Project Report on Manufacturing Unit of Bitumen Emulsion, Crum Project Report on Manufacturing Unit of Bitumen Emulsion, Crum Project Report on Manufacturing Unit of Bitumen Emulsion, Crum Project Report on Manufacturing Unit of Bitumen Emulsion, Crum

Rubber Modified Bitumen & Polymer Modified BitumenRubber Modified Bitumen & Polymer Modified BitumenRubber Modified Bitumen & Polymer Modified BitumenRubber Modified Bitumen & Polymer Modified Bitumen

PROJECT COST :

Total capital outlay:

Particulars Value (Rs. In Lac.)

Land On Lease

Land Development 5.50

1 .Factory Shed & Building 36.22

2. Total Plant & Machinery 417.75

3. Furniture & Fixture & Accessories 3.10

4. Security Deposit for power connection of 125 KW. 4.74

5. installation , Electrification & Others 11.21

6. Preliminary and Pre-operative Expenses 5.99

7. Working capital (Margin Money) 279.81

8. Project cost 764.32

9. working capital loan 839.411

10. Total capital investment 1603.73

Investment structure:

Particulars Value (Rs. In Lac.)

Total Fixed Cost 484.51

Total Working Capital 1119.22

Total 1603.73

COST OF CONSTRUCTION

THE COST & DETAILS OF CONSTRUCTION IS GIVEN HERE UN DER

Description Area Rate (Rs.)

Value / Cost (Rs. In Lacs)

Main Plant Shed 5569 sq.ft. 300 16.71 Gantry Shed with staircase & platform 807 sq.ft. 6.21 office Buildings 1000 sq.ft. 500 5.00 Store Room 250 sq.ft. 400 1.00 Laboratory Building 700 sq.ft. 500 3.50 Electric Room

Meter 100 sq.ft. Generator 400 sq.ft. 300 1.80 Panel Room 100 sq.ft.

Security Guard room 100 sq.ft. 300 0.30 Including toilet 0.50 W/C, Toilet Labour Quarters 300 sq.ft. 400 1.20 Cum Rest Room Total Cost of the Building 36.22

Total Cost of the Land & Building

— 41.72

Plant & Machinery: Amount

(Rs) Amount

(Rs) Tankages:

a. Bitumen Storage Tank with Insulation capacity 100 MT. with heating arrangement '

2 tanks @ Rs 1375000 2750000

b. Bitumen heating tank for Emulsion capacity 40 MT with heating arrangement

1 tank @ Rs 375000 375000

c. Bitumen heating tank for CRMB & PMB capacity 25 MT with heating arrangement

2 tanks @ Rs 285000 570000

d. Emulsion Processing/Storage tank Capacity 75 MT. with foundation

4 tanks @ Rs 750000 3000000

e. CRMB Processing/Storage tank with insulation Capacity 25 MT with foundation

2 tanks @ Rs 920000 1840000

f. PMB Processing/Storage tank with insulation Capacity 25 MT with foundation

2 tanks @ Rs 1020000 2040000

Decanting Vat with heating arrangement 165000 165000 Boiler including installation

Capacity 6 lacks calorie 950000 950000

Thermic fluid 25 drums 5225 Liters @Rs 611325 Cooling Tower with pipeline 50000 Compressor 75000 Emulsion Plant:

a. Collouid Mill b. Rest of the emulsion plant

CRMB/PMB Plant: a. High Shear Mill 4000000 8800000 b. Rest of the crmb/pmb plant 4800000

Tank Loading Gantry: a. Shed & Structure 11.5 MT @ Rs 54000 851000 c. Sheeting & painting 130000 b. Gantry pipe line with fittings 100000

Emulsion filling machine 2 Pes 171600 343200 CRMB / PMB filling machine 2 Pes 140000 280000 Empty & Filled barrel conveyor 630000 Pipeline, Motors & Valves 3600000 Total Plant & Machinery 35,830,525.00 Other Fixed Assets : Water Storage Tank K

capacity 50 KL 1 tank @ Rs 375000 375000

Kerosene day Tank with installation capacity 25 KL

1 tank @ Rs 275000 275000

Diesel Tank with installation capacity 25 KL

1 tank @ Rs 275000 275000

Electric Panel: MCC main Electric distribution panel 1 475000 475000

Electric Wiring Wires. Cables etc 645000 1120000 Cabling charges 475000

Laboratory Equipments 500000 Submersible pump with pipeline 225000 HT Electric Equipments 1500000

