Fly Ash Bricks

 

1. Name of the Product: -        Fly Ash Bricks

2. NIC Code: -               26931

3. Product Code: -                   29114

4. Production capacity: -         Quantity:    75 lakh bricks / year
Value:         Rs.4.125 crore

5. Month & year of preparation: -    February, 2011

 

6. PREPARED BY: -Glass & Ceramic Division
Micro, Small & Medium Enterprises - Development Institute

                     Ministry of MSME, Govt. of India

                      Bamunimaidam, Guwahati - 781 021 (Assam)

E-mail: dcdi-guwahati@dcmsme.gov.in    
Phone: 0361- 2550083, 2550073      
http//www.msmedi-guwahati.gov.in  
Fax: 0361-2550052    

 

                                       
Introduction of the Product
Fly Ash bricks can be extensively used in all building constructional activities similar to that of common burnt clay bricks. These bricks are comparatively lighter in weight and stronger than common clay bricks. The main raw materials fly ash is generated by thermal power stations in big quantity.

Plant capacity per year: - 1.0 crore bricks

 

Market & Demand Aspects

There is good demand for fly ash bricks. The awareness among the people is required and also same time the government has to give some special incentives for these types of activities. The technologies are eco friendly, reduces solid waste and dust in the nature. Compared to hollow brick and clay brick the cost is reasonable.  Construction of wall with these bricks is very easy and cost effective. Technology is indigenously available.

Raw materials: - Fly ash, gypsum, lime and stone dust.

Manufacturing Process and Source of Technology
Required raw material like Fly ash, Gypsum, lime and stone dust have to be mixed as per the ratio. The mixed product can be placed into automatic locking machine. This to be kept in moulds for manufacturing of automatic locking fly ash bricks. After the processing the bricks have to be dried after applying required water on the bricks. After two days drying the bricks can be sold. It is simple manufacturing process.
This technology can be availed from Central Building Research Institute, Roorke (UP).

Basis of Project Selection:-
An entrepreneur is said to be an opportunity seeker. For the potential entrepreneur his/her first task is to identify, explore and then select the business opportunity.
Presumption:-

  • The proposed project envisaged to manufacture 25,000 bricks per day.
  • The unit will run on single shift basis per day and 300 working days in a year at 75% capacity utilization.
  • To achieve production capacity, one month trial production is required.
  • The salary & wages is considered on the basis of prevailing market rate.
  • The break-even point is calculated on full capacity utilization basis.
  • Interest on total capital investment has been taken into account @15%.
  • 25% of the project cost is to be considered as margin money.
  • Cost of machinery & equipment, raw material indicated in the project are to be revised according to the prevailing market rates at the time of actual implementation.

Utilities: - 40 HP power

FINANCIAL ASPECTS:-
Fixed Capital:-
I. Land & Building
(a) Land: 3000 sqm                                                                         3,00,000/-
(b) Built-up area:
Work shed: 75 sqm                                                                          1,50,000/-
Cemented Platform: 10 m x 30 m                                                     1,00,000/-
Bore well, Motor, Water sprinkling system                                               1,50,000/-
Storage shed for Gypsum, Lime, etc.                                                         1,00,000/-                                                                                                           8,00,000/-
II. Machinery and equipment


 Sl. No.

Description

Qty.

Value (Rs.)

1

Mixer with 15 HP motor and other accessories

2

2,00,000/-

 

2

Hydraulic automatic brick making machine (cap.30 T) with 15 HP motor and other accessories

2

4,00,000/-

 

3

Belt conveyor run by 3 HP motor

1

  80,000/-

 

4

Water pump  1.5 HP   

1

  90,000/-

 

5

Pallet Trolley

6

60,000/-

6

Brick testing machine

1

1,00,000/-

7

Misc. hand tools, moulds, weigh batcher etc.

 

  80,000/-

8

Furniture & fixtures

 

  80,000/-

9

Electrification, installation etc.

