|
Chemical Porcelain Ware
| Product Code |
: |
94342 |
| Quality and Standards
|
: |
IS 7402 : 1974, 1975
IS 155011 : 1968
IS 3953 : 1966
IS 3990 : 1967
IS 454 : 1971 |
| Uploaded on |
: |
May 2007 |
Introduction
Chemical Porcelain is a white vetrified
dense translucent or glazed body, made of china clay, quartz,
felspar, talc, alumina and additives in different shapes of
thin walled items such as flat tipped basins, beakers, round
rectangular capsules, combustion boats, crucibles, funnels
dental dissolving cups, parting disks and discs, pipette vest
spotting and dessicator plates, pipes, tubes etc, used in
the laboratories of educational institutions, scientific development
and industrial research, chemical, fertilizer, petro-chemical
establishments etc. Due to their inherent properties like
resistance to all reagents except hydrofluoric acid, resistance
to thermal shock with low coefficient of expansion, good thermal
conductivity and mechanical strength they have wide range
of uses.
Market Potential
The demand of chemical porcelain items
is ever increasing in view of extensive research and development
besides growing industrial activities in the field of chemical,
fertilizers and petrochemicals throughout the country. Therefore,
there is wide scope for setting up new units.
Basis and Presumptions
| Efficiency and working
hrs. considered for full capacity utilization |
75% efficiency
8hrs. working per day for 300 days a year |
| Time required for achieving
full envisaged capacity utilization |
3 months from the commencement
of commercial production |
| Labour wages |
Skilled workers 3, 000
Semi-skilled/ unskilled 2,400 |
| Interest rate |
13% |
| Margin Money |
25% |
| Pay back period of the
project |
5 years |
| Land rate |
Rs. 2000 per sq. mt.
|
| Construction rate |
Rs. 5000 per sq. mt.
|
Implementation Schedule
| Sl.No. |
Activity |
Period
(in months) |
| 1. |
Time required for preparation
of project report |
1 |
| 2. |
Selection of site |
½ |
| 3. |
Registration of SSI |
½ |
| 4. |
Availability of finance
|
1½ |
| 5. |
Construction of building
|
5 |
| 6. |
Machinery procurement
and erection |
3 |
| 7. |
Raw materials procurement
|
1 |
| 8. |
Recruitment of labour
|
1 |
| 9. |
Trial runs |
10 |
If C.P.M. chart is drawn of the above
activities, the total time taken would be about 8 months to
implement the project as many activities may be completed
simultaneously.
Technical Aspects
Process of Manufacture
The hard mineral powders like Quartz,
Felspar etc. are ground to 200 mesh fineness and mixed with
China clay, talc etc. in suitable proportions in blungers
with requisite quantity of water. The slurry is passed through
vibrating screen consisting of magnetic separator and stored
in agitator. The slurry is then passed to filter press by
diaphragm pump where it is dewatered and the body is formed
into cakes. The cakes are passed through de-airing pugmill
for thorough pugging and extrusion into dense homogenous plastic
mass free from air bubbles. The body is then shaped into required
products by pressing, casting depending upon the sizes, shapes
and properties of the end product. The shaped articles are
dried and biscuited at about 1000ºC. After inspection
the biscuited ware are suitably glazed for firing at temperature
ranging from 1280ºC to 1350ºC. After unloading from
the kiln, these are sorted out, tested and packed for marketing.
Quality Control
and Standards
The Bureau of Indian Standards has formulated and published
the following specifications on various chemical porcelain
for guidance and maintenance of the quality of the product:
| IS 5009:1969 |
Buchner funnels |
| IS 7402 (Part 1):1974
|
Filter container |
| IS 7402 (Part 2):1975
|
Filter candles |
| IS 5011:1968 |
Gooch Crucibles |
| IS 3953:1966 |
High temperature Ceramic
combustion boats |
| IS 3990:1967 |
High temperature Ceramic
combustion tubes |
| IS 454:1971 |
Perforated plates for
desicators |
| IS 2837 (Part 1):1975
|
Crucibles |
| IS 2837 (Part 2):1977
|
Basins |
| IS 2839:1979 |
Methods of tests and
quality. |
Production Capacity
Production target (per annum)
| Quantity |
: 1200MT |
| Value |
: Rs. |
Pollution Control
and Energy Conservation
There are no toxic effluents discharged through the waste
water. However, to control dust pollution at the place of
dry grinding of raw materials and mixing, it is recommended
to provide cyclonic dust collector, with connecting chutes
and coverage. The oil fired shuttle kiln has to be provided
with high stack and modern control systems for attaining high
efficiency and low discharge of toxic effluents through the
kiln.
