Project of Manufacturing of Bitumen Emulsion Crum Rubber Modified Bitumen

Project Report on Manufacturing Unit of Bitumen Emulsion, Crum Rubber Modified Bitumen & Polymer Modified Bitumen

PROJECT COST : Total capital outlay: Particulars Land Land Development 1 .Factory Shed & Building 2. Total Plant & Machinery 3. Furniture & Fixture & Accessories 4. Security Deposit for power connection of 125 KW. 5. installation , Electrification & Others 6. Preliminary and Pre-operative Expenses 7. Working capital (Margin Money) 8. Project cost 9. working capital loan 10. Total capital investment

Value (Rs. In Lac.) On Lease 5.50 36.22 417.75 3.10 4.74 11.21 5.99 279.81 764.32 839.411 1603.73

Investment structure: Particulars Total Fixed Cost Total Working Capital Total

Value (Rs. In Lac.) 484.51 1119.22 1603.73

COST OF CONSTRUCTION THE COST & DETAILS OF CONSTRUCTION IS GIVEN HERE UNDER Description Main Plant Shed Gantry Shed with staircase & platform office Buildings Store Room Laboratory Building Electric Room Meter Generator Panel Room Security Guard room Including toilet W/C, Toilet Labour Quarters Cum Rest Room Total Cost of the Building Total Cost of the Land & Building

Area 5569 1000 250 700

sq.ft. 807 sq.ft. sq.ft. sq.ft.

100 400 100 100

sq.ft. sq.ft. sq.ft. sq.ft.

300

sq.ft.

Rate (Rs.) 300 sq.ft. 500 400 500

Value / Cost (Rs. In Lacs) 16.71 6.21 5.00 1.00 3.50

300

1.80

300

0.30 0.50

400

1.20 36.22

—

41.72

Plant & Machinery: Amount (Rs) Tankages: a. Bitumen Storage Tank with Insulation capacity 100 MT. with heating arrangement ' b. Bitumen heating tank for Emulsion capacity 40 MT with heating arrangement c. Bitumen heating tank for CRMB & PMB capacity 25 MT with heating arrangement d. Emulsion Processing/Storage tank Capacity 75 MT. with foundation e. CRMB Processing/Storage tank with insulation Capacity 25 MT with foundation f.

PMB Processing/Storage tank with insulation Capacity 25 MT with foundation Decanting Vat with heating arrangement Boiler including installation Capacity 6 lacks calorie Thermic fluid 25 drums Cooling Tower with pipeline Compressor Emulsion Plant: a. Collouid Mill b. Rest of the emulsion plant CRMB/PMB Plant: a. High Shear Mill b. Rest of the crmb/pmb plant Tank Loading Gantry: a. Shed & Structure c. Sheeting & painting b. Gantry pipe line with fittings Emulsion filling machine CRMB / PMB filling machine Empty & Filled barrel conveyor Pipeline, Motors & Valves Total Plant & Machinery Other Fixed Assets : Water Storage Tank K capacity 50 KL Kerosene day Tank with installation capacity 25 KL Diesel Tank with installation capacity 25 KL Electric Panel: MCC main Electric distribution panel Electric Wiring Wires. Cables etc Cabling charges Laboratory Equipments Submersible pump with pipeline HT Electric Equipments Genet including installation: a. 30KVA b. 125 KVA

Amount (Rs)

2 tanks @ Rs

1375000

2750000

1 tank @ Rs

375000

375000

2 tanks @ Rs

285000

570000

4 tanks @ Rs

750000

3000000

2 tanks @ Rs

920000

1840000

2 tanks @ Rs

1020000

2040000

165000

165000

950000

950000

5225 Liters @Rs

11.5

MT @ Rs

2 2

Pes Pes

611325 50000 75000

4000000 4800000

8800000

54000 130000 100000 171600 140000

851000

343200 280000 630000 3600000 35,830,525.00

1 tank @ Rs

375000

375000

1 tank @ Rs

275000

275000

1 tank @ Rs

275000

275000

1

475000

475000

645000 475000

1120000 500000 225000 1500000 1149000

380000 769000 5,944,000.00

Value in Rs. Lacs FURNITURE & FIXTURE Working table. Stool. Office table & Chairs. Almirah. Wooden Rack and Computer & Printer etc. Electrification, Installation & Others towing & Design Charges 125.000 1.25 Erection & Commissioning Charges 800.000 8.00 Others 196.175 1.96 11.21 1.121 175

