DUSTLESS CHALK (SCHOOL CHALK)
[EIRI/EDPR/1404] J.C: 180
INTRODUCTION
As found in nature, chalk has been used for drawing since prehistoric times, when, according to archaeologists, it helped to create some of the earliest cave drawings. Later, artists of different countries and styles used chalk mainly for sketches, and some such drawings, protected with shellac or a similar substance, have survived. Chalk was first formed into sticks for the convenience of artists. The method was to grind natural chalk to a fine powder, then add water, clay as a binder, and various dry colors. The resultant putty was then rolled into cylinders and dried. Chalk did not become standard in schoolrooms until the nineteenth century, when class sizes began to increase and teachers needed a convenient way of conveying information to many students at one time. Not only did instructors use large blackboards, but students also worked with individual chalkboards, complete with chalk sticks and a sponge or cloth to use as an eraser.
Almost all chalk produced today is dustless. Earlier, softer chalk tended to produce a cloud of dust that some feared might contribute to respiratory problems. Dustless chalk still produces dust; it’s just that the dust settles faster. Manufacturers accomplished this by baking their chalk longer to harden it more. Another method, used by a French company, is to dip eighty percent of each dustless chalk stick in shellac to prevent the chalk from rubbing off onto the hands.
Making white classroom chalk
To make white classroom chalk, the manufacturer adds water to calcium carbonate to form a thick slurry with the consistency of clay. The slurry is then placed into and extruded from a die – an orifice of the desired long, thin shape. Cut into lengths of approximately 24.43 inches (62 centimeters), the sticks are next placed on a sheet that contains places for five such sticks. The sheet is then placed in an oven or the hot sun where the chalk cures until it is very dry. After it has cured, the sticks are cut into 80 millimeters lengths.
Making colored classroom chalk
Pigments (dry, natural, colored materials) are mixed in with the calcium carbonate while both are dry (the procedure is similar to sifting flour and baking powder together before adding liquid, as in a cake recipe). Water is then added to the mixture, which is then baked in the same manner as white classroom chalk.
Boxing the chalk
Placed in small boxes, the completed chalk sticks are stacked in large boxes to be shipped to supply stores. Care must be taken when packing to prevent breakages. The quality of the box used must be strong enough to withstand breaking during transportation and handling.
COST ESTIMATION
Plant Capacity 50,000 Cases/Day
Land & Building (1500 sq.mt.) Rs. 1.52 Cr
Plant & Machinery Rs. 59.00 Lac
Working Capital for 2 Months Rs. 5.45 Cr
Total Capital Investment Rs. 7.91 Cr
Rate of Return 45%
Break Even Point 36%
CONTENTS
INTRODUCTION
USES
QUALITY CONTROL & BIS SPECIFICATIONS
MARKET SURVEY
DUSTLESS CHALK MANUFACTURERS
RAW MATERIALS
FORMULATION
MANUFACTURING PROCESS
PROCESS FLOW DIAGRAM
LAY OUT PLAN
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
A NOVEL DUSTLESS CHALK
ADVANTAGES OF THE PRESENT METHOD
DUSTLESS ERASER FOR BLACKBOARDS
DUSTLESS BAG DISCHARGE HOPPER
COMPLETE PANT SUPPLIERS FOR DUSTLESS CHALK (SCHOOL CHALK)
SUPPLIERS OF PLANT AND MACHINERIES
RAW MATERIAL SUPPLIERS
APPENDIX – A:
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)
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