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
