1

Project Profile on Detergent Powder

PURPOSE OF THE DOCUMENT

The objective of the pre-feasibility is primarily to facilitate potential entrepreneurs in project identification for investment and in order to serve this objective; the document covers various

aspects of the project concept development, startup, marketing, and finance and business management.

[We can modify the project capacity and project cost as per your requirement. We can also prepare project report on any subject as per your requirement.

M/S Institute for Industrial Development A unit of M/S Samadhan Samiti 27/1/B Gokhle Marg Lucknow 226001 Mail : iidincubator17@gmail.comWeb : www.entrepreneurindia.tv industryincubator.co.in

2

Introduction

Synthetic detergents occupy a vital place in the present age particularly when the modern society is

constantly looking for quick, effective and economic cleaning agents. Synthetic detergents emerged

as a regular industry after Second World War only. The development of this industry is closely

linked with Petro-chemical industry which forms the basic for its raw materials. Detergents when

dissolved in water acquire better cleaning properties and hence facilitate easy removal of dirt & dust

and grease etc.

Apart from their use in clothes washing, detergents also have applications in the following

industries.

1. In industry, in laundry and dry cleaning.

2. In textile processing, grain milling, metal plating and foods canning.

3. In dairy foods and beverages processing and in restaurants.

4. In plant maintenance and industrial house-keeping.

3

Major Application of Detergents

Synthetic detergents are preferred to soaps on account of economy and efficiency. Unlike soaps

synthetic detergents remain un effected by the presence of natural lime and magnesium salts in

water and maintain cleaning properties in hard water with practically no wastage. Therefore these

are more economical.

Synthetic detergents available in the market are used for washing cloth cotton linen and other

fabrics. Liquid detergents are also sold for the purpose of dish washing and cleaning floors

industrial use in textiles, and commercial buildings, hospitals, and hotels, similarly railway coaches,

road vehicles, aircrafts, milk bottling plants and food preservation equipment are washed with the

help of detergents.

Textile industry is one of the largest consumers of synthetic detergents. In the processing stage the

cotton, rayon and synthetic fibers are scoured wetted with chemical detergents. They are used as

dyeing and finishing operations and also in the printing trade in woolen textile industry. Detergents

are used in the scouring operations of raw material, yarn and woven fabrics.

In paper industry detergents are used as wetting agents to facilitate the pulp making operations.

Detergents are used in degreasing of rags, in pretreatment in the electroplating and galvanizing

process, for wetting of ores, and mineral extraction.

In scouring of leather, detergents are employed to impart softening and penetrating properties to

the leathers. In rubber industry, detergents are used as wetting and dispersing agents and as

lubricants.

Synthetic detergents are regularly used for cleaning equipment, packing containers employed in the

food processing industry, in brewing and wine making industry. In brewing and

wine making industry, the process cleaning and sterilization of vats, still and bottles is facilitated by

detergents.

4

Market Potential.

According to India Detergent Market Outlook, 2021, the overall market for detergent is growing with

a CAGR of 13.06% from the last five years.

Detergents are available in three forms, namely powder detergent, bar detergent and liquid

detergent. Powder detergents are widely accepted by Indian consumers and dominate the industry.

Even though detergent bars are still used in rural areas, they are fast disappearing from the market

because of ineffectiveness.

The detergent industry in India is mostly captured by organized players, but unorganized regional

players have a significant hold on the rural areas. HUL, Rohit Surfactants, P&G, Nirma and Jyothy

Laboratories are the major players in the organized market. They have popular brands like Ghari,

Surf Excel, Active Wheel, Rin, Tide, Nirma, Ariel, Mr. White and Henko in their product portfolio.

On the basis of pricing, the organized detergent market can be further divided into three categories,

such as popular (economy), mid-range and premium. The popular category consists of brands like

Ghari, Nirma and Wheel; the mid-range category consists of Tide, Rin and Mr. White; and the

premium category includes Surf Excel, Henko and Ariel. Hindustan Unilever dominates the high-

priced premium and mid-range category, whereas Ghari dominates the low-priced popular category.

Detergent Powder Making Formula

Different companies have their own customized formula. In addition, you have to craft the formula

according to your target market demographic. However, a basic formula with the ingredients in

percentage for ready reference is.

