Detailed Project Report on detergent powder & cake manufacturing (cake manufacturing (fena type) (mixing process)

DETERGENT POWDER & CAKE MANUFACTURING
(FENA TYPE) (MIXING PROCESS)
[CODE NO.3208]  


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 facilitates 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.

         The principal types of synthetic detergents are an ionic, non-ionic and employtics. Sodium dodecyle benzene sulphonate is an example of the ionic type while nylon phenol, nylone oxide obtained from ethylene oxide is the non-ionic  type. The amploytic detergents like the alkyl amino propionates behave  as cations in acidic solutions and like anions in alkaline solution.

     Among the numerous detergent powders are available today in the market eg. Fena, Hipoline, T.Series, Areal, Surf, Sunlight, Nirma, Wheel detergent powders and cakes are most popular.
     
Soaps are the earliest form of detergents. Though at present the term detergent is used for synthetic detergents derived from petroleum products. The origin of soap making is unknown. The phoenicians were acquainted with it by at least 600 B.C. and it was known the gauls not later than about 300 B.C.

From the 1940's on-ward, synthetic detergent have expanded rapidly all over the world. Their rapid development has been stimulated by the enormous and fast growth of the international petro-chemical industry. The transition from conventional hard soaps to synthetic detergent cake has been rapid and irreversible response by consumers. So that to-day, synthetic detergent accounts in most developed and under developing countries in the world. To improve detergency of the detergent cakes powders, certain  other  components were added to it  known as builders, synergers, fillers and brighteners etc.

The synthetic detergent industry is one of the largest chemical process industries. The most recent estimates indicate an annual U.S production of synthetic detergents of about 3 million tones with an approximate annual value of 2 billion. The industry differs from many other chemical process industries, however, in that the bulk of its production is sold directly to individuals for house  hold consumption primarily as branded products, rather than to industrial or institutional users.


COST ESTIMATION

Plant  Capacity                                                     :    13.00 Tons/day           
land & Building (1360 sq.mtrs)                         :    Rs. 24.00 Lacs
Plant & Machinery                                                :    Rs. 12.00 Lacs
Working Capital for 2 Months                            :    Rs. 2.80  Cr
Total Capital Investment                                    :    Rs. 3.21  Cr
Rate of Return                                                      :   40%
Break Even Point                                                 :   36%


INTRODUCTION    
PROPERTIES OF WASHING SOAP AND WASHING POWDER    
USES AND APPLICATION    
FEATURES OF DETERGENT POWDER FOR HARD WATER    
B.I.S. SPECIFICATION    
RAW MATERIAL REQUIREMENT    
OVERVIEW OF DETERGENT INDUSTRY IN INDIA    
TIDE    
PRODUCT MARKET ANAYSIS    
SWOT ANALYSIS    
BCG MATRIX    
MARKETING STRATEGY    
MARKETING MIX    
PROMOTION:    
MARKET ANALYSIS    
MARKET SURVEY    
MARKET OVERVIEW    
FIGURE 2: SUB-CATEGORY BY DETERGENT TYPE    
DOMINANCE BY MNCS    
FIGURE 3: MARKET SHARE BY MANUFACTURERS    
FIGURE 4: MARKET SHARE BY BRAND    
DEFINING THE RESEARCH PROBLEM    
DEVELOPMENT OF PRODUCT CONCEPTS:    
DATA ANALYSIS AND INFERENCE BUILDING    
A) ASSESSMENT OF THE OPPORTUNITY FOR A NEW VARIANT    
1) REASON FOR USING CURRENT BRAND / VARIANT:    
TABLE 1 REASON FOR USING CURRENT BRAND    
2) USE OF MULTIPLE MEDIUM FOR WASHING CLOTHES    
TABLE 2 MEDIUM OF WASHING CLOTHS    
TABLE 3 NO. OF MEDIUM USED FOR WASHING    
3) USE OF MULTIPLE WASHING DETERGENT BRANDS    
TABLE 4 DETERGENT BRANDS USED    
TABLE 5 NO. OF DETERGENT BRANDS USED    
B) CHECKING IMPORTANT ATTRIBUTES/BENEFITS    
ON THE BASIS OF RANKS    
TABLE 6 MEDIAN RANKS FOR FEATURES IN DETERGENT BRAND    
ON THE BASIS OF RATINGS    
TABLE 7 STATISTICS FOR EACH FEATURE OF DETERGENT BRAND    
EXPORT DATA OF DETERGENT POWDER    
EXPORT DATA OF DETERGENT CAKE    
PRESENT MANUFACTURERS/SUPPLIERS/EXPORTERS OF
DETERGENT POWDERS    
COMPARATIVE ANALYSIS AND TEST OF DETERGENTS    
NO STOPPING AS OF NOW    
BRANDS TESTED    
KEY FINDINGS    
TEST RESULTS FOR PHYSICOCHEMICAL PARAMETERS    
FRAGRANCE    
WHICH VARIANT TO USE AND WHERE?    
PACKING AND MARKING    
PLASTIC ALERT    
MANUFACTURE OF DETERGENT POWDER    
PROCESS - I    
PROCESS - 2    
1. FORMULATION : FOR 500 KG BATCH.    
2. FORMULA : FOR 100 KG. BATCH.    
THE FORMULATION USED FOR MANUFACTURING THE DETERGENT
POWDER IS GIVEN BELOW:    
PROCESS OF MANUFACTURE    
OF WASHING DETERGENT POWDER    
SURF EXCEL TYPE DETERGENT POWDER    
FORMULATION - 1    
HIGHER GRADE/QUALITY ARIEL TYPE DETERGENT POWDER
(ENZYME BASED DETERGENTS)    
FORMULATION - 1    
FORMULATION OF DETERGENT POWDER,    
SURF EXCEL TYPE    
FORMULATION OF DETERGENT POWDER, WHEEL TYPE    
OTHERS FORMULATION AND PROCESS OF GOOD QUALITY DETERGENT POWDER    
THE FOLLOWING FORMULATIONS ARE FOR MANUFACTURE OF DETERGENT POWDER:-    
PRECAUTION    
THE GRINDING MACHINE    
RAW MATERIALS    
METHODS FOR PERFORMANCE TESTS FOR SURFACE ACTIVE AGENTS    
PART-I RELATIVE DESPERSING POWDER    
SURFACE ACTIVE AGENTS    
OUTLINE OF METHOD    
APPARTUS    
PREPARATION OF SOLUTIONS    
PROCEDURE    
CALCULATION AND REPORTING    
CALCULATION    
WHERE    
PART - II RELATIVE EMULSIFYING POWER    
OUTLINE OF METHOD    
REAGENTS    
LIQUID PARAFFIN    
APPARATUS    
PREPARATION OF STOCK SOLUTION    
PROCEDURE    
CALCULATION AND REPORTING    
PART - V WETTING POWER    
OUTLINE OF THE METHOD    
APPARATUS    
FORMULATION OF DETERGENT POWDER    
FORMULATION OF DETERGENT CAKE (FENA TYPE)    
FORMULATION OF DETERGENT POWDER (FENA TYPE)    
TYPICAL FORMULATION OF DETERGENT POWDER AND BAR    
MANUFACTURING PROCESS OF DETERGENT CAKE    
PROCESSING DETAILS OF DETERGENT BAR & CAKES    
CORRESPONDINGLY RAISED.    
SURF EXCEL TYPE DETERGENT POWDER    
FORMULATION - 1    
PROCESS    113
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERIES    
MACHINERY USED    
SIGMA MIXER    
BELT CONVEYOR    
SIMPLEX PLODDER    
ROTARY CUTTER    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET