Industry Overview
Calcium carbonate (CaCO3) is one of the most widely used inorganic filler materials in industrial manufacturing due to its ability to enhance product performance while reducing formulation costs. Filler materials are added to resins, binders, plastics, composites, rubber, concrete, paints, coatings, adhesives, sealants, and paper to improve mechanical, physical, and processing properties. Among the various fillers available, ground calcium carbonate is one of the most extensively utilized across the plastics and elastomer industries.
Calcium carbonate occurs naturally in the Earth's crust and is found in mineral forms such as limestone, marble, chalk, travertine, and calcite. It also occurs with magnesium as dolomite. Although these forms differ physically, they share similar chemical characteristics. The compound exists primarily in two crystalline forms, calcite and aragonite, which differ in the arrangement of calcium and carbonate ions. Pure calcium carbonate is a white powder that decomposes into calcium oxide and carbon dioxide when heated and reacts readily with acids, releasing carbon dioxide gas.
Most naturally occurring calcium carbonate deposits were formed millions of years ago through the accumulation of shells and skeletons of marine organisms. Over geological time, these deposits were compressed into extensive limestone formations that now serve as major raw material sources. Owing to its abundance, versatility, and favorable physical properties, calcium carbonate continues to play an important role in the production of masterbatches, plastic products, construction materials, and numerous industrial applications.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 120 MT/Day |
| Land & Building (6105 sq.mt.) | Rs. 5.65 Cr |
| Plant & Machinery | Rs. 5.57 Cr |
| Working Capital for 2 Months | Rs. 6.99 Cr |
| Total Capital Investment | Rs. 18.56 Cr |
| Rate of Return | 23% |
| Break Even Point | 59% |
Content Index
- INTRODUCTION
- CALCIUM CARBONATE
- KEY FACTS
- OTHER NAMES:
- FORMULA:
- ELEMENTS:
- COMPOUND TYPE:
- MELTING POINT:
- SOLUBILITY:
- FILLER (MATERIALS)
- TYPES
- CALCIUM CARBONATE (CACO3)
- KAOLIN
- MAGNESIUM HYDROXIDE (TALC)
- WOLLASTONITE (CASIO3)
- GLASS MICROSPHERE FILLER (LEFT) AND FIBER FILLERS (RIGHT)
- FLY ASHES
- NANOFILLERS
- POLYMER FOAM BEADS
- MASONRY FILLER
- OTHER FILLERS
- TABLE OF FILLER MATERIALS AND PHYSICAL PROPERTIES
- MASTERBATCHES
- RAW MATERIAL
- USES OF CALCIUM CARBONATE FILLER
- CALCIUM CARBONATE IS USED FOR MAKING MASTERBATCHES:-
- MASTERBATCH IS USED IN THE FOLLOWING AREAS:
- APPLICATION
- IN PRODUCING PLASTIC DOORS, CEILING PANELS, FRAMES
- IN POWER CABLES PRODUCTION
- IN BLOWING FILMS PRODUCTION
- IN SPINNING PRODUCTION
- IN PLASTIC COMPOSITES PRODUCTION
- SELECTION OF COLORANTS
- CALCIUM CARBONATE FILLERS FOR RAFFIA
- WHAT IS RAFFIA TECHNOLOGY AND ITS OUTPUTS
- TYPICAL SPECIFICATIONS
- ASTM TESTING METHODS
- MARKET OVERVIEW
- GLOBAL MARKET OVERVIEW
- SEGMENTATION ANALYSIS
- MARKET, BY PRODUCT
- MARKET, BY END-USER
- MARKET, BY GEOGRAPHY
- KEY PLAYERS
- SOME OF THE MAJOR PLAYERS ARE
- MERGERS AND ACQUISITION FORM KEY STRATEGY.
- TOP PLAYERS IN THE MARKET INCLUDE:
- CACO3 INDIA MARKET
- ASIA-PACIFIC EXPECTED TO DOMINATE THE GLOBAL MARKET
- LIST OF BUYERS IN INDIA
- FACTORS TO BE CONSIDERED
- RAW MATERIALS COMPOSITION
- RAW MATERIAL COMPOSITION
- THE PROPOSED PRODUCTION OF GROUND CALCIUM CARBONATE (GCC) IS 120 TPD.