Ingredients Premium grade (Wt, %) Popular grade (Wt, %)

85% active LAB acid slurry 18 15

Sodium carbonate (soda ash) 35 32

Sodium metasilicate 2 No

Alkaline sodium silicate No 7

5

Sodium bicarbonate 10 10

Sodium Sulphate (anhydrous) 20 25

Sodium tripolyphosphate 10 7

Sodium carboxy methyl cellulose 1.5 1

Phthalocyanine blue color or oil-soluble yellow colour 0.1 0.1

Optical whitener 0.3 0.2

Perfume 0.1 0.1

Detergent powder manufacturing Process.

Although there are three ways of manufacturing dry detergent, only two are commonly used today.

In the blender process favored by smaller companies, the ingredients are mixed in large vats

before being packaged. The second commonly used method of production is called the

agglomeration process. Unlike the blender process, it is continuous, which makes it the choice of

very large detergent manufacturers. In the third method, dry ingredients are blended in water

before being dried with hot air. Although the resulting product is of high quality, the fuel costs and

engineering problems associated with venting, reheating, and reusing the air have led to this

method being largely replaced by agglomeration.

The blender process

First, ingredients are loaded into one of two machines: a tumbling blender or a ribbon blender. The

tumbling blender, shaped like a rectangular box, is turned and shaken from outside by a machine,

while the ribbon blender is a cylinder fitted with blades to scrape and mix the ingredients. After the

ingredients inside the blender have been mixed, a doorway at the bottom of the bowl is opened.

With the blender still agitating the ingredients, the mix is allowed to run out onto a conveyor belt or

other channeling device. The belt then moves the detergent to another area of the factory where it

can be dropped into boxes or cartons for delivery to wholesalers or distributors.

6

The agglomeration process

In this method, dry ingredients for a detergent are first fed into a large machine known as a Shuggi

agglomerator (Shuggi is the manufacturer). Inside the agglomerator, sharp, whirling blades mix the

material to a fine consistency; the process resembles food being textured inside a food processor.

After the dry ingredients have been blended, liquid ingredients are sprayed on the dry mix through

nozzles fitted into the agglomerator's walls. The blending continues, causing an exothermic (heat-

producing) reaction to occur. The resulting mixture is a hot, viscous liquid similar to gelatin that

hasn't hardened.

Next, the liquid is allowed to flow out of the agglomerator. As it leaves the machine, it collects on a

drying belt where its own heat, exposure to air, and hot air blowers render it friable—easy to crush

or crumble. The newly made detergent is then pulverized and pushed through sizing screens that

ensure that no large lumps of unmixed product go out to the market. The result of this process is a

dry detergent made up of granules of the mixed detergent.

The slurry method

In this process, ingredients are dissolved in water to create a slurry. With a pump, the slurry is

blown through nozzles inside the top of a cone shaped container as hot, dry air is simultaneously

forced into the bottom of the cone. As the slurry dries, "beads" of dry detergent fall to the bottom of

the cone, where they can be collected for packaging.

Liquid detergent

If the detergent is to be liquid rather than powder, it is simply mixed back in—after all ingredients

are blended—with a solution consisting of water and various chemicals known as solubilizers. The

solubilizers help the water and detergent blend together more fully and evenly.

7

Detail of raw material used in manufacturing of detergents.

Major raw materials used in the making of detergent powder are :- Soda ash, Carboxy methyl

chloride, sodium perborate, lather forming chemical, colours and perfume. Following is the utility of

the given ingredients.

Soda ash (Sodium carborate)

Soda ash depresses acid bleary and makes the washing process alkaline. moreover, soda ash

is a low priced salt to break the dirt.

Carboxy methyl chloride (cellulose)

This prevents the dirt from resettling on the surface of the cloth and is particularly useful

for cotton clothes.

Sodium perborate

This acts as a high bleach and also retains the colours of the clothes. In addition it also

breaks up the dirt particles.

Perfume

Perfumes and aromatic mixture are used in detergent to subside the intense smell of

detergent ingredients. Major perfumes used in detergent powders are P Methoxy, P Methyle,

Di-Oxide, Musk Ketone etc.

Colour.

Instead of white, coloured detergents are the preferred ones. Majorly, copper

phthalocyamine is used for this purpose because it also blocks light and temperature.