 

1,00,000/-

 

 

 

11,90,000/-

III. Pre-operative expenses  50,000/-
Total Fixed Capital:   (8,00,000/- + 11,90,000/- + 50,000/-)                   20,40,000/-         
Working Capital (per month)
(1) Salary & Wages:


Personnel

Nos.

Salary (Rs)

Total (Rs)

 

Manager

1

7,500/-

7,500/-

 

Supervisor

1

5,000/-

5,000/-

 

Clerk cum typist

1

  3,000/-

3,000/-

 

Skilled Workers

4

3,000/-

12,000/-

 

Unskilled Workers

10

2,000/-

20,000/-

 

Peon / Watchman

1

2,000/-

2,000/-

 

+ 15% Perquisites

7,500/-

 

57,000/-

(2) Raw Material:

Particulars

Qty. (MT)

Rate (Rs)

Amount (Rs)

 

Fly ash

1,300

1,200/-

15,60,000/-

 

Gypsum

300

2,000/-

  6,00,000/-

 

Lime

200

3,000/-

6,00,000/-

 

Stone dust

100

  1,000/-

  1,00,000/-

 

 

 

28,60,000/-

 

Utilities:                                                                                              30,000/-

Other misc. recurring expenses


Postage & Stationery

1,000/-

Repair & Maintenance

5,000/-

Transport charges

5,000/-

Misc. expenditure

2,000/-

 

13,000/-

Total Working Capital per month:


Raw material

28,60,000/-

 

Salary & Wages

57,000/-

 

Utilities

30,000/-

 

Other misc. recurring expenses

13,000/-

 

 

29,60,000/-

 

 

 

 

Working Capital for 3 months

88,80,000/-

 

 

 

Total Capital Investment:


Fixed Capital

 20,40,000/-

Working Capital (for 3 months)

 88,80,000/-

 

1,09,20,000/-

Say,

1,10,00,000/-

FINANCIAL ANALYSIS

Cost of Production (P.A)


Total recurring cost per year

3,43,20,000/-

Depreciation on building @5%

25,000/-

Depreciation on m/c & equipment @10%

1,19,000/-

Interest on capital investment @18%

19,80,000/-

 

3,64,44,000/-

Turnover per year

Item

Qty. (nos.)

Rate (Rs.)

Value (Rs.)

Fly ash bricks

75 lakh

5.50/- each

4,12,50,000/-

Net Profit (per year)

48,06,000/-

Profit ratio on Sales

11.65 %

Rate of Return

43.69 %

Break Even Analysis (B.E.P)

 

(a) Fixed Cost: -

 

  • Total Depreciation        

1,44,000/-

 

  • Interest on capital investment

19,80,000/-

 

  • 40% of the salary & wages

2,73,600/-

 

  • 40% of the utilities

1,44,000/-

 

  • 40% of the other contingent expenses

62,400/-

 

 

26,04,000/-

 

(b) Net profit per year

 

 

 

 

 

48,06,000/-

 

   
B.E.P = 35.14 %

List of Suppliers Address

Plant & Machineries

M/s. Susanji Udyog (P) Ltd, C-47, Indl. Estate, Sanat Nagar, Hyderabad – 18
M/s. Bharat Boilers, Indl. Estate, Eluru, Dist. West Godavari, Andra Pradesh
M/s. Pratap Industries, P.O. Enkipadu, Vijayawada – 521 108 (AP)
M/s.Jayem Manufacturing Company, C-99, Sector – 4, Noida – 201 301 (UP)

Raw Materials

Fly ash                           : Available at thermal power stations
Gypsum                         : Availability in the neighboring country (Bhutan)
Hydrated Lime & Sand  : Locally available

Resource Centre of Technology: This technology can be availed from MSME-DI, Guwahati at free of cost.
List of units set up by using this project profile: Nil

 

 

 

Plaster of Paris

 

