Cement Mosaic Flooring Tiles
| Product Code | 29129 |
| Quality and Standards | IS 1237 |
| Production Capacity: Qty. | Quantity: 1500MT (8,00,000 nos.) Value : Rs. 65, 00, 000 |
| Uploaded on | January 2007 |
Introduction
Mosaic floor tiles are also known as terrazzo tiles. The main raw materials used for the manufacture are cement concrete and coloured stone chips. These tiles are made generally in the sizes of 200 x 200 x 20mm, and 300 x 300 x 25mm. These tiles can also be made in various other sizes, shapes according to market demand. The tiles are used for flooring of both residential and commercial buildings. The top surface of the tiles is decorated with marble stone chips of various colours with suitable addition of cement colour. These tiles are impermeable, easy to replace and long lasting.
Market Potential
Construction of floor by laying these tiles is time saving. It is also economical to repair the floor or do patch work by replacing the damaged tiles in course of use. Since the tiles are available in various decorative colours and sizes, the item is gaining popularity and the demand is increasing day-by-day. There is a great upsurge in the building construction activity due to increase in population. The requirement of residential houses hospitals and commercial buildings is increasing day by day. Government of India in its 10th Five Year Plan has given greater emphasis on housing activity. Socioeconomic changes in society, improved standards of living, renovation of old buildings and all-round development in the country, have increased building construction activity and the demand of Mosaic Flooring tiles.
Ceramic vitreous floor tiles, granite and marble stone tiles, red clay flooring tiles are some of the substitute material used in place of mosaic tiles. The demand for Mosaic tiles is estimated to be around 25% of the total requirement of flooring tiles. Taking the above factors into consideration the demand is expected to increase at the rate of 10% every year during the current plan period. Hence there is a good scope for setting up of new units for the manufacture of mosaic tiles.
Basis and Presumptions
- It has been taken into consideration that the unit will work on two shifts basis per day for 300 days in a year.
- To achieve full plant capacity 1 to 2 months trial production is required.
- Labour and wages mentioned as per the prescribed minimum wages.
- Interest rate at 12% considered in the project profile both for recurring and non-recurring investment.
- Margin money will vary from 10- 25% depending upon the location and scheme adopted by the entrepreneurs.
- Operative period of the project is around 10 years considering technology obsolescence rate and period of repayment of loan.
- The costs of land, construction charges, machinery and equipment, raw materials and consumables, other Contingent expenses etc. indicated in the scheme are based on the prices prevailing at the time of project preparation. Therefore, these are subject to necessary changes from time to time based on the local conditions.
Implementation Schedule
Activity |
Period(in months) |
| Project report preparation, selection of site, selection of machinery and registration as SSI etc. | 6 |
| Processing for financial assistance, procurement of machinery and civil construction etc. | 6 |
| Trial run and marketing set up etc. | 2 |
| Total Time | 14 |
Technical Aspects
Process of Manufacture
The basic raw materials used in the manufacture of mosaic floor tiles are cement (grey and white) stone/marble chips. Fine aggregates like sand, dolomite powder and colouring oxide ordinary portland cement can be used for mosaic tiles of dull colours. For such applications where distinct designs and deep colour shades and marble boundries are desired white cement may be employed. Hard limestone, dolomite chips, crushed cuddappha stone of suitable sizes are to be used as course aggregate. Colours should not be added in quantities exceeding 10% of the cement used in tile mix, otherwise strength of tiles will be adversely affected.
The process for the manufacture of Mosaic tiles consists of three layers, the facing, the intermediate and backing layers. The raw materials (cement, marble chips, marble powder, colouring oxides, sand stone chips) are mixed according to the pre-determined proportions thoroughly and mixture is kept separately on the platform of hydraulic/mechanical press for ready use. The mixture for three layers is prepared in the following proportions.
Facing mixture |
Proportion |
| Grey cement | 1.5 |
| Marble chips | 4 |
| White cement | 1 |
| Marble powder | 1 |
| Colouring oxide | 0.1 to 0.5% |
Intermediate Mixture |
|
| Grey cement | 1 |
| Sand | 1 |
Backing Mixture |
|
| Grey cement | 1 |
| Sand | 3 |
| Stone chips | 1 |
Suitable iron moulds are fitted with the bottom plate of the press. The facing mixture is first fed into the mould to a thickness of about 6.5mm and then intermediate and backing mixture is spread over to the thickness of about 9mm each. The mixture is pressed under the pressure of around 150kg/ sq. cm. which varies according to the size of the tile. The tiles are taken out from the moulds and kept for 24 hours for air setting and then immersed in water for curing for a period of about 15days. The cured tiles, are then taken from the curing tank and kept in shed for a period of about 4-5 days for drying. The tiles are then polished and ground on super (levelling machine. After polishing, the tiles are given final touch of finish by hand and then sent to store for despatch.
