MSME-DI KANPUR

PROJECT PROFILE

ON

CEMENT MOSAIC FLOORING TILES

NAME OF THE PRODUCT : CEMENT MOSAIC FLOORING TILES

PRODUCT CODE : 26921 & 29118.

QUALITY & STANDARD : IS:1237-2012.

IS:1443-1972.

YEAR OF PREPARATION : 2012 – 2013

PREPARED BY : MSME - Development Institute,

Ministry of Micro, Small & Medium Enterprises,
Government of India
107, Industrial Estate, Kalpi Road,
Kanpur-208012.
Tele. 2295070, 2295071 & 2295073 (EPBAX)
Tele. No. 2295072 (SENET & TRC)
Tele/Fax No.: 0512- 2240143
email: dcdi-kanpur@dcmsme.gov.in
Website: msmedikanpur.gov.in
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PROJECT PROFILE

ON

CEMENT MOSAIC FLOORING TILES

1. INTRODUCTION:

Mosaic Floor Tiles, which are known as Terrazzo Tiles, are made of cement
concrete and coloured stone chips. These are very attractive and colourful with
smooth shining surface. These tiles are made generally in the sizes of
200X200X20mm and 300X300 X25mm. These are extensively used for flooring
purposes in building and commercial complexes. These tiles can also be made in
various other sizes, shapes according to market demand. These are hard bearing
termite proof impermeable and easily cleanable. The top surface of the tiles is
decorated with marble stone chips of various colours with suitable addition of
cement colour.

2. MARKET POTENTIAL:

In view of growing building construction activity in rural and metropolitan cities

throughout the country, the demand for this Mosaic Tiles is ever increasing day by
day. Therefore, there is a good scope for the creation of additional capacity by
setting up new units in this line of manufacture in any part of the country.

3. BASIS & PRESUMPTIONS:

1. It is envisaged that the unit will work for 300 working days in a year on a single
shift basis of 8 hours per day.
2. Full plant capacity 1 to 2 months trial production is required to achieve.
3. The normal operative period is estimated 10 years, like considering the
technology involved in this type of industry. The usual payment period of loan is
about 8 years.
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4. PRODUCTION TARGET (Per Annum):

Quantity
(a) Grey Mosaic Tiles : 28,500 sq. mtr.
(b) Coloured Tiles 18,000 sq. mtr.

Value : Rs. 59,40,000/-

5. PRODUCTION DETAILS & PROCESS OF MANUFACTURE:

The process for the manufactured of mosaic tiles consists of two layers, the facing
and the backing layers. The mixtures for these layers are prepared and stored in
compartments provided in the work tables on both sides of the hydraulic presses.
Ratio of cement and coloured stone chips in the facing mixture varies from 1:15 to
1:5 and the proportion of sand and gray cement in the backing mixture is 3:1. The
moisture content of these mixtures differs from each other. The facing mixture
should be in the form of slurry whereas the backing mixture is in the dump
condition.

Four moulds are provided to 4 workmen who are engaged to work on one press
one after another. The steel mould fitted up with a bottom plate is filled in first with
facing mixture by means of a ladle to a depth of ¼” and over it moist backing
mixtures are spread out upto an area all thickness exceeding ¾“. The top portion is
lowered down and mixture is subjected to a pressure of approximately 2000 lbs per
sq inch and the final thickness of the pressed tiles generally brought down to ¾”.

After withdrawing the moulds from the press the tiles are removed and stocked in a
wooden rack fitted with handles on both sides where they are allowed to remain for
about a day. The tiles are then taken to task where they are submerged under
water for about 48 hours. After removing from the tanks, the tiles are kept under a
curing shed for about 2 weeks by spraying water every day. Then the tiles are
semi-polished in disc or super leveling machines.