- MANUFACTURING PROCESS
- PROCESS STEPS - GROUND CALCIUM CARBONATE PRODUCTION
- PROCESS STEPS
- THE PROPOSED TYPICAL SCHEMATIC IS AS FOLLOWS:
- UTILITY REQUIREMENT (ESTIMATED) - MONTH
- PLANT & MACHINERY BROADLY USED FOR THE PROCESS
- A) JAW CRUSHER
- JAW CRUSHER DIAGRAM
- JAW CRUSHER WORKING PRINCIPLE
- JAW CRUSHER FEATURES
- HIGH RELIABILITY
- HIGH STRENGTH
- STRONG BEARING CAPACITY
- BELT TYPE CONVEYOR
- BELT CONVEYOR DESIGN
- BELT CONVEYOR WORKING PRINCIPLE
- CONE CRUSHER
- AIR CLASSIFYING MILL
- DESIGN & OPTIONS:
- PULVERISER
- JET MILL
- PRINCIPLE OF OPERATION
- APPLICATIONS
- STORAGE SILO
- SLACKED LIME PACKING MACHINE
- PACKING MACHINE STRUCTURE
- FEEDING DEVICE
- MAIN TRANSMISSION DEVICE
- POWER SUPPLY SYSTEM
- ROTARY BIN
- WEIGHING MECHANISM
- BAGGING WEIGHING FRAME
- CYLINDER CONTROL MECHANISM
- DUST COLLECTING PLATE
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- MARKETS:
- WATER SUPPLY:
- CLIMATE:
- TRANSPORTATION:
- WASTE DISPOSAL:
- LABOR:
- REGULATORY LAWS:
- TAXES:
- COST OF SITE
- COMMUNITY FACTORS:
- FLOOD AND FIRE CONTROL:
- HEALTH SAFETY AND ENVIRONMENT
- DUST EMISSIONS ARE ONE OF THE MOST SIGNIFICANT IMPACTS.
- PROPOSED IMPLEMENTATION SCHEDULE
- MARKET SURVEY
- GLOBAL CALCIUM CARBONATE FILLER MASTERBATCH MARKET: SEGMENT ANALYSIS
- THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET ANALYSIS BY TYPES IS SEGMENTED INTO:
- THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET INDUSTRY RESEARCH BY APPLICATION IS SEGMENTED INTO:
- BASED ON APPLICATIONS, THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET FROM 2018 TO 2028 COVERS:
- SUPPLIERS OF PLANT & MACHINERY/TURNKEY CONSULTANTS
- BOILER
- GENERATOR SET (DG SET)
- COOLING TOWERS
- BALL MILLS
- SILO
- PACKAGING MACHINE
- WASTE GENERATION & MANAGEMENT/GREEN BELT
- GREEN BELT
- WASTE WATER
- HEALTH SAFETY AND ENVIRONMENT
- ANTICIPATED ENVIRONMENTAL IMPACTS
- CONSTRUCTION PHASE
- OPERATION PHASE
- MITIGATION MEASURES (PROPOSED)
- SAFETY & ENVIRONMENT MANAGEMENT PLAN
- SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
- PROPOSED IMPLEMENTATION SCHEDULE
- PROJECT FINANCIALS
- BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
- MACHINERY PHOTOGRAPHS
- PLANT & MACHINERY BROADLY USED FOR THE PROCESS
- JAW CRUSHER
- BELT TYPE CONVEYOR
- CONE CRUSHER
- AIR CLASSIFYING MILL
- PULVERISER
- JET MILL
- STORAGE SILO
- RAW MATERIAL PHOTOGRAPHS
- PRODUCT PHOTOGRAPHS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Ground calcium carbonate is primarily used as an industrial filler material. It improves product properties, enhances processability, and helps reduce production costs in plastics, rubber, paints, coatings, adhesives, paper, sealants, and construction materials. It is also widely used in the manufacture of plastic masterbatches, where it provides improved stiffness, dimensional stability, surface finish, and cost efficiency without significantly affecting product performance.
Calcium carbonate is widely used because it offers an effective balance of performance and cost. Its natural abundance, chemical stability, whiteness, and compatibility with many polymers make it suitable for numerous industrial formulations. It can improve rigidity, processing characteristics, and surface quality while lowering raw material costs, making it one of the most economical filler materials available.
Calcium carbonate is naturally found in limestone, marble, chalk, travertine, calcite, and dolomite. Many deposits originated from marine organisms that formed shells and skeletons composed of calcium carbonate. Over millions of years these materials accumulated, compacted, and formed extensive geological deposits that are now mined for industrial use.
Calcium carbonate filler is commonly used in plastics, rubber, paper, paints, coatings, adhesives, sealants, cable compounds, films, raffia products, and plastic composites. Manufacturers select it because it improves product consistency, supports efficient processing, and provides a cost-effective solution for a wide range of industrial applications.
A calcium carbonate masterbatch is a concentrated blend of calcium carbonate filler dispersed in a polymer carrier resin. It is added during plastic processing to improve material properties, simplify handling, and achieve consistent filler distribution. Masterbatches are commonly used in film extrusion, injection molding, blow molding, raffia production, and cable manufacturing.
Successful plant planning requires suitable raw material availability, appropriate crushing and grinding equipment, reliable utilities, efficient plant layout, environmental controls, transportation access, labor availability, regulatory compliance, and proper waste management. These factors help ensure efficient production, product quality, operational safety, and long-term commercial viability.
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