Thursday, 10 November 2011

Start a Cement concrete tiles and paving blocks Making Plant


(197) Start a Cement concrete tiles and paving blocks   Plant


         


1) Product & Applications
Cement concrete tiles and paving blocks are precast solid products made out of cement concrete. The product can be made in various shapes and sizes as per the requirement. These blocks are generally interlocking type and are mostly adopted for paving open surface to facilitate easy movement and for convenience in walking. Paving the walk ways with such blocks besides providing convenience of walking adds to the beautification of the area.
2) Industry Profile and Market Assessment
Construction industry and development of infrastructure facilities are a priority at present and government has laid a lot of emphasis on the same. Providing housing to one and all is also a priority. Besides government initiative in construction of houses private sector builders are also very actively involved in different housing projects. All these activities call for landscaping provision of garden path for the area and provision for paved foot paths. Even otherwise pavement, Bus stops carriage ways also require paved paths. All these necessarily need cement concrete blocks/Tiles. Such concrete blocks are also used inside factories and residential complexes for paving the approach roads. This paving prevents water accumulation in the region and avoids formation of slosh mud pools there by maintaining the cleanliness of the area and its beauty. The demand for such blocks and tiles is generally from urban and semi urban areas as such the unit manufacturing the product should be accordingly located. The demand for such products depends on the growth of economy and rate of urbanization. With massive urbanization work taken up by the government and providing better facilities to population the demand for these concrete products is bound to grow.
3) Manufacturing Process & Know How
The process of manufacturing is simple and standardized. Cement concrete is a mixture of cement, sand and stone chips in correct proportions. The items are mixed in water and churned thoroughly in a concrete mixture. The process involves proportioning, Mixing, Compacting, Curing & Drying. A concrete mix of 1:2:4 :: cement: sand: stone chips by volume are used for making paving blocks.
All the items of raw material are placed in the concrete mixer and water added. The mixer is then rotated for 15-20 minutes. The mixed material is then discharged on to the moulds. Care is taken that the mixture does not dry. Vibrators are employed during the process of pouring the mix so as to ensure that it sets well and is compact there is no porosity. After compacting the blocks are demoulded and allowed to dry for 24 hours away from direct sun. The blocks thus hardened are cured with water to permit moisturisation or settling of cement for next 20 days. The water in the curing tanks is generally changed every 3 days. After being cured the blocks are allowed to dry in shade so that initial shrinkage of the blocks is complete before they are used. This generally takes 15 days.
Know how is available with Central Government research Laboratories. The machinery is all indigenously available.
The production capacity envisaged is 1200 tons of blocks per annum on single shift basis for 300 days.
4.) Plant and Machinery
The main plant and machinery required comprise
  •   Concrete Mixer capacity 10 cft. and accessories. – 1 no.
  •   Hydraulically operated block making machine – 1no.
  •   Mechanical Tile making press. – 1nos
  •   Curing Tanks – 2 no
  •   Moulds & Tools.
  •   Pump set. – 1 no
The total cost of machinery is estimated to be Rs.8.00 lakhs. The cost of miscellaneous assets like office furniture, office equipment, working tables 7 benches is estimated to be Rs. 0.75 lakhs
The total requirement of power shall be 10 HP; the unit will need 3000 lits of water daily.
6)  Raw material and Packing Material
The basic raw materials for the unit are cement, sand & stone chips. The unit will require 15 tonnes of cement, 35 tonnes of sand and 70 tonnes of stone chips per month for the production capacity envisaged.
Particulars
Qty/month
Unit
Rate (Rs./ton)
Value(Rs.)
Cement
15
Tons
5824
87360
Sand
35
Tons
455
15925
Stone Chips
70
Tons
546
38220
The total cost of raw material and consumables is estimated to be Rs.16.98 lakhs per annum at rated capacity.
At 70% capacity in 1 st year the cost works out to Rs11.88 lakhs.
7) Land and Building
The unit will require a open area of 500 sq. mts and a built up area of 200 sq. mts. The total cost of land and building is estimated to be Rs. 12.72 lakhs.
8) Manpower
For smooth functioning of the unit the requirement of man power is expected to be around 37 persons.
Sales person
Self
Skilled Workers
2
Semi skilled workers
8
Supervisor
1
Watchman/Peon
1
The annual salary bill is estimated to be around
Rs.8.00 lakhs
9)  Sales Revenue: (100% capacity)
Average Selling price of blocks has been taken as Rs. 3800 per ton. The annual income at installed capacity of 1200 tons is Rs 45.60 lakhs.

At 70% capacity utilization it is Rs.31.92 Lakhs.
10)  Cost of Project:
Rs. lakhs
Land & Building12.72
Plant & Machinery8.00
Other assets0.75
Contingencies2.14
P & P expenses.1.00
Margin money1.57
Total25.18
Means of Finance
Promoters Contribution7.47
Term Loan17.71
Total25.18
11.)  Profitability:(70%capacity)  
Rs. lakhs
Sales31.92
Raw material11.88
Salary8.00
Utilities0.56
Stores & Spares0.40
Repairs & Maintenance0.60
Selling expenses1.59
Administrative expenses0.69
Depreciation1.00
Interest on T.L2.30
Interest on W.C0.28
Cost of production27.30
Profit4.62
12.)  Requirement of Working Capital
MarginW.CMargin Money
Raw material15 days30%0.490.15
Stock of finished goods15 days25%1.140.28
Working expenses1 month100%0.810.81
Sale on credit15 days25%1.330.33
Margin money for W.C1.57
 13)  Break Even point: 50%
14)  Machinery Suppliers
a.  M/S Engineers Enterprises ,
Maniyakaranpalayam Road ,
Coinbatore
b.  M/s Victor electric and Machinery Manf.
3616, Netaji Subhash Marg,
New Delhi 110 002.
c.  M/S Buildtech Engineering Co.
Shree Ashadweep Complex,
16, civil Liunes,
Roorkee
d.  M/S Karthik Industries,
36, J.C. Road ,
Bangalore .
e.  M/S Susanji Udyog Pvt. Ltd,
C-47, Industrial Estate,
Sanathnagar,
Hyderabad .
f..  M/S Ashok Engineering Works,
81, Ajit Industrial Estate Kakhial,
Ahemedabad.






















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