SUBMITTED TO
SUBMITTED BY
D r. B . CHANDRACHOODAN S3NMABI RA
SWALIH . V
D I R ENO: C T O60 R, ROLL
A PROJECT REPORT ON DETERGENT POWDER MANUFACTURING COMPANY F A C U LT LT Y O F UNIVERSITY NOORUL ISLAM MANAGEMENT KUMARACOIL STUDIES NOORUL ISLAM UNIVERSITY KUMARACOIL
INTRODUCTION T!" #r$%&' '()!"*+'" ' '"*-&!"'( $/ * #&*( /$r ' #r$12!$( $/ ''r+'( #$'r ! * 2*#*2!4 $/ 50 $(" #'r *((1. T' *7$r 1"' $/ ''r+'( #$'r" !" !( $1"'$&" /$r *"!(+ 2&$'" *( 1'("!&". T'4 *r' "1!*-&' /$r *( *"!(+ *( *&"$ /$r *2!(' *"!(+ !( &*1(r!'" *( !" *"'r". T' 2$1(r48" r'91!r''( $/ ''r+'( #$'r !" &*r+'&4 ' r$1+ !#$r. T' #r'"'( '*( /$r ''r+'( #$'r !" '"!*' * ;< $(". T' '*( /$r ' #r$12 !" #r$7'2' $ r'*2 5,55= $(" *( 5,<;; $(" -4 ' 4'*r =05; *( =0=3, r'"#'2!)'&4 . D1' $ ' !"*)*(*+' $/ ' &*1(r4 "$*# !( ' *r *'r, ' ''r+'( 2*>' *( #$'r *)' *>'( *( !#$r*( r$&' !( ' *"!(+ 'r*. T' '?#*("!$( $/ ' #'r$@2'!2*& !(1"r!'" ' r* *'r!*& !" '*"!&4 *)*!&*-&'. R'&*!)'&4 &'"" 2$"&4 *( '*"4 $ 1"' *)' *&r'*4 2r'*' * +$$ *r>' /$r ''r+'( #$'r *( 2*>'. T' '*( !&& -' ')'r !(2r'*"!(+ *( 'r' !" +$$ #r$% !( ' I(1"r4. T' #r!(2!#*& r* *'r!*&" r'91!r' *r' *&>4& -'('(' "1&#$(!2 *2!, "$!1 r! #$&4#$"#*', "$!1 "1&#*', "$!1 "!&!2*', *( 2*1"!2 "$*. C*1"!2 "$* *( "$!1 "!&!2*' 2*( -' $-*!(' &$2*&&4 !&' ' $'r r* *'r!*&" *)' $ -' !#$r'. D''r+'(" *r' *&"$ >($( *" "4('!2 ''r+'(". T'4 *r' !'r'( /r$( $!& -*"' "$*# $1+ -$ "$*#" *( ''r+'(" 5
*r' "1r/*2*(". T'!r !#$r*( *##&!2*!$( !" 2&'*(!(+. B'2*1"' $/ * (1-'r $/ *)*(*+'" ''r+'(" *r' #$#1&*r *( "$*#" *( !" '*( !" *&*4" 'r' !/ ' #r$12 #$""'""'" -$ 91*&!4 *( #r!2' ''2!)'('"". T'r' *r' * (1-'r $/ )*r!'!'" $/ ''r+'(" )*r4!(+ !( #'r2'(*+'" $/ *2!)' *'r #r'"'( !( ' *( *&"$ !'r'( 2$&$1r". M*(1/*21r!(+ #r$2'"" !" )'r4 "!#&' *( $(&4 !?!(+ !" !()$&)'.