Lather producing chemical

This chemical is required to produce lather and also enhances the cleaning capacity of the

detergent.

8

Detergent Making Machines.

Detergent manufacturing machines include systems and equipment that can be used to produce

detergents in various forms of powder, liquid and gel.

With advancements in technology, the manufacturing techniques have changed a lot and a variety of

sophisticated machines are available to produce effective detergents for different cleaning

applications.

Some of the common detergent making machines used in the industry is -

• Detergent Cake Making Plant

• Detergent Mixing Machine

• Rotary Sealing Machine.

Design

Machines for detergent manufacturing are designed keeping the various operations, processes and

stages of soap manufacturing in mind. For example, a detergent making machine should support the

batch as well as continuous processes of detergent manufacturing. Some of the salient features that

should be there in a detergent making machine are -

• Easy to operate and maintain

• Sturdy design

• Durable

• Efficiently supports that different functions of detergent making

• Less power consumption.

Buying Tips - Detergent making Machines

While buying a detergent making machine, it is important that one has to know his requirement, so

that one can purchase a right machine for your specific need. Different types of machines are

available in industry that designed for manufacturing a particular type of detergent like powder

detergent manufacturing machine, liquid detergent machine, etc. Hence it important that one buys a

machine as per one's need. Generally one should prefer a machine with a sturdy and robust

structure as durability is the most important factor.

9

Detergent Powder Manufacturing License & Registration

First of all, determination of form of business. And accordingly, register the business. Apply for the Trade License from the Municipal Authority. Additionally, apply for MSME Udyog Aadhaar online registration. Apply for the ‘Consent to Establish’ from the Pollution Control Board. Obtain the GST registration. Apply for BIS certification. Choice of a brand name of the product and secure the name with Trademark

Implementation Schedule

The project can be implemented in 3 months' time as detailed below:

Sr. No. Activity Time Required

(in months) 1 Acquisition of premises 1 2 Construction (if applicable) 3 Procurement & installation of Plant & Machinery 1 4 Arrangement of Finance 1 5 Recruitment of required manpower 1 Total time required (some activities shall run concurrently) 3

Quality Control & Standards

In order to manufacture good quality detergent, it is utmost urgent to purchase good quality of

raw material from only the established and renowned suppliers. Before putting the raw material

into operation all those has got to be tested for their chemical properties at the gate testing

facilities and after the finished product. Quality means the producer has to satisfy the desire and

urge of uses. Keeping in view the demand of people from quality point of view it is necessary to

adopt better technique of manufacturing and good quality of raw material. To manufacture a

detergent of good quality, specific BIS standard can be followed

10

Pollution Control

There might be some pollution in the manufacturing of detergent powder. However, the producer

is advised to adopt and follow the prescribed norms by the pollution control board. Before

switching over to manufacturing, NOC from the concerned State Authority is very much required in

this case. To minimize the pollution some control measures and monitors can be installed.

Energy Conservation

To conserve the energy required thickness of vessels should be taken. Only necessary

machinery and equipment and jig jags should be purchased. Proper space is given to proper flow

for manufacturing raw material and finished products. Control is maintained over consumption of

electricity light and fuel so that extravagance expenditure can be checked.

Project Financials

Basis & Presumptions:

The basis for calculation of production capacity has been taken of single shift basis, working of 25 days per Month on 75% efficiency.

The maximum capacity utilization on single shift basis for 300 days a year.

Interest rate for Fixed and Working capital of the project has been taken at an average rate of 12 %

Land and Building is owned and Cost of Plant and Machinery has been taken as per prices Prevailing in the market.

The wages for skilled workers are taken as per prevailing rates in this type of industry.

The essential production machinery and test equipment required for the project have been indicated.

The unit can achieve its full capacity utilization during the 2nd year of operation.

Financial Assistance required from Bank/ Financial Institutions :

Term Loan : 476,000.00

Working Capital : 950,000.00

11

Cost of Project.

S.NO. PARTICULARS AMOUNT 1 Land & Building 420000.00 2 Plant and Machinery 147500.00 3 Furniture & Fixture 62500.00 4 Computer 50000.00 4 Preoperative expenses 15000.00 5 Margin for Working Capital 327700.00 Total 1022700.00

Means of Finance.