The polar tints of red, yellow, buff and brown are very popular and they are
obtained usually from oxides of iron. ‘Pole Green’ shades obtained by additions of
chromium oxides are also quite good. Brighter coloures are produced by the use of
white cement rather than grey cement. Dark grey can be obtained by addition of
small quantities of manganese block on ‘carbon black’. Generally colours should
not be added in quantities exceeding 10 per cent of the weight of cement used in a
batch, as they are otherwise likely to lesson the strength of the tiles and increase
drying shrinkage.
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6. QUALITY CONTROL & STANDARDS:

The Bureau Of Indian Standards has formulated standard specifications such as: -
IS: 1237- 2012 & IS: 1443- 1972.

7. FINANCIAL ASPECTS:

A. Fixed Capital:

Land & Building Value (Rs. )

i) Land 1 acre. 60,000/-

ii) Built up area

Working Shed 50 sq. mtr. 85,000/-
Tanks & Workers Convenience 30,000/-
Well with pump set 40,000/-
Fencing on Compound Wall 25,000/-
Total: Rs. 2,40,000/-

B. Machinery & Equipment:

Sl. Description Qty. Amount

No (Nos.) (Rs.)
1. Hydraulic Press with gauge capacity 150 2 60,000/-
kgs per sq cm (2000 lbs per sq inch)
2. Hydraulic pump (double piston with 5 HP 1 25,000/-
motor of 940 RPM combined type V belt
drive capable of feeding 4 to 5 presses
attached with safety valve, works
automatically with accumulator.
3. Hydraulic accumulation complete with 1 15,000/-
pressure valve and connecting pipe.
4. Super leveling (grinding) machine motor 1 50,000/-
combined type V belt drive with 5 HP motor
of 1440 RPM attached with automatic device
for matching the plate of 6’ dia when work
put. Grinding capacity 4 tiles of 250X250mm
at a time.
5. Colour mixing machine with reduction gear 1 20,000/-
system and 5 HP motor
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6. Standard size pulveriser having capacity of 1 50,000/-

300 kg/hr of marble to a fineness of 100-250
mesh with connecting motor 40 HP and
2000 RPM.
7. Semi-Polishing machine with 1 Hp motor for 1 5,000/-
sample polishing and test tiles
8. Electrification & installation charges @ 10% 22,500/-
9. Tiles moulds 25,000/-
10 Weighing Machine work, working table, L.S. 25,000/-
rocks, sieves, shelves etc.
11 Office equipment 20,000/-
Total: - Rs. 3,17,500/-

TOTAL FIXED CAPITAL: Rs. 5,57,500/-

8. WORKING CAPITAL (Per Month)

(a) Personnel:

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

Manager (Works & Office) 1 10,000/- 10,000/-
Supervisor 1 7,000/- 7,000/-
Clerk-cum-Typist 1 7,000/- 7,000/-
Skilled Workers 4 6,000/- 24,000/-
Unskilled Workers 5 5,000/- 25,000/-
Watchman 2 5,000/- 10,000/-
Total:- 83,000/-
Perquisites @ 15% 12,450/-
Total: - 95,450/-

(b) Raw material & Consumables (Per Month)

Sl. Item Qty. Rate(Rs.) Value (Rs.)

No.
1. Portland Cement (Grey) 40 M.T. 2800/-MT 1,12,000/-
2. White cement 8 M.T. 8000/-MT 64,000/-
3. Marble stone 60 M.T. 1500/-MT 90,000/-
4. Black & Other coloured 5 M.T. 500/-MT 2,500/-
chips
5. Sand 1000 Cft 5/Cft 5,000/-
6. Oxalic acid, polishing L.S. 15,000/-
materials, Colouring
oxides etc
Total: - 2,88,500/-
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c) Utilities (Per Month)

Power Rs. 10,000/-

Water Rs. 4,000/-
Total: Rs. 14,000/-

d) Other recurring expenditure (Per Month)

1. Postage & Stationery Rs. 1,000/-

2. Telephone Rs. 2,000/-
3. Travel Expenses Rs. 3,000/-
4. Repair & Maintenance Rs. 3,000/-
5. Consumable Stores Rs. 3,000/-
6. Other Misc. Expenses Rs. 2,000/-
Total: Rs. 14,000/-