=
PRODUCT Detergents, term applied to materials, the solutions of which aid in the removal of dirt or other foreign matter from contaminated surfaces. A detergent powder is a product formulated from the constituents such as surfactants, which perform the primary cleaning and washing action by reducing the surface tension of water builders, which boost the cleaning power of the surfactant and other additives. Detergent powder is proved to be effective in hard water and cool or cold water, whereas soap is often wholly ineffective under both conditions. The major use of detergent powders is in households for washing clothes and utensils. They are suitable for hand washing and also for machine washing in laundries and dish washers. Detergent powder falls into four major groups: Heavy duty detergents high and low foaming!, "ight duty detergents, #oap powders, and #oda products.
T' &'+*& 2$#&!*(2'" /$r '"*-&!"!(+ ' ''r+'( *(1/*21r!(+ 1(! !( I(!* 2$#r!"'" $/ : * R'+!"'r ' -1"!('"" !( I(!* *" "$&' %r - I !" r'91!r' $ $#'( * 21rr'( -*(> *22$1( /$r -1"!('"" r*("*2!$(" 2 A##&!2*!$( /$r ' SSI U(! L!2'("' /$r ' G$)'r('( S1-"!!*r4 *( $'r "*&& -1"!('"" -'('%". A##&!2*!$( /$r 2$("'( $ '"*-&!" *( 2$("'( $ $#'r*' -$ /r$ P$&&1!$( C$(r$& B$*r.
3
' F$r 1*&!4 C$(r$& ! !" ('2'""*r4 $ *)' BIS r'+!"r*!$( *( IS: <@56;: "#'2!%2*!$( !" r'91!r' /$r "4('!2 ''r+'( #$'r /$r $1"'$& 1"'. / A##&!2*!$( /$r r*' *r> r'+!"r*!$(. + F!r' '#*r'(: B'/$r' "1-!!(+ ' *##&!2*!$( , /$r $-*!(!(+ NOC ,$ ' C!'/ F!r' O2'r, $('r 1" '("1r' ' 2$#&!*(2' $/ *&& ' %r' *( "*/'4 +1!' &!('. I("1r*(2' : F$r ''r+'( *(1/*21r!(+ -1"!('"", 'r' *r' *(4 !("1r*(2' #$&!2!'" &!>' •
%r' #$&!24
•
#1-&!2 &!*-!&!4
•
-1!&!(+ *( *""' #$&!24 '2
MARKET POTETIAL A22$r!(+ $ I(!*( D''r+'( *r>' $1&$$> =0=5, ' $)'r*&& *r>' /$r ''r+'( !" +r$!(+ ! * CAGR $/ 53.06 /r$ ' &*" %)' 4'*r". ''r+'(" *r' *)*!&*-&' !( r'' /$r", (*'&4 #$'r ''r+'(", -*r ''r+'(" *( ''r+'( &!91!. P$'r ''r+'(" *r' !'&4 *22'#' -4 I(!*( 2$("1'r" *( $!(*' ' !(1"r4. E)'( $1+ ''r+'( -*r" *r' "!&& 1"' !( r1r*& *r'*", '4 *r' /*" !"*##'*r!(+ /r$ ' *r>' -'2*1"' $/ !(''2!)'('"". T' ''r+'( !(1"r4 !( I(!* !" $"&4 2*#1r' -4 $r+*(!' #&*4'r", -1 1($r+*(!' r'+!$(*& #&*4'r" *)' * "!+(!%2*( $& $( ' r1r*& *r'*". HUL, R$! S1r/*2*(", PG, N!r* *( J4$4 L*-$r*$r!'" *r' ' *7$r #&*4'r" !( ' $r+*(!' *r>'. <
O)'r ' &*" '2*', I(!* *" +r$( r''($1"&4 *( "$ *)' ' !(2$'" $/ !" #'$#&', ! * &*r+'r 21(> $/ ' I(!*( '$+r*#4 $)!(+ !($ 1r-*( *r'*" !( "'*r2 $/ -''r *( $r' &12r*!)' 2*r''r $#!$(". W! !" *)'(, 'r' *" -''( * "!+(!%2*( r!"' !( 2$("1'r 1r*-&'" *" '&&, ! "$' $/ ' '*r&!'" "!+(" $/ !" r!"' -'!(+ "$( -4 $"' !2 /1&%&&' ' $" -*"!2 $/ (''", &!>' *"!(+ 2&$'". A" * r'"1& $/ !", 'r' *" -''( *( !(1? $/ -14'r" !( ' ''r+'( *r>', ! $r' *( $r' #'$#&' -14!(+ *"!