1. Name of the Product: -                                     Plaster of Paris

2. NIC Code: -                                                      26945

3. Product Code: -                                                          21304

4. Production capacity: -                            Quantity:     900 MT / year
Value:         Rs.6.18 lakh

5. Month & year of preparation: -                        February, 2011

 

6. PREPARED BY: -                    Glass & Ceramic Division
Micro, Small & Medium Enterprises - Development Institute

Ministry of MSME, Govt. of India

Bamunimaidam, Guwahati - 781 021 (Assam)

E-mail: dcdi-guwahati@dcmsme.gov.in           Phone: 0361- 2550083, 2550073                                     http//www.msmedi-guwahati.gov.in                      Fax: 0361-2550052

 

Introduction of the Product
Plaster of Paris which is calcium sulphate with half molecule of water of crystallization (CaSo4.½ H2 o) and hygroscopic characteristics obtained by duly calcined the raw material i.e. Gypsum (CaSo4 2H2o). It possesses outstanding property of setting and subsequent hardening when mixed with water.
Plaster of Paris is extensively used in ceramic industry for preparation models and moulds. It is also used as main raw material in the manufacture of toys & statues, chalk crayons, gypsum plaster boards, and decorative picture frames besides wide range of applications in the interior decoration of buildings and other establishments.
Plant capacity per year: - 1,200 MT

Market & Demand Aspects

As there is growing building construction activity thus requiring large quantities of Plaster of Paris. Demand for the product is also increasing in making mould & models. There is also considerable demand for the plaster of Paris arising from a large number of studies and establishments engaged in making statutes and interior decoration as well as decorative plaster boards for false ceiling etc, which is in turn creating a good scope for setting up new units in this line of manufacture.
Raw material: - Gypsum
Manufacturing Process and Source of Technology
Gypsum is the basic raw material required to manufacture Plaster of Paris. These are cleaned and washed for removal of impurities, dried in sunlight and then pulverized. Gypsum powders are calcined in a rotary drum calcinatory using light diesel oil/firewood/coal as fuel. The low pressure burner is sufficient to reach the calcinations temp. ranges from 1600C to 1800C. The process of calcinations is done over a period of about 2 hours, so that 1½ molecule of water is removed to obtain the required properties. After cooling the calcined powder is passed through 150 mesh and packed in airtight polythene lined gunny bags.
This technology is locally available and also can be availed from Central Building Research Institute, Roorke (UP).
Basis of Project Selection:-
An entrepreneur is said to be an opportunity seeker. For the potential entrepreneur his/her first task is to identify, explore and then select the business opportunity.
Presumption:-

  • The proposed project envisaged to manufacture 3 MT per day.
  • The unit will run on single shift basis per day and 300 working days per year at 75% capacity utilization.
  • To achieve production capacity, 15 days trial production is required.
  • The salary & wages is considered on the basis of prevailing market rate.
  • The break-even point is calculated on full capacity utilization basis.
  • Interest on total capital investment has been taken into account @15%.
  • 25% of the project cost is to be considered as margin money.
  • Cost of machinery & equipment, raw material indicated in the project are to be revised according to the prevailing market rates at the time of actual implementation.

Utilities:  10 HP Power
FINANCIAL ASPECTS

Fixed Capital
Land & Building                                                                              Value (Rs.)
a) Land: about 1 acre                                                                         3,00,000=00
b) Building:
Office & Stores, etc- 100 sq. mtrs                                                   1,50,000=00
Work shed -150 Sq. mtrs.                                                              1,50,000=00
6,00,000=00
Machinery and Equipment

Sl.No.

Description

Qty.

Value (Rs.)

1

Attribution disc. Pulverisor 1/2 MT/hr with 7 HP motor & accessories

1

2,50,000=00

2

Rotary cylindrical drum calcinor (fabricated) size 2.5 mtr. (Length) x 2 mtr. (dia), capacity 4 MT / charge mounted on a fuel fired roasting oven made of common bricks provided with firing grates on either side of the oven and an exhaust chimney therewith and complete with a vapour outlet, thermometer, motor, gear and accessories.