Genet including installation: 1149000

a. 30KVA 380000

b. 125 KVA 769000

5,944,000.00

Value in Rs. Lacs FURNITURE & FIXTURE Working table. Stool. Office table & Chairs. Almirah. Wooden Rack and Computer & Printer etc. 3.10 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

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 4.00 5.99 TOTAL FIXED CAPITAL

1. Land Development 550 2. Shed & Building 36.22 3. Plant & Machinery 417.75 4. Utility Services 4.74 5. Furniture & Fixture 3 10 6. Electrification. Installation & Others 11.21 7. Preliminary & Preoperative Exp. 5.99 Total Fixed Capital requirement 484.51

Raw material Requirement for the Production of the proposed products as detailed below:

Sl. No.

Particulars QTY Unit (MT/KL)

Sources Rate units Including Transportation

Cost (Rs. In Lac)

1. Bulk Bitumen 3060 MT IOCL / HPCL 25350.00 775.71 2. Emulsifier 10 MT Akzo Nobel 186000.00 1860 3. Kerosene - SKO 45 ML IOCL/HPCL 35000 00 15 75 4. Crum Rubber 12 MT Middleton 18500.00 222 5. Gilsonite 108 MT Spectrum 26000.00 2808 6. Polymer SBS 40 MT Spectrum 160000.00 64.00 7. Cacl2 1.2 MT Open market 23000.00 0 28 8. Misc.(Cacl2. HCL) 16 KL Open market 80000.00 12 80 9. Packing Materials Balmer Lawrie

- Drums 8000 pes 875.00 70 00 Total Requirement at 100% Capacity utilization 987.44 For the above calculation is based on one month's requirement. And at 100% capacity utilization ANNUAL CONSUMPTION AT :- 60% 70% 80% Raw Material a) In MT 28800 33600 38400 b) In Rs. (Lacs) 7109.54 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

POWER PLANNING & COST SATTEMENT OF SALARY AND WAGES

Amt. in Rs Amt in Rs Amt in Rs

Operation (Primary Cost)

Plant Manager /Lab In-charge 1 40000 Plant Operator 2 21000 21000 Loading/Packing Supervisor 1 7500 Gantry & drum filling operator 2 7000 6000 Recanting Tank Operator 1 6000 Casual Labour 2 9000 Lab Assistant 1 10000 Store & Maintenance 1 8500 Manager Logistic & invoicing 1 15000 Maintenance 1 10000 161000 Other Benefit 24150 Total Monthly Cost 185150 Total Annual Primary Staff Cost 2221800 Marketing (Administrative Cost) bd Sales

1 75000

Sales Executive - Kolkata 1 25000 Sales Assistant - Kolkata 1 18000 Sales Executive - Bhubaneshwar 1 22000 Sales Executive - Patna 1 22000 Manager - Special Projects 1 25000 Regional Sales Manager - Guwahati 1 35000 Sales Executive - Ranchi 1 20000 242000 Finance Accountant

25000

Cashier 1 18000 Manager Administration 1 15000 Peon/Delivery/Collection Boy 1 5000 Inception 1 9000 Office Asst. 1 4500 Manager procurement 1 20000 Purchase Asst 4 7500 Manager HR & IT 1 15000 119000 Total for Marketing & Finance 361000 Owner Benefits 54150

Total Monthly Cost 415150 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% UTILIZA TION)

Sl. no Products name & quantity Rate Per Mt. (Rs.) Value (Rs.in Lao

I. Bitumen Emulsion -24.000 Ml 23,900 5736.00

2. CRMB -14,400 MT 30000 4320.00 3. PMB - 9,600 32,000 3072.00

TOTAL 13,128.00

TOTAL SALE (100%) - Rs. 13,128.00 Lac.