Financial Aspects
A Fixed Capital
| (i) Land and Building
|
(Rs.) |
| a) Land 2500 sq. mtrs.
@ Rs. 2000 sq. mts |
5000000
|
| b) Building |
|
| Working shed 600 sq.
mtrs. @ Rs. 5 000 sq. mtrs. (ACC) |
3000000
|
| Store, office laboratory
(RCC) 200 sq. mtrs @ 7000 sq. mtr. |
1400000
|
|
Total
|
9400000
|
(ii) Machinery and Equipments
| Description |
Nos. |
Rate |
Value (Rs.) |
| Ball mill 6'x 4 1/2'
with porcelain lining, 10HP electric motor starter etc.
|
2 |
130000 |
260000 |
| Ball mill 4'x 4 1/2'
with porcelain lining 10HP electric motor starter etc.
|
2 |
90000 |
180000 |
| Blunger with 5HP electric
motor starter and accessories |
2 |
10500 |
21000 |
| Agitator size 5'L x 5'
W x 5'D complete with 3 HP motor starter and accessories
|
2 |
78000 |
156000 |
| Filterpress, chamber
dia 300mm with 50 plates |
1 |
250000 |
250000 |
| Diaphragm pump 6"
strokes 2" suction and 1 1/2 delivery with 5HP motor
|
1 |
90000 |
90000 |
| Vibrating screen 2' x
1.5 size with 1HP motor starter etc. |
2 |
25000 |
30000 |
| Hydraulic press with
accumulator, pipefitting, pressure gauge and accessory
etc. |
1 |
400000 |
400000 |
| Toggle press Hand operated
|
7 |
50000 |
350000 |
| Disintegrator, 18"
size with 7.5HP motor, starter etc. |
1 |
150000 |
150000 |
|
Total
|
1887000
|
| Electrification
and Installation charges @ 10% |
188700 |
|
Total
|
2075700
|
| Tools, dies and moulds
etc. |
LS |
|
180000
|
| Pollution control equipment
|
LS |
|
150000
|
| Office Furniture |
|
|
200000
|
| Laboratory testing equipment
|
|
|
200000
|
|
Total
|
2805700
|
| Tunnel Kiln,
oil fired, fiberlined (HTZ 128 modules) capacity 3.5 MT/day
with equipments and storage tank |
1600000
|
| Total cost
of machinery and equipments |
4405700
|
| (iii) Pre-operative
Expenses |
120000
|
| Total Fixed Capital
|
(Rs.) |
| a) Land and building
|
9400000
|
| b) Plant and machinery
|
4405700
|
| c) Pre-operative expenses
|
120000
|
|
Total
|
13925700
|
B. Working Capital (per month)
(i) Personnel (per month)
| Designation |
Nos. |
Salary / month |
Total (Rs.) |
| Manager/Ceramist |
1 |
17000 |
17000 |
| Supervisors |
2 |
8000 |
16000 |
| Accountant |
1 |
7000 |
7000 |
| Clerk-cum-typist |
1 |
4000 |
4000 |
| Skilled workers |
10 |
3500 |
35000 |
| Semi-skilled/unskilled
workers |
20 |
3000 |
60000 |
| Peons |
2 |
3000 |
6000 |
| Watchman |
2 |
3000 |
6000 |
|
Perquisite @ 22%
|
33220
|
|
Total
|
184220
|
i) Raw Material (per month)
| |
Qty. |
Rate |
Value (Rs.) |
| Ball Clay |
20MT |
1800 |
36000
|
| China Clay |
50MT |
2000 |
100000
|
| Felspar |
20MT |
1500 |
30000
|
| Quartz |
20MT |
1500 |
30000
|
| Zinc/Zirconium chemical
|
3MT |
60000 |
180000
|
| Packing materials |
LS |
70000 |
70000 |
|
Total
|
446000
|
| (iii)
Utilities (per month) |
(Rs.) |
| Power |
70HP |
63000 |
| L.D.O./ Kerosenes |
21,000 ltrs Rs. 35 /ltr.
