| Electrician |
1 |
5000 |
5000 |
| Accountant |
1 |
7000 |
7000 |
| Clerk-cum-Typists |
2 |
5000 |
10000 |
| Peon |
1 |
3000 |
3000 |
| Watchman |
2 |
3000 |
6000 |
|
Total
|
234000 |
| Perquisites
@ 22% of total Salary |
51480 |
|
Total
|
285480 |
(ii) Raw Materials (per month)
| Items |
Ind/ Imp |
Qty |
Rate (Rs.) |
Total (Rs.) |
| Quartz/Silica Sand |
Ind. |
13 MT |
1500/MT |
19500 |
| Felspar |
Ind. |
10 MT |
1500/MT |
15000 |
| China clay |
Ind. |
10 MT |
3000/MT |
30000 |
| Ball Clay |
Ind. |
5 MT |
1800/MT |
9000 |
| Fire Clay |
Ind. |
20 MT |
2000/MT |
40000 |
| Marble/Calcite |
Ind. |
750Kg |
2000/MT |
1500000 |
| Zinc Oxide |
Ind. |
50/Kg. |
65/Kg. |
3250 |
| Zirconium opacifier |
Ind. |
250 Kg. |
60/Kg. |
15000 |
| Barium Carbonate |
Ind. |
75 Kg. |
40/Kg. |
3000 |
| Colouring agents |
Ind. |
LS |
|
10000 |
| Plaster Paris |
Ind. |
2MT |
2200 MT |
4400 |
| L.D.O (Fuel) |
Ind. |
10KL |
35000/k litre |
350000 |
| Kiln furniture |
Ind. |
LS |
|
60000 |
| Packing materials |
Ind. |
LS |
|
10000 |
|
Total
|
2069150 |
(iii) Utilities (per month)
| Power charges 62 kW.
|
55800 |
| (iv) Other Contingent
Expenses (per month) |
(Rs.) |
| Postage and Stationery
|
2000 |
| Telephone |
4000 |
| Consumable stores |
10000 |
| Repair and maintenance
|
5000 |
| Transport Charges |
10000 |
| Advertisement and publicity
|
5000 |
| Insurance etc. |
5000 |
| Misc. expenses |
10000 |
|
Total
|
51000 |
| (v) Total Recurring
Expenses (per month) |
(Rs.) |
| Personnel (wages) |
285480 |
| Raw materials |
2069150 |
| Utilities |
55800 |
| Other contingent expenses
|
51000 |
|
Total (L.S.)
|
2461430 |
| (vi) Total Working Capital
for 2 months |
4922860 |
C. Total Capital Investment
| 1. Fixed |
17715000 |
| 2. Working capital (2
months) |
4922860 |
|
Total
|
22637860 |
| Machinery
Utilization (on the basis of 24 hours working) |
| Ball Mills |
100% |
| Screw blunger |
100% |
| Filter press |
80% |
| Jigger Jolly |
80% |
| Tunnel Kiln |
80% |
Financial Analysis
| (1) Cost of Production
(per annum) |
(Rs.) |
| Total recurring expenditure
|
29537160 |
| Depreciation on building
@ 5% |
5720000 |
| Depreciation on machinery
and Equipments @ 10% |
247500 |
| Depreciation on kiln
@ 20% |
700000 |
| Interest on total capital
investment @ 13% |
2942922 |
|
Total
|
39147582 |
(2) Turnover (per year)