Manually operated presses are also used for making the tiles for small batches of production. But the tiles made by this press do not have uniformity due to difference of pressure in each cycle with variation in pressure of the manually operated presses.
Suitable iron moulds are fitted with the bottom plate of the press. The facing mixture is first fed into the mould to a thickness of about 6.5mm and then intermediate and backing mixture is spread over to the thickness of about 9mm each. The mixture is pressed under the pressure of around 150kg/ sq. cm. which varies according to the size of the tile. The tiles are taken out from the moulds and kept for 24 hours for air setting and then immersed in water for curing for a period of about 15days. The cured tiles, are then taken from the curing tank and kept in shed for a period of about 4-5 days for drying. The tiles are then polished and ground on super (levelling machine. After polishing, the tiles are given final touch of finish by hand and then sent to store for despatch. Manually operated presses are also used for making the tiles for small batches of production. But the tiles made by this press do not have uniformity due to difference of pressure in each cycle with variation in pressure of the manually operated presses.
Quality Control and Standards
For maintaining uniformity in quality the following Indian standards specification may be considered:
IS 1237:1980 Cement concrete flooring tiles.
As per IS 1237:1980 the use of raw materials is divided into three forms viz. topping mixture, intermediate mixture and backing mixture.
Production Capacity
It is envisaged that unit will produce about 8 lakhs pieces of assorted sizes valued at Rs. 65,00,000
Motive Power 40 HP..
Pollution Control
There is no water pollution in manufacture of mosaic tiles, however, there would be some air pollution while handling dry raw materials like cement and marble powders. Simple methods to cover the discharging bins for mixing or connecting it with cyclonic dust collector would be sufficient to control the pollution. Alternatively, the operator should use dust mask.
Energy Conservation
It is not applicable as far as fuel energy is concerned. Simple precautions and knowledge of effective utilization of electrical power is necessary.
General precautions for saving energy particularly electricity and fuel oils are required to be followed by the unit by adopting energy conservation techniques not only to conserve and power and fuels but also to save considerable expenditure on their consumption in its own interest and also in the interest of the nation as a whole.
Financial Aspects
Fixed Capital
Land and Building |
4000 tonnes |
| Land 30,000 sq. mts. @ Rs. 3334 / Sq. Mtr | 1,00,00,000 |
| Building | |
| Office, Stores etc. 1000 sq. mtrs @ Rs. 10000/m2 | 1,00,00,000 |
| Workshed 1600 sq. mts. @ 5000/m2 | 80,00,000 |
| Curing Tanks | 8,00,000 |
| Compound wall, sanitation civil work, Gate and roads etc. | 12,00,000 |
| Total | 3,00,00,000 |
Machinery and Equipments |
Area in Sq.mt. |
(Rs.) |
| Hydraulic press (Cap. 150kg/sq. cm) with pressure gauge | 3 | 4,00,000 |
| Hydraulic double piston pump with 5HP motor combined with safety valve, capable of feeding 4 to 5 presses | 1 | 3,00,000 |
| Levelling (grinding) machine complete with all attachments grinding capacity 4 tiles at a time (5HP) | 4 | 5,00,000 |
| Colour mixing muller for mixing colour with cement (3HP), D.G. Set, Bore well with water storage tank, water distribution system, pollution control systems electrical lighting etc. | Lot | 20,00,000 |
| Semi polishing machine with 2HP motor for sample polishing for testing | 1 | 1,00,000 |
| Total | 39,00,000 | |
| Erection and installation charges for the above machines @10% of the cost | 3,90,000 | |
| Tipping borrows 4 cft/7 cft cap | 1,00,000 | |
| Plain and checkered tile moulds complete with frame, plate and plug 3 sizes, 10 sets | 8,00,000 | |
| Weighing machine, working tables racks etc. | 6,00,000 | |
| Testing equipments and material handling equipments | ||