(+ *2!(' #$'r". H$')'r, !" 2$("!1'" $(&4 =0 $/ ' #$#1&*!$(. T'r' !" ' r'*!(!(+ ;0 $/ ', *r$1( =00 !&&!$( $1"'$&", $ *" '!r &*1(r4 -4 *(. T' *r>'!(+ "r*'+4 #&*((!(+ $ !#&''( !" #'('r*!(+ #r!2!(+ #$&!24 -'2*1"' ' #r'"'(2' $/ ' #$#1&*r 2$#'!$r" !( ' *r>'. MANUFACTURING PROCESS The major raw materials used to produce detergent powder are Al$yl ben%ene sulphonic acid, sodium tri polyphosphate, sodium sulphate, sodium silicate, and caustic soda. &austic soda can be obtained locally while the other raw materials are supposed to be imported. However, there is a possibility to manufacture sodium sulphate and sodium silicate locally as the starting materials for these chemicals are locally available. Au'iliary material i.e. printed polyethylene is necessary as pac$ing materials. #tandard detergent powder manufacturing plant consists of mi'ing, drying, after drying, pac$ing and antipollution units. These units are briefly described as follows:
Mixing unit: "inear al$yl ben%ene sulphonate paste is metered into a slurry
preparation tan$ together with metered sodium silicate solution, and solid phosphates, sulphates and additives. The slurry preparation tan$ acts as a coarse mi'er. Here lumps are bro$en down and air poc$ets are eliminated. (aterials after blending are conveyed to an ageing vessel. (i'ing is carefully controlled to prevent aeration of the slurry. )eed slurry passes through a coarse filter, homogeni%er and fine filter. Deaeration of product is carried out if necessary. The slurry of constant solid content and viscosity is ready for spray drying. This detergent slurry is heated and transferred to the top of the spray drying tower by high pressure pump.
Drying unit: @ Fr'' $!(+, ($( 1"4, ($( 2*>!(+ ''r+'(
#r$12" !( -'* /$r *r' #r$12' -4 S#r*4 Dr4!(+ $"&4 !( 2$1('r 21rr'( $ 1"!(+ #r'""1r' ($&' *$!*!$(. T' !?' "&1rr4 !" "#r*4' r$1+ ($&'" 1('r #r'""1r' $ 2r'*' "*&& r$#&'". I(&' '#'r*1r'" )*r4 *22$r!(+ $ #r$12 *( 1# $ <00C !(&' '#'r*1r'" *r' 1"' /$r "$' ''r+'(". H$ *!r /r$ !r'2 %r' *!r '*'r" !" 1"' /$r S#r*4 Dr4!(+. E?*1" !+ '2!'(24 242&$('" -*+ $1"'" *r' 1"' $ 2$(r$& '!""!$(" *( *?!!' #r$12 r'2$)'r4 *r' #*r $/ ' "#r*4 r4!(+ #&*(. T' r!' ''r+'( #$'r !" *>'( $1 * ' -$$ $/ ' $'r, *( !" r*("/'rr' $ ' "!')' -4 -'& 2$()'4$r *( *!r &!/ '91!#'(. After drying unit: @ T' r!' ''r+'( #$'r 2$&&'2' /r$
' -$$ $/ ' "#r*4 $'r !" #('1*!2*&&4 2$()'4' $ ' #r$12 "!&$" */'r "!')!(+. H'r' %&'r' *$"#'r!2 *!r !" 1"' *"
6
' 2$$&!(+ 2$()'4!(+ '!*. D'("' #*"' 2$()'4!(+ "4"'" *r' ($r*&&4 #r'/'rr'. A/'r ' +r*(1&'" *)' -''( 2$$&', '* "'("!!)' !(+r'!'(", !2 *r' ($ 2$#*!-&' ! ' "#r*4 r4!(+ '#'r*1r'" &!>' -&'*2, '(4'" *( /r*+r*(2', *r' *'. Pacing unit: @ T' %(*& #r$12 !" #*2>' 'r'. D''r+'(
#$'r !" /' !($ ' #*2>!(+ *2!(' /r$ -*++!'".
