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
Activity |
Period(in months) |
| Possession of land | 2 |
| Construction of building | 5 |
| Purchase of machinery | 8 |
| Installation of machinery | 12 |
| 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
Production Capacity (per annum)
| Quantity | : 130 MT |
| Value |
| Motive Power | 48H. P. |
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
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 |
Machinery and Equipments
Production Unit Description |
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 | |
| Pre-operative Expenses | 80000 |
Total Fixed Capital
(Rs.) |
|
| Land | 4000000 |
| Building | 3200000 |
| Plant and Machinery | 3883500 |
| Preliminary Expenses | 80000 |
| Total | 11163500 |
Working Capital (Per Month)
Salary and Wages
Designation |
Nos. |
Salary / (Rs.) |
(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 | 65000 | 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 | ||
Raw Materials (per month)
Description |
Quantity |
Qty |
Rate (Rs.) |
| Bone ash | 9 MT | 16000 | 144000 |
| China clay | 2.4 MT | 3000 | 7200 |
| Felspar | 6.1 MT | 1500 | 9150 |
| Frit | 1 MT | 19000 | 190000 |
| Plaster of Paris | 2 MT | 2200 | 4400 |
| Fire clay | 3.0 MT | 2500 | 7500 |
| Sillimanite | 0.18 MT | 1500 | 900 |
| Decoration paper | L.S. | 15000 | 15000 |
| Packing material | L.S | 15000 | 15000 |
| Other Contingent expenses | L.S | 5000 | 10000 |
| Total | 232150 | ||
Utilities
Value (Rs.) |
||
| Power 48 HP | 43200 | |
| Diesel L.D.O. 12 KL @ Rs. 35,000 per K.L. | 420000 | |
| Total | 463200 | |
Other Contingent Expenses (per month) |
(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 |
Total Working Capital (per month)
(Rs.) |
|
| Raw Materials | 232150 |
| Salaries and Wages | 839300 |
| Utilities | 463200 |
| Other Contingent expenses | 33500 |
| Total | 1568150 |
| Other Contingent expenses | 3136300 |
Total Capital Investment
| Fixed capital | 11163500 |
| Working Capital for 2 months | 3136300 |
| Total | 14299800 |
Financial Analysis
Cost of Production (per annum) |
Value (Rs. lakhs) |
| Total recurring expenditure | 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 |
Turn-over (per year)
Items |
Qty. |
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 | ||
Net Profit (per annum)
| Turnover – Cost of Production | |
| 22550000 – 21280124 | |
| 1269876 |
Net Profit Ratio
Net Profit per annum x 100 Turn Over per annum |
||
| 5.63 |
Rate of Return
Net profit per year × 100 Total Capital Investment |
||
8.88 |
Break-even Point
Fixed Cost |
(Rs) |
| Depreciation on Building | 160000 |
| Depreciation on Plant and Machinery and Furnace | 418350 |
| Depreciation on Furniture and Fixture | 25000 |
| Interest on Borrowings @ 13% | 1858974 |
| 40% of Salary and Wages | 4028640 |
| 40% of Other Contingent Expenses | 13400 |
| Insurance | 30000 |
| Total | 6534364 |
B.E.P
Fixed Cost × 100 Fixed Cost + Profit |
||
6534364 x 100 6534364 + 1269876 |
||
83.72% |
Addresses of Machinery Suppliers
- M/s. Shiv Industries
206, Veena Dalvi Industrial Estate,
Oshiwara, Jogeshwari (W),
Mumbai - 400 102v - M/s. Erich Magnetics
176/6B/10, Old Tijab Mill,
Bholanath Nagar, Shahadra,
Delhi - 110 032 - M/s. Amic Industries Private Limited
10, B.T. Road, Kolkata - 700 056 - M/s. Eleind Engineering Private Limited,
D-20/2, Okhla Industrial Area,
Phase - II, New Delhi - 110 020 - M/s. Alam Ji Plaster Udyog
Ramji Ki Gol,
Tehsil Gurmalani,
Barmer (Rajasthan) - M/s. Ceekay Plasters and Chemicals,
64, Industrial Area, Bikaner
(Rajasthan) - M/s. Tower Minerals
Post Office- Malpur,
Zenipur, (Rajasthan) - M/s. Mahavir Minerals Private Limited
Jautani Bazar,
Ajmer, (Rajasthan)
Raw Material Suppliers
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