3.10

PRELIMINARY AND PRE-OPERATIVE EXPENSES Company Formation Expenses 1.05 Establishment / Rent / Rates and Taxes 0.34 Salary and Wages 060 Project Report. Consultant. Technical Fees and market research report TOTAL FIXED CAPITAL 1. Land Development 2. Shed & Building 3. Plant & Machinery 4. Utility Services 5. Furniture & Fixture 6. Electrification. Installation & Others 7. Preliminary & Preoperative Exp. Total Fixed Capital requirement

550 36.22 417.75 4.74 3 10 11.21 5.99 484.51

4.00

5.99

Raw material Requirement for the Production of the proposed products as detailed below: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Particulars

QTY

Bulk Bitumen Emulsifier Kerosene - SKO Crum Rubber Gilsonite Polymer SBS Cacl2 Misc.(Cacl2. HCL) Packing Materials - Drums 8000

3060 10 45 12 108 40 1.2 16

Unit (MT/KL) MT MT ML MT MT MT MT KL

Sources

IOCL / HPCL Akzo Nobel IOCL/HPCL Middleton Spectrum Spectrum Open market Open market Balmer Lawrie

Rate units Including Transportation 25350.00 186000.00 35000 00 18500.00 26000.00 160000.00 23000.00 80000.00

Cost (Rs. In Lac) 775.71 1860 15 75 222 2808 64.00 0 28 12 80

875.00

70 00

pes

Total Requirement at 100% Capacity utilization For the above calculation is based on one month's requirement. And at 100% capacity utilization

987.44

ANNUAL CONSUMPTION AT :60%

70%

Raw Material a) In MT b) In Rs. (Lacs)

80%

28800 7109.54

33600 38400 8294 46 9479.39

Consumable a) In MT b) In Rs (Lacs)

10.66

1244

1422

Packing a) In Rs. (Lacs)

24.19

28.22

32 26

TOTAL

7144.40

8335.13 9525.86

Amt. in Rs Amt in Rs

POWER PLANNING & COST SATTEMENT OF SALARY AND WAGES Operation (Primary Cost) Plant Manager /Lab In-charge Plant Operator

1 2

40000 21000 21000 7500 7000 6000 6000 9000 10000 8500 15000 10000

Loading/Packing Supervisor Gantry & drum filling operator

1 2

Recanting Tank Operator Casual Labour Lab Assistant Store & Maintenance Manager Logistic & invoicing Maintenance Other Benefit Total Monthly Cost Total Annual Primary Staff Cost

1 2 1 1 1 1

Marketing (Administrative Cost) bd Sales Sales Executive - Kolkata Sales Assistant - Kolkata Sales Executive - Bhubaneshwar Sales Executive - Patna Manager - Special Projects Regional Sales Manager - Guwahati Sales Executive - Ranchi Finance Accoun tant Cashier Manager Administration Peon/Delivery/Collection Boy Inception Office Asst. Manager procurement Purchase Asst Manager HR & IT Total for Marketing & Finance Owner Benefits

1

75000

1 1 1 1 1 1 1

25000 18000 22000 22000 25000 35000 20000 25000

1 1 1 1 1 1 4 1

18000 15000 5000 9000 4500 20000 7500 15000

Amt in Rs

161000 24150 185150 2221800

242000

119000 361000 54150

415150 Total Monthly Cost Total Annual Staff Cost 4981800 Management Technical Team 2 50000 Consultant 1 50000 Managing Director 1 90000 Director 1 60000 EA to MD 1 15000 265000 Owner Benefits 39750 Total Monthly Cost 304750 Total Annual Primary Staff Cost 3657000 Total Man Power & their Annual Cost 36 10860600 The total manpower requirement as envisaged for the project has been estimated on the are Plant

SALES DETAILS (PERANNUM)AFTER WASTAGE (100% UTILIZATION) Sl. no

Products name & quantity

Rate Per Mt. (Rs.)

Value (Rs.in Lao

I.

Bitumen Emulsion -24.000 Ml

2. 3.

CRMB -14,400 MT PMB - 9,600

TOTAL SALE (100%)

-

23,900

5736.00

30000 32,000 TOTAL

4320.00 3072.00 13,128.00

Rs. 13,128.00 Lac.