|
735000
|
|
Total
|
798000
|
| (iv) Other Contingent
Expenses (per month) |
(Rs.) |
| Postage and Stationery
|
2000 |
| Telephone |
4000 |
| Repairs and Maintenance
|
10000 |
| Transportation charge
|
10000 |
| Other overhead exp. |
5000 |
| Insurance |
2500 |
|
Total
|
33500
|
| (v) Total Working
Capital (per month) |
(Rs.) |
| Staff and labour |
184220
|
| Raw Materials |
446000
|
| Utilities |
798000
|
| Other Contingent expenses
|
33500
|
|
Total
|
1461720
|
| Working Capital (for
2 months) |
2923440
|
C. Total Capital Investment
| Fixed capital |
18331400
|
| Working capital |
2923440
|
|
Total
|
21254840
|
Financial Analysis
| (1) Cost of Production
(per year) |
(Rs.) |
| Total recurring cost
|
17540640
|
| Depreciation on building
@ 5% |
470000
|
| Depreciation on machinery
and equipment @ 10% |
188700
|
| Depreciation on Kiln
@ 20% |
320000
|
| Depreciation on office
equipment @ 25% |
50000
|
| Depreciation tools, dies
and moulds @ 20% |
36000
|
| Interest on total investment
@ 13% |
2763129
|
|
Total
|
21368469
|
(2) Turnover (per year)
| Item |
(Rs.) |
| Chemical Porcelain ware
1200MT @ Rs. 20000 / MT |
24000000
|
| (3) Profitability |
= |
Sales – cost of production
|
| |
= |
21368469-24000000
|
| |
= |
2631531
|
| |
|
|
| (4) Profit on Sales
|
= |
2631531x100
-------------------- |
| |
|
24000000 |
| |
|
|
| |
= |
10.96 |
| |
|
|
| (5) Rate of Return |
= |
2631531 x 100
------------------ |
|
|
21254840 |
| |
|
|
| |
= |
12.38 |
(6) Break-even Point
| Fixed Cost |
(Rs.) |
| Total Depreciation |
1064700
|
| Total Interest |
2763129
|
| 40% of salary |
884256
|
| 40% of other Contingent
expenses |
148800
|
| Insurance |
30000
|
|
Total
|
4890885
|
| B.E.P |
= |
Fixed Cost × 100
----------------------- |
| |
|
Fixed Cost + Profit |
| |
|
|
| |
= |
4890885 x100
----------------------- |
| |
|
4890885 + 2631531 |
| |
|
|
| |
= |
65.02 |
Addresses of
Machinery Suppliers
1. M/s. Lokmanya Eng. Works
26/Bharatkhand Cotton Mill
Compound, Narod Road,
Ahmedabad.
2. M/s. Jivanlal Shiv Panchal
Opp. Old Civil Hospital,
Gheekanta Road, Ahmedabad
3. M/s. Modern Engg. and Fabrication Works
Behind Kubeshwar Mahadev,
Saijpur (Ambavadi),
Naroda Road, Ahmedabad
4. M/s. Sharma Kiln Technology
Kothawala Flat, Harekrishna
Complex, Near Paldi,
Ahmedabad - 380007
Raw Material Suppliers
1. M/s. Gujarat Minerals
Opp. S. T. Stand, Vejalpur - 363
721, Tal. Kalol,
Dist. Panchmahal (Gujarat)
2. M/s. Ashok Minerals and Grinding Ind.
F-237-238, MIA, Madri, Udaipur,
(Rajasthan)
3. M/s. Sompura Mines and Mineral Suppliers
Ravishankar Pyrnashankar
Road, Thangadh, Bikaner,
(Rajasthan.)
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
|