1

3,50,000=00

3

Burners & other misc. equipments etc.

LS

1,00,000=00

4

Office equipment, furniture and fixtures

LS

1,00,000=00

 

Total

 

8,00,000=00

Pre-operative expenses                                                                        50,000=00
Total Fixed Capital: (6,00,000 + 8,00,000 + 50,000)                    14,50,000=00

Working capital (per month):
Salary & Wages


Personnel

Nos.

Salary (Rs)

Total (Rs)

Manager cum Supervisor

1

7500

7,500=00

Chemist

1

4000

4,000=00

Clerk cum Typist / Store Keeper

1

3000

3,000=00

Skilled Workers

2

3000

6,000=00

Unskilled Workers

4

2000

8,000=00

Peon / Watchman

1

2000

2,000=00

+ 15% Perquisites

5,000=00

 

35,500=00

Raw Material

Particulars

Qty.

Rate (Rs.) / MT

Value (Rs.)

Gypsum

100 MT

2,000/-

2,00,000=00

Woven bags for packing

LS

-

1,00,000=00

 

 

 

3,00,000=00

Utilities:                                                                                                15,000=00

Other misc. recurring expenses


Postage & Stationery

500=00

Repair & Maintenance

5,000=00

Transport charges

5,000=00

Misc. expenditure

5,000=00

 

15,500=00

Total Working Capital (per month):


Raw materials

3,00,000=00

Salary & Wages

35,500=00

Utilities

15,000=00

Other misc. recurring expenses

15,500=00

 

3,66,000=00

Working Capital (for 3 months)

10,98,000=00

Total Capital Investment:


Fixed Capital

14,50,000=00

Working Capital (for 3 months)

10,98,000=00

 

25,48,000=00

FINANCIAL ANALYSIS

Cost of Production (per year)


Total recurring cost per year

43,92,000=00

Depreciation on building @5%

15,000=00

Depreciation on m/c & equipment @10%

80,000=00

Interest on total Investment @15%

3,82,000=00

 

48,69,000=00

Annual Turnover

Item

Qty.

Rate (Rs.)

Value (Rs.)

Plaster of Paris

900 MT

6,500/- MT

58,50,000=00

Net Profit (per year)

9,81,000=00

Profit ratio on Sales

16.76%

Rate of return

38.50%

Break Even Analysis (B.E.P)

(a) Fixed Cost

 

  • Depreciation

95,000=00

  • Interest

3,82,000=00

  • 40% of salary & wages

1,70,400=00

  • 40% of other contingent expenses

74,400=00

 

7,21,800=00

(b) Net profit per year

9,81,000=00

B.E.P = 42.40%

List of Suppliers Address
Plant & Machineries
1. M/s. Amic Industries, 10, BT Road, Kolkata-36
2. M/s. Durgapur Engineering Co. Ltd. Marshal House, 33/1, Netaji Subhas Road,
Kolkata-700001
3. M/s. Wesman Engineers Co. (P) Ltd. 1/2, Allerby Road, Kolkata-20
4. M/s. Continental Thermal Engineers, 806, II Stage, 4th Main, A Block,
Rajajinagar, Bangalore-10
Raw Materials
1. M/s. Mysore Minerals, 39, MG Road, Bangalore-1
2. M/s. Shri Venkateswara Products, Vadakku Venganallur, Opp. Raju's College,
3. M/s. Andhra Pradesh Mining Corporation, 6-3-672, Punjagutta, Hyderabad-82
4. M/s. Madras Mineral Suppliers No.2/10, Toovipuram,Tuticorin-3 (Tamil Nadu)
5, Anderson, Habibulla Avenue, Chennai-4
6. Gypsum: Availability in the neighboring country (Bhutan)

Resource Centre of Technology: Manufacture of Plaster of Paris does not require very high technology. This technology can be availed from MSME-DI, Guwahati at free of cost.
List of units set up by using this project profile: Nil

 







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