Actual Sale:Year

Production capacity 60% 70% 80%

1st 2nd 3rd & onwards

Sale value 7876.80 9189.60 10,502.40

After wastage of Raw Materials @ 2% (Final Sale Value) 7719.28 9005.81 10,292.35

COMPUTATION OF WORKING CAPITAL 1st year Particulars

Basis days

Raw materials Work-inprocess Stock of finished products Sundry debtors TOTAL

59.54

Total amount required 277.84

208.38

69.46

3rd Year Total Bank Margin amount Finance money required 317.53 238.15 79.38

92.83

30.95

144.41

108.31

36.10

165.04

123.78

41.26

371.33

278.50

92.83

433.22

324.91

108.51

495.11

371.33

123.78

75%

385.%

289.47

96.49

450.29

337.72

112.57

514.62

385.%

128.66

75%

1119.22

839.41

279.81

1305.76

979.32

326.44

1492.30 1119.22 373.08

Bank finance

Margin money

10

Bank Total finance amount required 75% 238.15

178.61

5

75%

123.78

15

75%

15 45

2nd year Bank Margin finance money

PROFITABILITY STATEMENT Particulars Installed capacity of total products (Pes. In Lac) % of utilization of installed capacity Production during the year (Pes. In Lac.) Sales value of total production. Cost of production Raw Materials Salary & wages Electricity charges Land lease Rent Repair & Maintenance Tax insurance Postage & Stationery/Printing Transport/Conveyance Office expenses Packaging & forwarding Miscellaneous Expenses Depreciation Total cost of production Gross profit Less Interest on loan Preliminary expenses written off @ 10% Profit before tax Taxation Profit after tax Depreciation add back cash accrual Repayment Net Cash Accrual

1st year 48,000

2nd year 3rd sear

4th year

5,h year

48,000

48,000

48,000

48,000

60 28,224 7719.28

70 32.928 9005.81

80 37,632 1029235

80 37,632 10292.35

80 37,632 10292.35

7144.40 108.60 65.10 52.00 2.40 1.20 0.72 6.48 0.42 0.72 0.21 44.33 7426.58 292.70

8335.13 119.46 75.95 52.00 2.64 1.32 0.84 7.56 0.48 0.84 24 39.92 8636.78 369.03

9525.86 130.32 86.80 52.00 2.88 1.44 0.96 8.64 0.54 0.96 0.27 35.95 9S46.62 445.73

9525.86 141.18 86.80 52.00 3.12 1.44 0.96 8.64 0.54 0.96 0.27 32.39 9854.16 438.19

9525.86 142.04 86.80 52.00 3.36 1.44 0.96 8.64 0.54 0.96 0.27 29.20 9852.07 440.28

144.35 0.60 147.75 44.33 103.42 44.33 147.75 43.38 104.37

153.52 0.60 214.91 64.47 150.44 39.92 190.36 80.00 110.36

160.71 0.60 284.42 85.33 199.09 35.95 235.04 80.00 155.04

151.11 0.60 286.48 85.94 200.54 3239 232.93 80.00 152.93

141.51 0.60 298.17 89.45 208.72 29.20 237.92 80.00 157.92

BREAK EVEN POINT (1sl year assessment) Rs.in Lac 7719.28

A. Sales Value B. Variable Cost a) Raw material cost

7144.40

b) Utilities! 80 %) c) Wages d) Interest on W/C loan

52.08 58.79 100.73 7356.00 363.28

C. Contribution(A-B) D. Fixed cost a) Salary/Admn. expenses b) Repair & maintenances c) Utilities (20%) d) Depreciation e) Tax & Insurance f) Interest on term loan

B.E.P

49.81 2.40 13.02 44.33 1.20 43.62 154.38

Fixed cost X 100 =42%

=

Contribution 1. Profit on Sale

:

04% On (PBT).

2. Profit on Investment

:

18% On (PBT).

3. B. E. P.

:

42%

PROCESS FLOW CHART

WATER

Cacl2

HCL

EMULSIFIER

CHEMICAL MIXING TANK

KEROSENE

EMULSIFIER SOLUTION

WATER REQUIRED

STATIC MIXTURE BITUMEN COLLIOD MILL

FINISHED PRODUCTS

FINISHED PRODUCTS TANK

PACKED (BARRELS)

BULK

DESPATCH