S.NO. PARTICULARS AMOUNT 1 Own Contribution 546700.00 2 Term Loan 476000.00 Total 1022700.00

Fixed Capital (i) Land and building Amount(In Lakhs) i) Land 200 Sq mtr. Nil ii) Working Shed 140 Sq. mtr@Rs3000

sq.mtr 420,000.00

Total 420,000.00 (ii) Machinery and Equipment

S.no

. Description Qty. nos. Price/uni

t Amount (In

Rs.) 1 Mixer/Blender (hand operated)100 kg

capacity properly lined inner side

1 65,000.00 65,000.00

2 Trays/Pan made of stainless steel 5 2,200.00 11,000.00 3 Grinding Machine 1 32,500.00 32,500.00 4 Weighing Machine 1 12,000.00 12,000.00 5 Weighing balance for packing 1 15,000.00 15,000.00 6 Miscellaneous like Gloves, Bag seaving

machine

12,000.00

Total 147500.00 7 Furniture and Fixture/ Office

Equipment 62500.00

8 Computers 50000.00 Total Fixed Capital 680000.00

12

Total Capital Investment Rs.

1 Total Fixed Capital 680000.00 2 Working Capital for 3 Months 1277700.00 Total 1957700.00

Total working capital Rs.

1 Salary and Wages (i) 92,000.00

2 Raw Material (ii) 281,400.00

3 Utilities (iii) 41,000.00

4 Other Contingent Expenses (iv) 11,500.00 Total(Per Month) 425,900.00 Working Capital for 3 months 1,277,700.00

Staff and labour

S.No. Designation No. Salary(Rs.) Total(In. Rs.)

1 Production Manager 1 20,000.00 20,000.00 2 Skilled Worker 2 15,000.00 30,000.00 3 Un Skilled Worker 2 12,000.00 24,000.00 4 Clerk/Typist 1 10,000.00 10,000.00 5 Peon/Watchman 1 8,000.00 8,000.00 Total(Per Month) 7 92,000.00

Raw Materials S.No. Particulrs Rate(Rs)/Kg Quantity Total(In. Rs.)

1 Soda Ash 21.00 6500 Kg 136,500.00 2 Acid Slurry 74.00 625 Kg 46,250.00 3 T.S.P 45.00 1000 Kg 45,000.00 4 Sodium Silicate 10.00 1315 Kg 13,150.00 5 Sodium Sulfate 8.00 2250 Kg 18,000.00 6 Urea 26.00 500 Kg 13,000.00

13

7 Ethanolamine 50.00 125 Kg 6,250.00 8 Trialkylamine 50.00 65 Kg 3,250.00 9 Sodium perporate 120.00 125 Kg 15,000.00 Total(Per Month) 281,400.00

Utilities (Units) Rate Amount

1 Power 5500 K w h 7 38,500.00 2 Water 2,500.00 Total(Per Month) 41,000.00

Other contingent expenses S.No. Particulars Amount(In.Rs)

1 Repair and Maintenance 1500.00 2 Postage and Stationery 1000.00 3 Telephone Charges 1000.00 4 Transporatation and Freight 2000.00 5 Sales Expenses 5000.00 6 Other Maufacturing Expenses 1000.00 Total(Per Month) 11500.00

Financial Analysis

Cost of Production S.No. Particulars In. Rs.

1 Total Recurring Expenditure 5110800.00 2 Depreciation on Plant and Machinery @ 15% 22125.00 4 Depreciation of Furniture/Fixture & Office Equipment @ 10 % 6250.00 5 Depreciation of Computers @ 60 % 30000.00 6 Finance Cost 171120.00 Total Cost Of Production 5340295.00

14

Turnover (per annum) S.No. Particulars Qty(nos.) Rate (in Rs) In. Rs.

1 Detergent Powder 150000Kgs/Annum 40.00 6,000,000.00 TOTAL TURNOVER 6000000.00

Profit Rs 659705/=

Percentage Profit on Sales 11%

Ratios

i) Rate of Return on Total Capital Investment

= Net Operating Profit/ Invested Capital

= 34%

ii) Return on Assets

=Sales/Average total Assets

=0.97

iii) Return on Equity

= Sales/ Stockholder's Equity

= 1.21

iv) Debt to Equity Ratio

= Total Term Liabilities/Total Shareholder's Equity

= 0.9

iv) Interest Coverage Ratio

= Earning before Interest & Tax/ Interest Expense

= 4.86.