CAPITAL INPUTS
S&.N$. =.
P*r!21&*r"
A$1(
Pr$7'2 2$" * 2*#!*& '?#'(!1r' •
L*( B1!&!(+ S' 00 "9./.
R".6,00,000
300 "9./ •
V*(
•
*+uipment
R".,00,000 R".,00,000
#igma (i'ture, Three oll (illing machine, -lodder type simple' cutting machine, oll ma$ing (achine, #ealing machine, eigh /alance etc. ! Total capital e'penditure
- W$r>!(+ 2*#!*& T$*& #r$7'2 2$" M!"2'&&*('$1" *""'" 3. T$*& !()'"'(
R!."#$%%$%%%
R".=0,00,000 R!.&#$%%$%%%
R".,000 R".,,000
MANPO'ER RE(UIREMENTS T' /$&&$!(+ *-&' "$" ' *(#$'r r'91!r''(" $/ ' #r$7'2. T' %r r'91!r'" 3< '#&$4''". S&. N$. 5. =. 3. <. . 6. . ;. . 50. 55. 5=. 53.
D'"2r!#!$( P&*( M*(*+'r Pr$12!$( *( T'2(!2*& *(*+'r F!(*(2!*& *( A!(!"r*!$( *(*+'r C$'r2!*& *(*+'r A22$1(*( 1*&!4 2$(r$& *(*+'r Pr$12!$( F$r'*( O#'r*$r M'2*(!2 E&'2r!2!*( U(">!&&' &*-$r Dr!)'r G1*r ;
R'9. N$. 5 5 5 5 = 5 3 ; = 5 50 5 =
T$*&
3<
IMPLEMENTATION SC)EDULE N$r*&&4 "!? $(" *r' r'91!r' /$r ' 2$#&'' !#&''(*!$( $/ ' #r$7'2, !(2&1!(+ *2!('r4 'r'2!$(, r* *'r!*& #r$21r''(" '2.
FINANCIAL ASPECTS MEANS OF FINANCE
5. =.
E91!4 L$*(
;0 =0
ESTIMATED COST ANAL*SIS +,%%- caacity/
5. =. 3.
F!?' 2$" V*r!*-&' 2$" T$*& 2$"
,00,000 =0,,000 ,,000
0ARIA1LE COST W*+'" *( "*&*r!'"
: R".;,00,000
M!"2'&&*('$1" '?#'("'" : R".,000 R* *'r!*&"
: R".50,00,000
W*'r, '&'2r!2!4, $'r E?#'("'" &!>' r'#*!r'" *(
*!(*('(2', #$"*+' *( "*!$('r4 *( r*("#$r*!$( : R".=,00,000
T2ta3 4aria53e c2!t
6 R!.7%$"#$%%%
TURNO0ER AT ,%%- CAPACIT* S.N$ 5.
D'"2r!#!$( D''r+'(
4 50$("
R*'
A$1( ;=,0,000
#$'r T$*&
;=,0,000
COST OF PRODUCTION S.N$. 5. =. 3.
D'"2r!#!$( T$*& $r>!(+ 2*#!*& D'#r'2!*!$( 5 I('r'" 5= T$*&
A$1( =0,00,000 ,000 =,=,;00 =30<;00
Net Pr28t f2r t9e year : S*&'" C$" $/ #r$12!$(
Q ;=,0,000 =3,0<,;00@ Q ,<,=00 #r$% -'/$r' *? PRO;ECTED PROFIT AND LOSS ACCOUNT P*r!21&*r" Y'*r 5 Y'*r = Y'*r 3 Y'*r < Y'*r S*&'" ,00,0 60,00,0 0,00,0 ,00,0 ;=,00,0 50
L'"" : P1r2*"' D!r'2 '?#'("'"
00
00
00
00
00
6,0,00 ,=0,00 ;,<0,00 ,00,00 50,00,0 0 0 0 0 00 5,0,00 5,0,00 =,30,00 =,;0,00 3,00,00 0 0 0 0 0 <"$%%$ #%$&%$ #&$=%$ ><$=%$ >&$%%$ %%% %%% %%% %%% %%%
Gr2!! r28t L'"" : !(!r'2 '?#'("'" =,0,00 3,00,00 3,;0,00 <,=0,00 ,00,00 S*&*r!'" 0 0 0 0 0 D'#r'2!*!$ ( $( *2!('r4 3,00 ,000 ,000 ,000 ,000 5 E&'2r!2!4, r*("#$r* !$(, *'r 5,=0,00 =,00,00 =,00,00 =,00,00 =,00,00 #$"*+' 0 0 0 0 0 I('r'" 5= 5,5<,0 =,=,;0 =,=,;0 =,=,;0 =,=,;0 D'#r'2!*!$ 0 0 0 0 0 ( $( !"2'&&*(' $1" *""' 50 3,0 ,00 ,00 ,00 ,00 D'#r'2!*!$ ( $( )*( 55
50 E1T L'"" : T*? 30 EAT carry f2r@ard t2 1S
=,000 0,000 0,000 0,000 0,000 <,$=$="$ ?#% "%% "%% "%% "%% 5=,<<,6 5=,6;,3 5<,6,3 56,3<,3 5,05,3 50 50 50 50
7&$%<$ ,&#
7&$#&$ =&%
=<$&,$ =&%
=?$,=$ =&%
<<$=>$ =&%
Y'*r <
Y'*r
6,60,0 00
6,60,0 00
=,5,3 00
=,<,5 00
3<,5,3 0 ,$=>$< %$?&%
3;,53,3 0 ,$<,$& 7$>&%
<<,36,3 0 ,$#%$< #$<&%
3,;,0 0 ,000 =$,7$# %%
3,5=,0 0 ,000 7$="$# %%
=,3,0 0 000 ,$>7$# %%
PRO;ECTED 1ALANCES)EET P*r!21&*r" Y'*r 5 Y'*r = Y'*r 3 SOURCES OF FUNDS O('r /1( 6,60,0 6,60,0 6,60,0 B$rr$' 00 00 00 /1( !('r'" Pr$% =0,=, ==,, =<,;, */'r *? 00 00 00
=,0<,5 =,,3 0 TOTAL ,$7#$& ,$7?$" <$%&# &$%&% APPLICATION OF FUNDS6 E91!#'( ,00,00 <,6=,0 " 0 0 L'"" : 3,00 ,000 <$>7$# =$?"$# D'#. %% %%
5=
VAN L'"" : D'#.
M!"2'&&*( '$1" " *""'" L'"" : D'#. C*" * -*(> TOTAL
,00,00 0 =,000 <$"#$% %%
<,,00 0 0,000 <$7#$% %%
<,=,00 0 0,000 =$"#$% %%
3,,00 0 0,000 =$7#$% %%
,000 5,=0 63,0 6,=0 <;,0 3,0 ,00 ,00 ,00 ,00 ",$7#% >=$"#% #>$7#%
5,=0,0=, ;<0 ,$7?$" &$%&%
5,=;,, 5<0 ,$=>$< %$?&%
5,3,;5, <<0 ,$<,$& 7$>&%
APPRAISAL PA* 1ACK PERIOD *EAR ANNUAL RETURN
5 = 3 <
3,=,00 0 0,000 7$"#$% %%
=,0<,5 =,,30 3<,5,30 3;,53,30 <<,36,30
CUMILATI0E RETURN
=,0<,5 ;,63,; 3,<, 5,35,6;,36 5,6,0<,
T' #*4-*2> #'r!$ !" -'''( 3 r *( < 4'*r. I( ' '( $/ 3r 4'*r R".3,<, !&& -' r'2'!)'. H'(2' -*&*(2' $ -' r'2'!)' Q ,,000@3,<, Q =,=0,0= T' !' /$r r'*&!!(+ R".=,=0,0= !( ' < 4'*r Q =,=0,0= 5,35,6;,36 Q 0.056 53
5,<,66, <0 ,$#%$< #$<&%
S$ ' #*4-*2> #'r!$ Q 30.056 Q 3.056 4'*r". NET PRESENT 0ALUE
I !" *""1' * ' 2$" $/ 2*#!*& !" * 5=. *EAR
RETURN
5 = 3 <
=,0<,5 =,,30 3<,5,30 3;,53,30 <<,36,30
P0 FACTOR
0.;3 0. 0.5= 0.636 0.6 PRESENT VALUE OF CASH INFLOWS LESS : PRESENT VALUE OF CASH OUTFLOW NET PRESENT 0ALUE
PRESENT 0ALUE =,3,<<6.53 =3,;,633.;3 =<,;,;6.6; =<,=,356.0< =,5,<33.53 5,=3,;,6;.;5 ,,000 7?$%=$>&?.?,#
S!(2' ' NPV !" #$"!!)' %+1r', ' #r$7'2 2*( -' *22'#'. ACCOUNTING RATE OF RETURN
A22$1(!(+ r*' $/ r'1r( Q A)+ r'1r( 500 A)+ !()'"'( A)'r*+' r'1r( Q 5,6,0<, Q 3,=0,5 ARR Q 3,=0,5 500 ,,000 ARR Q 36. INTERNAL RATE OF RETUURN +IRR/ Ste 6, C2Butati2n Of Annuity Di!c2unt Fact2r 5<
ADF Q Or!+!(*& 2$" $/ !()'"'( A)+ 2*" !($ Q ,,000 3,=0,5
Q =.5 Ste 6 7 L2cati2n 2f Annuity Di!c2unt Fact2r
A((1!4 *-&' !( ' &!(' $/ 4'*r", F*2$r =.5 &!'" -'''( == *( =3. Ste 6 = C2Butati2n Of Eact IRR
IRR Q L$'r r*' $/ r'1r( P$"!!)' NPV D!'r'(2' P$"!!)' NPV@N'+*!)' NPV
'2ring N2te C2Butati2n 2f NP0
*ear
5 = 3 <
Ca!9 P0F P0 P0F P0 7=in2@! 77777==,0<,5 0.;=0 =3,;5,<3. 0.;53 =3,65,550. 3 =,,3 0.6= 5,;;,50. 0.665 5,3,53. 0 0; 53 3<,5,3 0.5 5,=3,. 0.3 5;,<,;6. 0 ; <3 3;,53,3 0.<5 5,5,;3;. 0.<36 56,6=,63;. 0 ; 0< 5
<<,36,3 0.30 0 PV $/ r'1r(" L'"" : PV $/ 2*" $1$ NP0
56,<5,<6<. 3 6,,=0. 06 ,,000. 00 ?%$7%&.% >
0.3
5,<,5;. < <,<,<6. ; ,,000. 00 +,$7"$#<=. <,#/
IRR Q L$'r r*' $/ r'1r( P$"!!)' NPV D!'r'(2' P$"!!)' NPV@N'+*!)' NPV IRR Q ==;0,=0.06 5 ;0,=0.06 5,=,<3.<5 IRR Q ==0.3;6 Q ==.3;6 PROFITA1ILIT* INDE MET)OD
Pr$%*-!&!4 I('? Q PV $/ C*" !($ PV $/ 2*" $1$
Q 5,=3,;,6;.;5. ,,000.00 Q 5.==
56