| Items |
Qty |
Rate (Rs.) |
Value (Rs.) |
| Stoneware Crockery items
|
600 MT |
70000 MT |
42000000 |
| Deducted 5% towards rejection
|
|
|
2100000 |
|
Total
|
39900000 |
| (3) Net Profit (per
year) |
= |
Rs. 39900000 – 39147582
|
| |
= |
752418 |
| |
|
|
| (4) Net Profit Ratio
|
= |
Net profit per year x
100
-------------------- |
| |
|
Turnover per year |
| |
|
|
| |
= |
752418x 100
--------------- |
| |
|
39900000 |
| |
|
|
| |
= |
1.89 |
| |
|
|
| (5) Rate of Return |
= |
Net profit per year x
100
--------------------------- |
| |
|
Total investment |
| |
|
|
| |
= |
752418x100
---------------------- |
| |
|
22637860 |
| |
|
|
| |
= |
3.32 |
(6) Break-even Point
| Fixed Cost |
(Rs.) |
| Depreciation on Building
and equipment and Kill |
6667500 |
| Interest on total investment
|
2942922 |
| 40% of other contingent
expenses |
220800 |
| 40% of salary and wages
|
1370304 |
| Insurance |
60000 |
|
Total
|
11261526 |
| B.E.P |
= |
Fixed Cost × 100
----------------------- |
| |
|
Fixed Cost + Profit |
| |
|
|
| |
= |
22637860 x100
----------------------- |
| |
|
22637860 +752418 |
| |
|
|
| |
= |
93.74 |
Addresses of
Machinery Suppliers
1. M/s. Amic Industries Pvt. Ltd.
80-D, Dr.Suresh Sircar Road,
Kolkata-700014.
2. M/s. Modern Engg. and Fabricating Works
Behind Kubeshwar Mahadev,
Saijpur (Ambavadi), Naroda Road,
Ahmedabad-380016.
3. M/s. Lokmanya Engg. Works
20, Bharat Khand Cotton Mills
Compound, Naroda Road,
Ahmedabad-380016.
4. M/s Keshab Machineries Pvt. Ltd.
Bose Park, P.O. Sukeher,
24, Parganas Dt.,
West Bengal
5. M/s. Hindustan Company
123/7, Gopallal Tagore Road,
Bon Hoogly,
Kolkata-700035.
6. M/s. D.K Engg. Works,
8, Panchanathala New Road,
Balgharia, Kolkata -700056.
Tunnel Kiln/Khuttle Kiln Suppliers
1. M/s. Bengal Lion (Industrial Furnace) Ltd.
27-B Camac Street, Kolkata
2. M/s. Teksago-Bhagat Carakiln Pvt. Ltd.
D-828, New Friends Colony,
New Delhi-110005.
3. M/s. Sharma Kiln Technology Pvt. Ltd.
206, Hare Krishna Complex,
Opp. Kothawala Flat,
Ashram Road, Ahmedabad.
4. M/s. N.M Ceramic Kiln.
Post Box No. 30, B-8 Ram
Balram Apartment,
Kalol- 382721 (Gujarat)
5. M/s. Neptune Group Companies
252, GIDC Ind. Estate,
Phase II, Modhera Road, Dediasan,
Mehasana-384002.
Raw Material Suppliers
1. M/s. Golachar pallwad and Co.
Opp. Railway Station, Gandhi Nagar,
Ajmer Road, Beawar, (Rajasthan)
2. M/s. Jotya Prakash Mining Works
4, Gupta Gali Beawar,
(Rajasthan)
3. M/s. Satya Prakash Minining Works.
2, Gupta Gali, Beawar 305901
(Rajasthan)
4. M/s. Ashwain and Co.
Arsodia, Taluka-Idar,
Pin 383430.
5. M/s. Hindustan China Clay Works
Papinacheri, (Kerala)
6. M/s. Tahala Ram and Sons
Rathkhan,
Bikaner (Rajasthan)
7. M/s. Multani Minerals
Statopm Road,
Thangadh (Gujarat)
8. M/s. Ceramills Glaze and Ziroonium Co.
Daultabad Road, Gurgaon, (Haryana)
9. M/s. Hemvathi Nandan Nitrates (P) Ltd.
61-A, Industrial Development
Area, Chemical Zone,
Phase II, Mallapur, Nacharam,
Hyderabad (A.P.)
10. M/s.Shahzips (P) Ltd.
55, Industrial Estates,
Nunhai, Agra.
11. M/s. Ferro Coatings and Colours Ltd.
Post Koka, 24 Parganas,
Kolkata (W.B).
12. M/s. Rajasthan Plasters and Industries
Out side Coga Gate,
Bikaner (Rajasthan)
13. M/s. Snow-White Industries
40, Manendra Nagar, Rishikesh,
Dehra Dun (Uttaranchal)
Contact for more information:
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