Detailed Project Report (DPR) on ceramic tiles factory

CERAMIC TILES FACTORY
[CODE NO.3232]

     Tiles have been used as surfacing for walls and floors for thousands of years because of their beauty and durability.  They have been produced in most of the countries of the world because of the abundance of the raw materials and the simplicity of the manufacturing technology. These two factors, together with the employment, generating capacity of this labour - intensive industry have attracted the interest of developing countries.

     The term 'ceramic' is normally applied to products made of clay.  Clay is a general name for all earths that form a paste when mixed with appropriate amounts of water and that harden when heated.  Most clays are composed of silica and alumina while kaolins are their purest forms. Wall and floor tiles are  formed by pressing higher grades of clay after blending them with flint, feldspar and talc.
    
     Ceramic tiles are classified under two headings.

     (i)  Unglazed ceramic sets, flag and paving, hearth wall tiles.

     (ii) Glazed ceramic  sets, flay and  paving,  hearth  wall tiles.

->   Unglazed stets, flag and paving, hearth and wall tiles :-

     This heading covers ceramic stets, flags and tiles commonly for paving or for facing walls hearth etc., provided that they unglazed.

     Flags and paving, hearth and wall tiles are thinner in relation to their surface dimensions than are building bricks.

Whereas  bricks  play  an essential part  in  construction  work, forming  the very framework of the building, flags and tiles  are more especially intended for setting in cement on the surface  of existing  wall, etc. They also differ from roofing tiles in  that they  are usually flat and do not need to be pierced or  provided with the nibs or otherwise shaped for interlocking and that  they are designed to be placed side by side without overlapping. Flags are larger than tiles and are usually rectangular; tiles may be of other geometric shapes (hexagonal, Octagonal, etc.). Tiles are mainly used for facing walls, mantelpieces, hearth, floors and paths,  flags are more especially used for paving or flooring  or as hearth slabs.

     In  general  unglazed tile may be defined as a  hard,  dense tile  of  uniform  composition throughout,  deriving  colour  and texture from the materials of which the body is made.

=>   Glazed stets, flags and paving, hearth and wall tiles :-

     This heading covers tiles, flags and stets that have been glazed, frequently after some form of decoration. For the purpose of  this heading, the term "glazing" includes salt glazing  (i.e. spraying  the  goods  with salt during the firing  to  produce  a vitreous  glaze), as well as methods using the  enamels,  glazes, etc.

     Glazed  tiles  may  be  defined  as  a  tile  with  a  fused impervious facial finish composed of ceramic materials, fused  to the  body of the tile which may be  non-vitreous,  semi-vitreous, vitreous or impervious.

     Ceramics industry in India is about 100 year old and has by now formed a sizable industrial base. In fact the industry has been growing at the rate of 10 to 15/- per annum.

     Ceramic arts and crafts are age-old professions in India. With   the  impact  of  modern  science  and  technology,   these traditional   arts  have  grown  into  an  important   industrial occupation for a large number of our people.

     Over  the  years, the ceramic and allied industries  of  our country  have  witnessed great changes, both in the  quality  and quantity  of  products manufactured, and today  these  industries play a vital role in the country's industrial and socio-economic-progress.

COST ESTIMATION

Plant  Capacity                                                                :    1500.00 BOXES/day
land & Building (4000 sq.mtrs)                                    :    Rs. 2.07  Cr
Plant & Machinery                                                           :    Rs. 3.00  Cr
Working Capital for 2 Months                                       :    Rs. 1.85  Cr
Total Capital Investment                                                :    Rs. 7.07  Cr
Rate of Return                                                                 :    25%
Break Even Point                                                            :    62%


INTRODUCTION                                            
PROPERTIES                                            
USES AND APPLICATIONS                                    
B.I.S. SPECIFICATION                                        
TEST FOR WARPAGE                                        
MARKET SURVEY                                            
BEST TILE MANUFACTURERS AND RETAILERS                        
TOP 10 TILES COMPANIES IN INDIA 2015-16                        
LIST OF TOP 10 TILES COMPANIES IN INDIA                        
PRESENT MANUFACTURERS/SUPPLIERS/EXPORTER                
RAW MATERIALS                                            
CLAYS                                                
FLINT                                                    
PROPERTIES                                            
FELDSPAR                                                
GRADES                                                
USES                                                    
RAW MATERIAL POSITION                                    
QUARTZ :                                                
FORMULATION FOR PREPARATION OF GLAZES                        
COMPOSITION OF ONE TILE (FOR GLAZED TILE)                    
MANUFACTURING PROCESS                                    
RAW MIX PREPARATION                                    
DRYING OF RAW MIX                                        
PRESSING AND DRYING                                    
INSPECTION SORTING AND PACKING SYSTEMS                    
PROCESS FLOW SHEET                                    
PLANT LAYOUT                                            
PRINCIPLES OF PLANT LAYOUT                                
PLANT LOCATION FACTORS                                    
EXPLANATION OF TERMS USED                                
IN THE PROJECT REPORT                                    
PROJECT IMPLEMENTATION SCHEDULES                        
SUPPLIERS OF PLANT & MACHINERY                            
ROLLER KILN                                            
JAW CRUSHER                                            
TUNNEL DRYER                                            
SUPPLIERS OF RAW MATERIALS                                
CHINA CLAY                                            
PIGMENT                                                
PRINTING INK                                            
       
                            
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET