Detailed Project Report (DPR) on Acrylic Bath Tub and Shower Tray

ACRYLIC BATH TUB AND SHOWER TRAY

[EIRI/EDPR/1446] J.C. 227(INR), 228(US$)

INTRODUCTION

A bathtub, bath or tub (informal) is a large container for holding water in which a person may bathe. Most modern bathtubs are made of acrylic or fiberglass, but alternatives are available in enamel on steel or cast iron; occasionally, waterproof finished wood. A bathtub is usually placed in a bathroom either as a stand-alone fixture or in conjunction with a shower.

Modern bathtubs have overflow and waste drains and may have taps mounted on them. They are usually built-in, but may be free-standing or sometimes sunken. Until recently, most bathtubs were roughly rectangular in shape but with the advent of acrylic thermoformed baths, more shapes are becoming available. Bathtubs are commonly white in colour although many other colours can be found. The process for enamelling cast iron bathtubs was invented by the Scottish-born American David Dunbar Buick.

Two main styles of bathtub are common:

Western style bathtubs in which the bather lies down. These baths are typically shallow and long. 

Eastern style bathtubs in which the bather stands up. These are known as ofuro in Japan and are typically short and deep. 

History of bathtubs and bathing:

Documented early plumbing systems for bathing go back as far as around 3300 BC with the discovery of copper water pipes beneath a palace in the Indus Valley Civilization of ancient India; see sanitation of the Indus Valley Civilization. Evidence of the earliest surviving personal sized bath tub was found on the Isle of Crete where a 5-foot (1.5 m) long pedestal tub was found built from hardened pottery.

The clawfoot tub, which reached the apex of its popularity in the late 19th century, had its origins in the mid 18th century, where the ball and claw design originated in Holland, possibly artistically inspired by the Chinese motif of a dragon holding a precious stone. 

The design spread to England where it found much popularity among the aristocracy, just as bathing was becoming increasingly fashionable. Early bathtubs in England tended to be made of cast iron, or even tin and copper with a face of paint applied that tended to peel with time. 

The Scottish-born entrepreneur David Buick invented a process for bonding porcelain enamel to cast iron in the 1880s while working for the Alexander Manufacturing Company in Detroit. The company, as well as others including Kohler Company and J. L. Mott Iron Works, began successfully marketing porcelain enameled cast-iron bathtubs, a process that remains broadly the same to this day. Far from the ornate feet and luxury most associated with clawfoot tubs, an early Kohler example was advertised as a "horse trough/hog scalder, when furnished with four legs will serve as a bathtub." The item's use as hog scalder was considered a more important marketing point than its ability to function as a bathtub. 

In the latter half of the 20th century, the once popular clawfoot tub morphed into a built-in tub with a small apron front. This enclosed style afforded easier maintenance and, with the emergence of colored sanitary ware, more design options for the homeowner. The Crane Company introduced colored bathroom fixtures to the US market in 1928, and slowly this influx of design options and easier cleaning and care led to the near demise of clawfoot-style tubs.

Claw foot tub:

The clawfoot tub or claw-foot tub was considered a luxury item in the late 19th century, originally made from cast iron and lined with porcelain. Modern technology has contributed to a drop in the price of clawfoot tubs, which may now be made of fiberglass, acrylic or other modern materials. Clawfoot tubs usually require more water than a standard bathtub, because generally they are larger. While true antique clawfoot tubs are still considered collectible items, new reproduction clawfoot tubs are chosen by remodellers and new home builders and much like the Western-style bathtubs, clawfoot tubs can also sometimes include shower heads.

COST ESTIMATION

Plant Capacity                                              140.00 Nos./Day
Land & Building (5000 Sq.Mtr)                  Rs. 8.88 Cr
Plant & Machinery                                       Rs. 1.06 Cr.         
W.C. for 2 Months                                       Rs. 2.66 Cr.           
Total Capital Investment                             Rs. 13.26Cr..              
Rate of Return                                             50%   
Break Even Point                                        33%

CONTENTS

INTRODUCTION

HOW TO MAKE A BATHTUB

PROCESS FOR MANUFACTURING LAMINATED BATH TUB OR SHOWER TRAY

POLY METHYL METHACRYLATE CASTING

FLOW SHEET

FORMULATION OF ACRYLIC BATH TUB AND SHOWER TRAY

OTHER RELATED INFORMATIONS

SHOWER TRAY

METHOD FOR MANUFACTURING A PREFABRICATED SHOWER MODULE

MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY

MANUFACTURERS/SUPPLIERS OF RAW MATERIALS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)