| Office equipments and furniture | 5,00,000 | |
| Total cost of m/c and equipment is | 70,90,000 | |
| Pre-Operative Expenses | 5,00,000 | |
Total Fixed Capital |
(Rs.) |
| Land and building | 3,00,00,000 |
| Plant and machinery | 70,90,000 |
| Pre-operative expenses | 5,00,000 |
| Total | 3,75,90,000 |
Working Capital (Per Month)
Staff and Labour (per month) |
No. |
Salary |
(Rs.) |
| General Manager | 1 | 25,000 | 25,000 |
| Supervisors | 4 | 5,000 | 20,000 |
| Accountant/Clerk | 4 | 5,000 | 20,000 |
| Skilled Workers | 12 | 5,000 | 60,000 |
| Un-skilled Workers | 20 | 3,500 | 70,000 |
| Watchman/Peons | 6 | 3,500 | 21,000 |
| Total | 2,16,000 | ||
| Perquisites @ 15% | 48,000 | ||
| Total | 2,64,000 | ||
Raw Material (per month)
Particulars |
Quantity |
Rate |
Amount (Rs.) |
| Portland (Grey) cement | 60 MT | 4,000 | 2,40,000 |
| White cement | 58 MT | 8,000 | 4,64,000 |
| Sand | 160 MT | 200 | 32,000 |
| Stone/Marble chips | 48 MT | 3,000 | 1,44,000 |
| Mineral colours | 2 MT | 10,000 | 20,000 |
| Total | 900,000 |
Utilities (per month) |
(Rs.) |
|
| Power 30x16x4x25 | LS | 48,000 |
| Water Charges | LS | 5,000 |
| Total | 53,000 | |
Other Contingent Expenses |
(Rs.) |
| Postage and Stationery | 5,000 |
| Telephone | 10,000 |
| Consumable Stores | 10,000 |
| Repair and Maintenance | 18,000 |
| Transport Charges | 10,000 |
| Insurance | 23,000 |
| Sales Expenses, advertisement and publicity | 25,000 |
| Total | 1,01000 |
Total Recurring Cost (per month)
| Staff and Labour | 2,64,000 |
| Raw materials | 9,00,000 |
| Utilities | 53,000 |
| Total | 13,18,000 |
| Total working Capital (on 3 months basis) | 39,54,000 |
Total Capital Investment
| Fixed capital | Rs. 3,75,90,000 |
| Working capital | Rs. 39,54,000 |
| Total | Rs. 4,15,44,000 |
Machinery Utilization
| Efficiency and working hrs. considered for full capacity | Efficiency 80% of the installed capacity of 16 hrs. and 300 days in a year. |
| Time/period of achieving capacity utilization | 6 months from the date of commencement of commercialproduction. |
Financial Analysis
Cost of Production (per year) |
(Rs.) |
| Total recurring cost (per year) | 1,58,16,000 |
| Depreciation on building @5% | 10,00,000 |
| Depreciation on machinery and equipment @10% | 3,90,000 |
| Interest on Capital Investment @12% | 49,85,000 |
| Depreciation on mould, racks, tools, testing equipments @25% | 5,75,000 |
| Depreciation on office equipment and furniture @, 20% | 1,00,000 |
| Total | 2,28,66,000 |
Total Turnover (per annum)
Particulars |
Quantity |
Rate (Rs.) |
Amount (Rs.) |
| Grey mosaic tiles 10" × 10" | 6,00,000 | 18.33/ tiles | 1,10,00,000 |
| Grey mosaic tiles 8" × 8" | 6,00,000 | 16.67 /tiles | 1,00,00,000 |
| Coloured tiles | 4,00,000 | 22.50/ tile | 90,00,000 |
| Total | 3,00,00,000 |
Net Profit (per year)
3,00,00,000 - 2,28,66,000 = 71,34,000 |
Net Profit Ratio
Net profit per year x 100 Turnover per year 71,34,000 × 100 3,00,00,000 23.78% |
Rate of Return
Net Profit per year × 100 Total Investment 71,34,000 × 100 4,15,44,000 17.17% |
Break-even Point
Fixed Cost (per year) |
(Rs) |
| Total Depreciation | 19,65,000 |
| Total Interest | 49,85,000 |
| 40% of Salary and wages | 12,67,000 |
| 40% of other contingent expenses | 4,85,000 |
| Insurance | 2,76,000 |
| Total | 89,78,000 |
B.E.P
Fixed cost × 100 Fixed cost + Profit 89,78,000 x 100 89,78,000 + 71,34,000 55.7% |
Addresses of Machinery and Equipment Suppliers
- M/s. Bhagvati Engg. Works
Nazarbag,
Morvi - 363 691
(Gujarat) - M/s. Bhavani Engg. Works
37, Sunshine Industrial Estate,
Behind Maniar Traders,
Near Ajit Mill Rakhial,
Ahmedabad - 380 023 - M/s. Hydro Engg. Works
K1/116, G.I.D.C., Morvi, (Gujarat) - M/s. Ashok Engg. Works
8/1, Ajit Industrial Estate,
Rakhial, Ahmedabad - 380 023 - M/s. Jay Khodiyar Engg. Works
6, Pruthvi Plot,
Morvi - 363 691, (Gujarat) - M/s. Naveen Engg. Works
K1/102, G.I.D.C.,
Morbi - 363 641, (Gujarat) - M/s. Vishwakarma Engg. Works
Behind Sukhram Nagar,
Navneet Prakashan,
Rajpur - Gomtipur,
Ahmedabad - 380 021
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
