Detailed Project Report on Dustless Chalk (School Chalk)

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)