15

RAW MATERIALS SUPPLIERS

SODIUM SILICATE Ravi Industries 608, Indra Prakash Bldg. 21 Barakhamba Rd. New Delhi,NCT of Delhi-110001 TEL : (0) 11 23311636 FAX : (0) 11 23311636 Rishipal Glass & Chemicals Pvt. Ltd. 75, Rajasthani Co-op. Indl. Est. G T Karnal Rd. Delhi,NCT of Delhi-110033 TEL : (0) 11 27115679 FAX : (0) 11 27452571 Titan Biotech Ltd. A-2/3, 308 3rd Flr., Lusa Towers Azadpur Comml. Cmplx. Delhi,NCT of Delhi-110033 TEL : (0) 11 27415668 FAX : (0) 11 27414181 E-mail: titanbiotech@mantraonline.com Arbuda Sil Chem Pvt. Ltd. 112/3 B, GIDC Est. Kadi,Gujarat-382715 TEL : (0) 2764 742324 Associated Chemical Co. Nr. CMC India Associated Indl. Est. Odhav Rd.,Odhav Ahmedabad,Gujarat-382415 TEL : (0) 79 2872424 FAX : (0) 79 2872325 E-mail: associat@wilnetonline.net Dinesh Chemicals Nr. CMC India Associated Indl. Est., Odhav Rd. Ahmedabad,Gujarat-382415 TEL : (0) 79 2872324 FAX : (0) 79 2872325 E-mail: associat@wilnetonline.net

16

SODIUM CARBONATE Indiana Chem-Port 349 GIDC Est. Makarpura Vadodara, Gujarat-390010 India TEL : +91 (0) 265 642067 FAX : +91 (0) 265 644717 E-mail: indiana@wilnetonline.net SP Chemicals At. & Post Baska Halol-Vadodara Rd. Tal. Halol Panchmahal, Gujarat-389352 India TEL : +91 (0) 2676 47227 FAX : +91 (0) 2676 47355 E-mail: pandu-pandya@usa.net Sunshine Chemicals Shree Ganesh House, 13 Tikona Park Mkt. NIT Faridabad, Haryana-121001 India TEL : +91 (0) 129 5217350 Keerthi (Bangalore) Pvt. Ltd. 2nd Flr., 31 J C Rd. Bangalore, Karnataka-560002 India TEL : +91 (0) 80 2224481 FAX : +91 (0) 80 2279898 Neeta Chemical Laboratories 23, Mezzanine Flr., 51/57 Dontad St. Mumbai, Maharashtra-400009 India TEL : +91 (0) 22 3727973 FAX : +91 (0) 22 3748025 E-mail: kadakiam@bom5.vsnl.net.in

17

SODA ASH Mg. Director AMBALA SILICATE UDYOG 141 Vikas Vihar, Vikas Vihar Ambala-134003, Haryana Fax:Phone:0171-2540041 Jatin Aggarwal, Partner BANSAL TRADING COMPANY 1st Floor, 4753/23, Ansari Road, Daryaganj New Delhi-110002 Mobile:Fax:Phone:+91 11 232 85383, +91 11 232 85849 Email: jatinagg@chem-india.com btc@chem-india.com Mukesh, Partner CHANDAN & CHANDAN INDUSTRIES 97, Narayan Mudali Street Chennai-600079, Tamil Nadu Fax:Phone:+91 44 25222539, 25243438 Email: chandan@giasmd01.vsnl.net.in Manoj Chaudhari, Sales Mgr CURE CHEM INDIA D-3/3582, Vasant Kunj New Delhi-110070 Fax:Phone:+91 11 268 98689 Email: cci@mantraonline.com Shashi Chand Jain, CMD DCW LTD Dhrangadhra Dhrangandhra-363315, Gujarat Fax:Phone:+91 265 2781914, 2871918 Email: dcwbby.dcwltd@gems.vsnl.net.in S. K. Mukherjee, Director GUJARAT HEAVY CHEMICALS F-Block, 2nd Floor, INTL Trade Tower, Nehru Place New Delhi-110019 Fax:Phone:+91 11 264 45154 Email: ghcl@giasdl01.vsnl.net.in; ghcl@vsnl.com