Actual Sale:-

Year Production capacity

Sale value After wastage of Raw Materials @ 2% (Final Sale Value)

1st 60% 7876.80 7719.28 2nd 70% 9189.60 9005.81 3rd & onwards

80% 10,502.40 10,292.35

COMPUTATION OF WORKING CAPITAL

1st year 2nd year 3rd Year Particulars Basis

days Bank finance

Total amount required

Bank finance

Margin money

Total amount required

Bank finance

Margin money

Total amount required

Bank Finance

Margin money

Raw materials

10 75% 238.15 178.61 59.54 277.84 208.38 69.46 317.53 238.15 79.38

Work-in- process

5 75% 123.78 92.83 30.95 144.41 108.31 36.10 165.04 123.78 41.26

Stock of finished products

15 75% 371.33 278.50 92.83 433.22 324.91 108.51 495.11 371.33 123.78

Sundry debtors

15 75% 385.% 289.47 96.49 450.29 337.72 112.57 514.62 385.% 128.66

TOTAL 45 75% 1119.22 839.41 279.81 1305.76 979.32 326.44 1492.30 1119.22 373.08

PROFITABILITY STATEMENT

Particulars 1st year 2nd year 3rd sear 4th year 5,h year Installed capacity of total products (Pes. In Lac)

48,000 48,000 48,000 48,000 48,000

% of utilization of installed capacity 60 70 80 80 80

Production during the year (Pes. In Lac.) 28,224 32.928 37,632 37,632 37,632

Sales value of total production. 7719.28 9005.81 1029235 10292.35 10292.35

Cost of production

Raw Materials 7144.40 8335.13 9525.86 9525.86 9525.86

Salary & wages 108.60 119.46 130.32 141.18 142.04

Electricity charges 65.10 75.95 86.80 86.80 86.80

Land lease Rent 52.00 52.00 52.00 52.00 52.00

Repair & Maintenance 2.40 2.64 2.88 3.12 3.36

Tax insurance 1.20 1.32 1.44 1.44 1.44

Postage & Stationery/Printing 0.72 0.84 0.96 0.96 0.96

Transport/Conveyance 6.48 7.56 8.64 8.64 8.64

Office expenses 0.42 0.48 0.54 0.54 0.54

Packaging & forwarding 0.72 0.84 0.96 0.96 0.96

Miscellaneous Expenses 0.21 24 0.27 0.27 0.27

Depreciation 44.33 39.92 35.95 32.39 29.20

Total cost of production 7426.58 8636.78 9S46.62 9854.16 9852.07

Gross profit 292.70 369.03 445.73 438.19 440.28

Less

Interest on loan 144.35 153.52 160.71 151.11 141.51

Preliminary expenses written off @ 10% 0.60 0.60 0.60 0.60 0.60

Profit before tax 147.75 214.91 284.42 286.48 298.17

Taxation 44.33 64.47 85.33 85.94 89.45

Profit after tax 103.42 150.44 199.09 200.54 208.72

Depreciation add back 44.33 39.92 35.95 3239 29.20

cash accrual 147.75 190.36 235.04 232.93 237.92

Repayment 43.38 80.00 80.00 80.00 80.00

Net Cash Accrual 104.37 110.36 155.04 152.93 157.92

BREAK EVEN POINT (1sl year assessment)

Rs.in Lac

A. Sales Value 7719.28 B. Variable Cost

a) Raw material cost 7144.40

b) Utilities! 80 %) 52.08 c) Wages 58.79 d) Interest on W/C loan 100.73

7356.00 C. Contribution(A-B) 363.28 D. Fixed cost

a) Salary/Admn. expenses 49.81 b) Repair & maintenances 2.40 c) Utilities (20%) 13.02 d) Depreciation 44.33 e) Tax & Insurance 1.20 f) Interest on term loan 43.62

154.38

B.E.P = Fixed cost X 100

= 4 2 %

Contribution

1. Profit on Sale : 04% On (PBT).

2. Profit on Investment : 18% On (PBT).

3. B. E. P. : 42%

PROCESS FLOW CHART

WATER HCL Cacl2 EMULSIFIER

CHEMICAL MIXING TANK

KEROSENE EMULSIFIER SOLUTION

STATIC MIXTURE WATER REQUIRED

BITUMEN

COLLIOD MILL

FINISHED PRODUCTS

FINISHED PRODUCTS TANK

PACKED (BARRELS) BULK

DESPATCH