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  1  Acid Slurry (ALKYL Benzene Sulphonate) PRODUCT CODE:314805001QUALITY AND STANDARDS:IS 8401:1987PRODUCTION CAPACITY:Qty. : 150 MT (per annum) Value : Rs. 75,00,000MONTH AND YEAR:January, 2003OF PREPARATIONPREPARED BY:Small Industries Service Institute 4th Floor, Harsiddha Chambers, Ashram Road, Ahmedabad - 380 014Ph. Nos. : 27540619, 27544248, 27543147 I NTRODUCTION Synthetic detergents had developedin the beginning of 20th century andstarted making inroads into the areaearlier served by washing compoundsi.e. soaps made traditionally from oils/fats and caustic soda. Since soaps havecomparatively lesser washingcharacteristics in hard water thansynthetic detergents, synthetic washingcompounds have been able to occupy a significant market which was enjoyedby washing soaps earlier. The termdetergents which srcinated from theLatin word detergine (i.e. to wipe off), isnow a days applied to all syntheticwashing compounds. Syntheticdetergents are not only used as cleaningmaterials but also have industrialapplications in textiles, pesticideindustry as carriers, etc. M  ARKET   P  OTENTIAL  Marketing is an important area of management in an industrial enterprise.It is a comprehensive term and includesall resources and economic activitiesnecessary to direct the flow of manufactured goods from producers toconsumers. The old concept of marketingwas product-oriented where as the newconcept is customer oriented. Customersare the champions whose needs, tastes,purchasing power, etc. are the guidingfactors for the sale of products.Synthetic detergents, being a massconsumption item have shown adramatic growth since its inception in1957. Presently, detergents are availableto the consumers in the form of powdersand cakes/bars. Bulk of the productionof these items is done in the small scalesector.  8  A  CID  S LURRY   (ALKYL B ENZENE  S ULPHONATE )  The present strategy employed for introducing a detergent in the marketcovers:i)Appointment of distributors invarious regionsii)Selection of whole sellers/retailers/agents in the variouscities/townsiii)Publicizing through theadvertisements, press media likeradio, television, cinema etc.iv)Introduction of sales promotionscheme etc. B  ASIS    AND  P  RESUMPTIONS  The profile is drawn on the basisof the following presumptions:Working hours/shift8 hoursNo. of shift/day1Working days300 Total no. of working2400hoursWorking efficiency70% Time period for achieving3rd year frommax. cap.the dateUtilisationon whichproduction willbe started.Labour chargesas per minim-um wages actof State Govt.Margin money25% of capitalinvestmentRate of Interest on fixed14%and working CapitalOperative period of the10 yearsprojectValue of machinery and equipmentis estimated on the basis of the prevailingcosts in the market. I MPLEMENTATION  S CHEDULE Project implementation will take aperiod of 8 months from the date of theapproval of the scheme. Break-up of activities with relative time for activity isshown below: Nature of ActivityPeriod in Month(Estimated)1.Scheme preparation0-1and approval2.SSI provisional1-2registration3.Sanction of loan2-54.Clearance from pollution3-4control board5.Placement of order4-5of delivery of m/c6.Installation of m/c67.Power connection6-78.Trial run7-89.Commencement9 onwardsof production.  T  ECHNICAL   A  SPECTS Process of Manufacture  Acid Slurry   Acid slurry or alkyl benzenesulphonate is prepared by sulphonationof Linear Slkyl Benzene (LAB) with asuitable sulphonating agent.Sulphonation can be done by thefollowing processes:(i)Batch sulphonation with either diluted SO 2  gas or concentratedsulphuric acid or a mixture of 20% oleum and 98% sulphuricacid or oleum alone.(ii)Continuous sulphonation with20% oleum.(iii)Continuous sulphonation with So 3  9  A  CID  S LURRY   (ALKYL B ENZENE  S ULPHONATE ) (sulphor trioxide gas may bederived either from liquid So 3  or from 65% oleum or from burningsulphur and converting So 2  to So 3 ).Raw material consumption per tonneof 85-88% acid slurry is given below:(a)Linear alkyl benzene 700-750 Kg.