18

SODIUM PERBORATE B. L. Paranjpe, Director NATIONAL PEROXIDE LTD Neville House,, Ballard Estate, Mumbai-400001, Maharashtra Fax:Phone:+91 22 226 18071 Email:npl@vsnl.com; mktg@haperol.com SODIUM SULPHATE

E. B. Desai, Director BARODA RAYON CORPN LTD Fatehnagar, P.O. Barodarayon Surat-394220, Gujarat Fax:Phone:+91 261 690 371, +91 261 390 372

Uttam Bhansali, CEO BHANSALI CHEMICALS (MANUFACTURING DIVISION) 12/1, Mutha Market, Ekabareswaran Street Chennai-600003, Tamil Nadu Fax:Phone:+91 44 253 51736, +91 44 253 50710 Email: bcmd@md3.vsnl.net.in

S. S. Agarwal, Director DEEPAK NITRITE LTD 9/10, Kunj Society, Alkapuri Baroda-390007, Gujarat Fax:Phone:+91 265 325 113

Mg. Director GWALIOR RAYON SILK MANUFACTURING COMPANY LTD Staple Fibre Division, Birlagram Nagda-456331, Madhya Pradesh Fax:Phone:07366-246760 Email: sfdiv.grasimbm@gems.vsnl.net.in Mg. Director KAKAR TRADING CO 9979, Nawab Ganj, Azad Market Delhi-110006 Fax:Phone:011-23541765 Email: kakar@vsnl.net

19

SUPPLIERS OF PLANT AND MACHINERY

CHEMICAL PLANT MACHINERY

DIPESH ENGINEERING WORKS Corporate Office: 3, Sheroo Villa, 87, J.P.Road, Near Andheri Sports Complex, Andheri (West), Mumbai - 400 053 Ph: 26336729, 26344695 Fax: 26315507 E-mail: kjpatel_71@hotmail.com Website: www.dipeshengg.com RAJ PROCESS EQUIPMENTS AND SYSTEMS PVT. LTD. Plot No. 166, Sector No. 7, PCNTDA, Bhosari, Pune - 411 026 PH: (020) 56114711/12, 27119973, 27124876 Email: rajindustries@vsnl.net Website: www.rajprocessequipments.com

TEXFAB ENGINEERS 65, Adarsh Industrial Estate, Chakudia Mahadev Road, Rakhial, Ahmedabad - 380 023 Ph: 079-22744668 Fax: 079-22745952 Email: texfabengQyahoo.com

WAHAL ENGINEERS Plot No. G-39, Friends Industrial Area, Shahbad, Daulatpur, Delhi - 110 042 Ph: 011-27821785 Mob: 9891223802 Fax: 91-11-27297877 E-mail: praveen@wahalengineers.com Website: www.wahalengineers.com

PSA NITROGEN LIMITED D-9/6, Okhla Industrial Area, Phese-1, New Delhi - 100 020 Ph: 26815336, 26816251 Fax: +91-11 26815337 E-mail: incon@vsnl.com

71, New DLF Industrial Area Fridabad (Haryana) 121 003 Ph: 0129-2254466, 2279295, 2254477

20

PULVERISER Mg. Director ABLE MANUFACTURERS 14-164, 1st Phase, Ida Patancheru-502319, Andhra Pradesh Fax:Phone:08455-40043 Email: ablemfrs@yahoo.com Mr. Vinubhai Panchal AMBIKA VIJAY WORKS 1H, Laxmi Industrial Estate, New Linking Road, Off Vera Desai Road, Versova, Andheri (West) Mumbai-400058, Maharashtra Fax:Phone:022-26366894/(R)26366222 Dinesh Verma, Proprietor ARIHANT ENGINEERING WORKS 124, Guru Nanak Timber Market, Dhar Road, Indore-452002, Madhya Pradesh Fax:Phone:+91 731 380 535 Email: arihantegineering@epatra.com G. D. T. Pinto, Partner D P PULVERISER INDUSTRIES Modi & Modi Building No. 2, 2nd Floor 76, Nagindas Master Road, Fort Mumbai-400023, Maharashtra Mobile:Fax:Phone:+91 22 226 70976, +91 22 226 74901 Email: tpinto@vsnl.in; epinto@bol.net.in