9. Total recurring expenditure (per month)

Total ( a to d ) Rs. 4,11,950/-

Total Working Capital for 3 months

4,11,950X 3 = Rs. 12,35,850/-

10. TOTAL CAPITAL INVESTMENT:

i) Fixed Capital Rs. 5,57,500/-

ii) Working Capital Rs. 12,35,850/-
Total: - Rs. 17,93,350/-

11. MACHINERY UTILISATION:

15% of installed capacity has been allowed as wastage while polishing

process.
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12. FINANCIAL ANALYSIS:

A) Cost of Production (Per annum)

Value(Rs.)
i) Working Capital 49,43,400/-
ii) Depreciation on machinery and equipment @ 10% 24,500/-
iii) Depreciation on building @ 5% 9,000/-
iv) Depreciation of Moulds @ 20% 5,000/-
v) Depreciation on Office Furniture @ 20% 5,000/-
vi) Interest on capital investment @ 16% 2,51,069/-
Total: - 52,37,969/-
Or Say 52,38,000/-

B) Turnover (Per annum)

Sl. Item Qty Rate Value (Rs.)

No. (in Sq. Mtr.) (Per Sq. Mtr.)
1. Grey Mosaic tiles 28,500 120/- 34,20,000/-
2. Coloured Mosaic 18,000 140/- 25,20,000/-
Tiles
Total: 59,40,000/-

13. Net Profit: (Per annum)

= Total Sales - Cost of Production

= Rs.59,40,000/- - 52,38,000/- = Rs 7,02,000/-

14. Net Profit Ratio(Per Annum):

Net Profit X 100 = 7,02,000 X 100 =11.82%

Turn over 59,40,000

15. Rate of Return (Per Annum):

= Net Profit X 100 = 7,02,000X 100 =39.14%

Total Capital Investment 17,93,350
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16. BREAK EVEN POINT

= Fixed Cost X 100
Fixed Cost + Annual Profit

Fixed Cost:

1. Depreciation on Building Rs. 9,000/-

2. Depreciation on Machinery & Equipment Rs. 24,500/-
3. Depreciation on Moulds Rs. 5,000/-
4. Depreciation on Office Furniture Rs. 5,000/-
5. 40% of salaries Rs. 4,58,160/-
6. 40% of other recurring expenses Rs. 67,200/-
7. Interest on Capital Investment Rs. 2,51,069/-
Total:- Rs. 8,19,929/-

BEP = 8,19,929 X 100 =53.87%

8,19,929 + 7,02,000

17. ADDRESS OF MACHINERY & EQUIPMENT SUPPLIERS:

1. M/s Kusum Engg. Co., 25, Swallow Lane, Kolkata.

2. M/s New Metals Mfg. Co., 59, Najafgarh Road, New Delhi.
3. M/s Balan Potteries, Mech. Division, P.O. Gungaon Road, New Delhi.
4. M/s Oriental Machinery supply Agencies Ltd., P-17, Mission Row
Extension, Kolkata.
5. M/s Arun Engg. Works, Gondal Road, Rajkot.
6. M/s National Indian Engg. Co. Ltd., 7/10, Elphinston Circles, Mumbai.
7. M/s Sadhana Engg. Co., 220, G Raj Baugh Estate, Khadilkar Road,
Mumbai.
8. M/s Industrial Development & Service Organisation, A-141, Defence
Colony, New Delhi.
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18. Address of Raw Materials Suppliers:

1. M/s Matha Industries Rentachinatala, P.O. Gundtur Distt. (A.P.)

2. M/s South India Mining Slab Co., P.O. Botamcherla, kurnool Distt. (A.P.)
3. M/s Imperial Chemical Industries, Chowranghee, Kolkata.
4. M/s Goodwill Trading Co., 39, Nagdevi Street, Mumbai-3.
5. M/s Diamond Minerals No.22, A.L. Thalgate Othavadi Street,
Opp. To Dadabhai Temple, Mammalverpet, Chennai-12.

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PSB*