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 |
| Production Capacity: Qty. | 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
Activity |
Period(in months) |
| Time required for preparation of project report | 1 |
| Selection of site | ½ |
| Registration of SSI | ½ |
| Availability of finance | 1½ |
| Construction of building | 5 |
| Machinery procurement and erection | 3 |
| Raw materials procurement | 1 |
| Recruitment of labour | 1 |
| 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 | 242130 |
| 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. |
| Motive Power | 85HP. |
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
Land and Building |
|
| Land 2500 sq. mtrs. @ Rs. 2000 sq. mts | 5000000 |
| 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 |
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 | ||
| Pre-operative Expenses | 120000 | ||
Total Fixed Capital |
(Rs.) |
| Land and building | 9400000 |
| Plant and machinery | 4405700 |
| Pre-operative expenses | 120000 |
| Total | 13925700 |
Working Capital (per month)
Personnel (per month)
Designation |
Nos. |
Salary (Rs.) |
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 | ||
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 | ||
Utilities (per month) |
(Rs.) |
|
| Power | 70HP | 63000 |
| L.D.O./ Kerosenes | L.D.O./ Kerosenes | 735000 |
| Total | 798000 | |
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 |
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 |
Total Capital Investment
| Fixed capital | 18331400 |
| Working capital | 2923440 |
| Total | 21254840 |
Financial Analysis
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 |
Turnover (per year)
For calculation purposes, it is assumed that the unit shall manufacture flat toughened glass of size 5 to 6 mm. the average sale prices of which is taken at Rs.70 per sq.ft. total 3,84,000 sq.ft. (per year), after allowing rejection of 24,000 sq.ft., the saleable quantity will be 3,60,000 sq.ft., @ Rs.60/- per sq.ft.
| Item | (Rs.) |
| Chemical Porcelain ware 1200MT @ Rs. 20000 / MT | 24000000 |
Profitability
| Sales – cost of production | |
| 21368469-24000000 | |
| 2631531 |
Profit on Sales
2631531x100 24000000 10.96 |
Rate of Return
2631531 x 100 21254840 12.38 |
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
- M/s. Lokmanya Eng. Works
26/Bharatkhand Cotton Mill
Compound, Narod Road,
Ahmedabad. - M/s. Jivanlal Shiv Panchal
Opp. Old Civil Hospital,
Gheekanta Road, Ahmedabad - M/s. Modern Engg. and Fabrication Works
Behind Kubeshwar Mahadev,
Saijpur (Ambavadi),
Naroda Road, Ahmedabad - M/s. Sharma Kiln Technology
Kothawala Flat, Harekrishna
Complex, Near Paldi,
Ahmedabad - 380007
Raw Material Suppliers
- M/s. Gujarat Minerals
Opp. S. T. Stand, Vejalpur - 363
721, Tal. Kalol,
Dist. Panchmahal (Gujarat) - M/s. Ashok Minerals and Grinding Ind.
F-237-238, MIA, Madri, Udaipur,
(Rajasthan) - M/s. Sompura Mines and Mineral Suppliers
Ravishankar Pyrnashankar
Road, Thangadh, Bikaner,
(Rajasthan.)
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
