Detailed Project Report (DPR) on CP Bath Fittings

CP BATH FITTINGS

[EIRI/EDPR/4275] J.C.: 2456XL

INTRODUCTION

A bath fitting is a faucet device used for delivering water from a plumbing system. These faucets provide water control to the user in Bathing & Washbasin areas. With the help of these fixtures we can control flow of water, pressure of water and temperature of water while bathing & hand or face washing, brushing shaving etc. Certain technologies like quarter turn fittings, Single levers, Thermostatic fittings enhance the control & comfort of water usage.

It can consist of the following components: spout, handle(s), lift rod, cartridge, aerator, mixing chamber, and water inlets. When the handle is turned on, the valve opens and controls the water flow adjustment under any water or temperature condition. The faucet body is usually made of brass, though die-cast zinc and chrome-plated plastic are also used. 

The majority of residential faucets are single or dual-control cartridge faucets. Some single-control types use a metal or plastic core, which operates vertically. Others use a metal ball, with spring-loaded rubber seals recessed into the faucet body. The less expensive dual-control faucets contain nylon cartridges with rubber seals. Some faucets have a ceramic-disc cartridge that is much more durable. 

Faucets must comply with water conservation laws. In the United States, bath basin faucets are now limited to 2 gal (7.6 L) of water per minute, while tub and shower faucets are limited to 2.5 gal (9.5 L).

Different Types of Bathroom Fittings

Decorating your bathroom with different types of bathroom fittings is as important as decorating rest of your home. It speaks a volume about your personality. Looks are as much importance as the functional side of your bathroom. Whether you have renovated your home recently or bought a new home, after getting everything sorted out, do not try to overlook the importance of bathroom fittings that can provide your bathroom with a finished plush look. Nowadays assorted range of bathroom fittings are available that can suit any type of budget. Let us look at some of the available options:

Types and Styles of Taps

Taps are generally available in a wide variety of materials such as chrome, brass, stainless steel, gold and nickel. The most commonly used tap styles are crosshead and lever taps. The various types of taps include pedestal taps, wall mounted taps, double and single lever taps, etc.

Types of Bathroom Taps

Pillar Taps

Used on washbasins or counters. Has a vertical inlet. Combinations of two taps desired of both hot & cold water required. It is very effective in low water pressure conditions and also popular in areas of moderate climate.

This style is the most traditional design and it will fit classic and contemporary bathrooms alike. It’s also the easiest tap to install. Pillar taps are meant for baths and basins with two tap holes. The fixture has a pair of separate pillars for hot and cold water. Pillar taps are possibly the most common style of tap (particularly in the UK). They are individual taps that have their own valves to control the flow of water and fit into bath and basins that have two tap holes, one for the hot tap and one for the cold tap.

Bib Tap

Bib tap is a single faucet installed on wall having horizontal inlet; it can either give hot or cold water. Generally used as combination of two taps for hot & cold. It is installed at a height of 1145 mm from the floor in the bathing area. Long bib is used in bathing area & short bib near water closet. It is very effective in Indian conditions of low pressure & water scarcity.

Freestanding Tap

This tap design rises up from the worktop or the floor. It’s often used in a traditional bathroom but could also work in a contemporary bathroom. Freestanding tap is best for roll-top baths as well as countertop basins.

Deck Tap

This tap design features two handles with a single spout, The deck taps are smaller than freestanding or mixer tap and sits very low and flat along the rim of the bath.

Deck taps have two separate tap handles but the water will come through a single spout. The difference between Monobloc and deck taps is that deck taps are smaller and sit low and flat along the rim of the bath. Deck taps tend to create a more traditional but simple look for a bathroom but require a high hot and cold water pressure due to the fact that it is a mixer tap. Deck mounted taps are attached to the bath or basin using tap holes that have been drilled into the rim. They are the most common type of taps as they offer the easiest access for plumbing and pipes to lead the water into the tub or basin.

Monobloc Tap

This tap style dispenses both cold and hot water. The taps are typically curved or straight depending on the handle type. This design is perfect for minimalist and contemporary bathrooms. Monobloc taps can be fitted alongside a variety of different handles, including levers and capstans (more of which will be discussed further in the guide). Taps of this nature are known as ‘mixer’ taps.