(b)Sulphonating agent 20% oleum-800- 900 Kg.98% sulphuric acid - 1100–1200Kg.Quality Control and Standards As bulk of the detergent formulationsconsist mainly of acid slurry, soda ash,sodium tripoly phosphate, etc. to startwith, it would be sufficient if testingfacilities are installed for determining thepurity of these ingredients. So far asfinished formulation are concerned a listof the tests as prescribed in therespective standards of the BIS are givenbelow: Acid Slurry (IS 8401:1987)1.Determination of alkyl benzenesulphonic acid2.Free alkyl benzene content3.Free sulphuric acid4.Colour Production Capacity  Acid slurry - ½ MT per day/shiftor 150 TPA. F  INANCIAL   A  SPECTS  A. Fixed Capital  (i) Capital Requirements(Rs.)(a) Land and building Land 1000 sq.m. Building -350 sq.m.1,00,000(b) Factory shed including laboratory/2,00,000 water arrangements etc.Capital Requirements(Rs.)(c) Store/Godown(d) Office Total3,00,000(ii) Plant and Machinery for Acid Slurry (Rs.)1.Sulphonator: Stainless steel2,00,000verticle and cylindrical vesselfitted within agitator with MS jacket and complete with motor,Cap 1 m 3 2.Chilling plant1,50,0003.Settling tank- MS vertical dished1,00,000bottom, Lead line with agitator and motor Cap 3.5m 3 4.LAB feed tank: vertical cylindrical20,000tank, MS Cap 1.0 m 3 5.Oleum/Acid slurry feed tank vertical20,000cylindrical Tank Cap 2.5m 3 6.LAB main storage tank horizontal50,000cylindrical Tank Cap 2.5m 3 7.Oleum/acid storage tank30,000ms-horizontal Cylindrical tank cap 5m 3 8.Pumps barrel type with motor30,0009.Misc. equipment including valvers50,000pipelines, exhaust, weighing machinesetc. and laboratory Equipment.10. Furniture/fixtures30,00011.Installation/electrification 6,300 Total6,86,300Fixed CapitalRs. 3,00,000 + Rs. 6,36,300 =Rs. 9,36,300Recurring Expenditure/Month(iii) Raw Material/Month (for Acid Slurry 12.5 MT) (Rs.)(i)Linear alkyl benzene 9MT3,60,000@ Rs. 40,000 PMT (ii) Sulphuric acid 98% and oleum 14 MT84,000@ Rs. 6,000 PMT  Total444000 B. Working Capital (i) Salary/Wages (per month)(Rs.)1.Manager/Chemist-15,0002.Plant operator-25,0003.Unskilled workers-23,000  10 3.Net Profit (per year)4.Turnover Cost of Production ProfitRs.75,00,000 Rs. 62,43,000Rs. 12,57,0005. Net Profit Ratio=Net profit per year ×  100 Turnover =12,57,000 ×  10075,00,000=16.76%6. Rate of Return=Net profit ×  100 Total investment=12,57,000 ×  10023,87,700=52.64%7. Break-even Point (% of Total Production Envisaged)(i) Fixed Cost(Rs.)a.Depreciation on machinery and65,000equipmentb.Depreciation on office equipment6,000c.Depreciation on building12,000d.Interest on total capital3,41,656investment @ 14%e.Insurance12,000f.40% of salary and wages95,040g.40% of other contingent expenses48,000 Total5,77,696Or say5,78,000(ii) Net Profit (per year)B.E.P.=F.C. ×  100F.C + Profit=5,78,000 ×  1005,78,000+12,57,000=5,78,000 ×  10018,35,000=31.5%  A  CID  S LURRY   (ALKYL B ENZENE  S ULPHONATE ) Salary/Wages (per month)(Rs.)4.Clerk/typist-12,0005.Watchman/peon-23,000 Toal18,000 Perquisites 15%  2,700 Total20,700(ii) Other Expenditure (per month)(Rs.)1.Transport3,0002.Postage/stationery1,0003.Insurance1,0004.Repair maintenance5005.Packing3,5006.Miscellaneous expenses1,000 Total10,000(iii) Utilities(Rs.)Power/Water10,000 Total Recurring Expenditure (per month)Rs. 4,44,000+20,700+ 10,000+10,000= 4,84,700say 4,85,000 C. Total Capital Investment (i) Fixed CapitalRs. 9,86,300(ii) Working capital for 3 monthsRs. 14,54,100 Total24,40,400 F  INANCIAL   A  NALYSIS 1.Cost of Production (per year)(Rs.) Total recurring expenditure58,20,000Depreciation on building10,000@ 5%Depreciation on furniture6,000@ 20%Depreciation on plant and machinery65,630@ 10%Interest on total capital investment3,41,656@ 14% Total62,43,286or Say62,43,0002. Turnover (per year)ItemQty.RateValue(Rs.)(Rs.) Acid slurry150MT50,000 PMT75,00,000
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