COST ESTIMATION

Plant Capacity            600 Pieces/Day

Land & Building (3475 sq.mt.)    Rs. 4.37 Cr

Plant & Machinery                    Rs. 1.05 Cr

Working Capital for 3 Months    Rs. 1.99 Cr

Total Capital Investment          Rs. 7.68 Cr

Rate of Return                          31%

Break Even Point                      59%

CONTENTS

INTRODUCTION

TYPES AND STYLES OF TAPS

TYPES OF BATHROOM TAPS

PILLAR TAPS

BIB TAP

FREESTANDING TAP

DECK TAP

MONOBLOC TAP

MIXER TAP

SHOWER MIXER TAP

WALL MOUNTED TAPS

FLOOR MOUNTED TAPS

BATH FILLER TAPS

INTEGRATED OVERFLOW TAPS

BATHROOM TAP HANDLE TYPES

SINGLE LEVER BASIN MIXER

BASIN MIXER

BIDET MIXER

WALL MIXER

BATHROOM SET

DIVERTER

SPOUT

TYPES OF SHOWER HEADS

TYPES OF TOWEL RAILS

HOT WATER ENHANCEMENTS

MARKET OVERVIEW

RAISING THE BAR

AVENUES OF GROWTH

NEW ENTRIES

BATH-FITTING MARKET POISED FOR BIG GROWTH

TOP BATHROOM FITTINGS BRANDS IN INDIA

TOP BATHROOM FITTINGS BRANDS IN INDIA

BATHROOM FITTINGS & SANITARY WARE MARKET

COMPLETE BATHROOM SOLUTIONS:

WATER CONSERVATION TECHNOLOGY:

INCREASING PRESENCE OF FOREIGN PLAYERS:

RISE IN PREMIUM SEGMENT PRODUCTS:

GLOBAL EXPORT MARKET

BIS SPECIFICATION

MANUFACTURING PROCESS STEPS & PROCESS FLOW SCHEMATIC

CHECKING OF RAW MATERIALS

BODY MAKING

DIE CASTING

TYPE OF DIE CASTING PROCESSES

ADVANTAGES OF DIE CASTING PARTS

DURABILITY:

MASS PRODUCTION AT HIGH SPEED:

THINNER WALL CASTINGS:

CASTING WITH INSERTS:

FORGING

ADVANTAGES AND DISADVANTAGES

MACHINING

LEACHING

POLISHING

CHROMO PLATING (ELECTROPLATING)

ASSEMBLING

TESTING

PRESSURE TESTING

STRENGTH TEST

PROCESS FLOW CHART

PLANT & MACHINERY SUPPLIER

DIE CASTING MACHINES

GRAVITY DIE CASTING MACHINE

MELTING FURNACE

ELECTROPLATING PLANT

POLISHING MACHINE

SAND BLASTING MACHINE

FORGING PRESSES

BENCH GRINDER

DRILLING MACHINE

CNC MACHINES, CNC MACHINE TOOLS & LATHES

MILLING MACHINE

CNC LATHE MACHINE

POWER HACSAW

GRINDING MACHINE

EOT CRANES

DG SETS

POWER TRANSFORMERS

COOLING TOWER

ETP PLANTS

MEASURING AND TESTING INSTRUMENTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

PLATFORM WEIGHING MACHINE

POWDER COATING PLANTS

ANODIZING PLANTS

RAW MATERIALS SUPPLIERS

BRASS RODS

BRASS PIPE

BRASS SHEETS

PLANT LAYOUT REQUIREMENTS

PLANT LOCATION FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

WASTE DISPOSAL:

LABOR:

SITE CHARACTERISTICS:

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WASTE WATER

WASTE

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

GREEN BUILDING CONCEPT

THESE INCLUDE:

THERE ARE A NUMBER OF WAYS TO MAKE A BUILDING GREEN.

THESE INCLUDE:

GREEN MANUFACTURING:

SOLAR POWER

RAIN WATER HARVESTING

DOMESTIC USE

AGRICULTURE

INDUSTRY

TECHNOLOGIES

SYSTEM SETUP

RAINWATER HARVESTING BY SOLAR POWER PANELS

OTHER INNOVATIONS

ZERO WASTAGE

BENEFITS PROPOSED BY ADVOCATES INCLUDE:

SAVING MONEY

FASTER PROGRESS

IMPROVED MATERIAL FLOWS

LABOUR SKILL DEVELOPMENT PROGRAM

OVERVIEW

CORE FUNCTIONS

LINE MINISTRIES

SANITARYWARE TESTING LABORATORY/R&D/WAREHOUSE

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

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)