PROJECT REPORT FOR THE

EXPANDED ACTIVITIES
@
M/s. Ultratech Cement Ltd

LIQUID MIX
(WATER PROOFING AGENT)
1.Project Summary
The details of the expansion project is furnished below.
Actual Existing
Sl. No Description Particular's Consent for expansion Units
Production/Consumption Proposed
Water proofing Agent 1300 1300 TPM Proposed
1 Product Manufacture
Total 1300 1300 MPM After Expansion
DM Water 745 745
Sodium Ligno Sulphonate 200 200
Apco C5500
114 114
( Liquid form)
Biocide
6 6
( Liquid form)
2 Raw Materials MTPM Proposed
TEA
95 95
( Liquid form)
Apco C651
75 75
( Powder form)
Cement Powder 65 65
Total 1300 1300
Domestic Effluent 10 10
Industrial -Trade 800 800 KLD Proposed
Water Consumption
Total 810 810
3 (Source - From Bore
Domestic 0 0
well/Tanker)
Industrial - Trade 0 0 KLD Existing
Total 0 0
Domestic Sewage 0 0
Industrial-Trade 0 0 KLD Proposed
Waste Water Total 0 0
4
Generation Domestic 0 0
Industrial - Trade 0 0 KLD Existing
Total 0 0
Waste Water Domestic Sewage Septic Tank followed by soak pit
5 Existing
Treatment Facility Industrial/Trade NA
Utilization of Treated Domestic Sewage Septic Tank followed by soak pit
6 Existing
Water Industrial NA
7 No of employees Staff & worker 51 Nos
Existing
8 Utilization of Area Land Area Sq Ft
9 Project Cost (Rs) 55 Lakhs 55 Lakhs

We are initiating production of following product -

A) Seal & Dry 5 Plus

B) Seal & Dry ILW Plus.

C) Seal & Dry SBR.

D) Seal & Dry Flex

E) Seal & Dry High Flex

1
All the Products uses DM Water as a main ingredient and all Products are manufactured in a
Closed loop cycle. RM’s are charged in the Vessel, mixed for uniform consistency, QC
analysis done and after Quality checks found ok is filled in different SKUs.

A) Seal & Dry 5 Plus.

Process Description

Raw Material used for Seal & Dry 5 Plus.

The principal raw materials for Liquid Plant are De Mineralized Water and Apco C 5500 Liquid.
The material is mixed for uniform distribution.
Some basic information about each of these key materials is detailed in this. Right from selecting
the raw materials to batching and mixing, packaging and transporting — UltraTech ensures
flawless operation in every stage. Clearly, it's all about putting together the right ingredients for
that perfect recipe.

a) De Mineralized Water. (DM Water)

De Mineralized water is taken from Vendors who are strictly matching our stringent quality
parameters. Before starting the supply, we take the Third Party certificate from recognized Labs
to ensure we get the desired quality product.
It is stored at plant in dedicated Tanks, which in turn is pumped directly into Ultra Tech Liquid
Plant Mixing vessel, thus protecting it from the external environment and contamination.

b) Apco C 5500

Apco C 5500 is available in liquid form. It is available in local.

It comes packed in 200Kgs Carboys.

Raw material consumption

The approximate consumption pattern of raw materials is as follows:

Production quantity Unit

Raw materials
100 % MT / month
DM Water 15 15 MT / month
Apco C 5500 85 85 MT / month

Raw material Input:

DM Water is stored at DW Water tank where the Tanker carrying DM water is unloaded.
The DM water from the tank is directly transferred to Liquid Plant Mixing vessel by properly
weighing through Weigh Balance.
Apco C 5500 is charged slowly by weighing proper quantity ensuring uniform mixing.

2
Batching and Mixing

Collection and weighment of DM Water is done before charging in vessel.

All other Raw material is charged by proper weighing through accurate Weigh Balance.
Liquid Plant- Packing Unit:
Liquid is packed in 1Kg. & 5Kgs. HDPE Bottles, 10Kgs. & 20Kgs. Pails.
We are using Semi-Automatic Filing machine, comprising of Auto cut off Control valve, Load
cell for proper weighing.

1Kg. & 5Kgs. bottles are packed in cartons to ensure good quality product is delivered at
Customer end.

End product used for “Water Proofing Agent”

Process Flow Chart

DM Water
Apco 5500
Storage

Mixing
Vessel
11.5

Filling Stations (Weigh metric filling)

Section Packing
V Plant

3
Quality Control System

The quality control of the Liquid plant products is ensured at various stages from selection
of raw material to manufacturing process.

a) Raw Material Selection & Use

Selection of the raw material will be done from the approved sources meeting
specification to use them. The sources are identified and quality of DM Water is
tested with help of external agencies or consultants.

The other chemicals used are taken from reputed Vendors.

b) Manufacturing

Manufacturing of the Liquid plant products is done using SS Agitators and in Syntax
Tanks.

The mixing of raw material is done with control parameters & for set time to ensure
good quality product.

The product quality is monitored while manufacturing through highly

sophisticated Lab equipment’s.

4
 B) Seal & Dry ILW Plus.

This product is produced by mixing Sodium Ligno Sulphonate powder in DM

water in Mixing vessel at room temperature and is simply a cold blending
process.
After the powder is mixed TEA and Biocide is added to enhance property of
Products.

Process Description

Raw Material used for Liquid Plant

The principal raw materials for Liquid Plant are De mineralized Water, Sodium Ligno Sulphonate
powder, TEA and Biocide.
Some basic information about each of these key materials is detailed in this. Right from selecting
the raw materials to batching and mixing, packaging and transporting — UltraTech ensures
flawless operation in every stage. Clearly, it's all about putting together the right ingredients for
that perfect recipe.

a) De Mineralized Water. (DM Water)

De Mineralized water is taken from Vendors who are strictly matching our stringent quality
parameters. Before starting the supply, we take the Third Party certificate from recognized Labs
to ensure we get the desired quality product.
It is stored at plant in dedicated Tanks, which in turn is pumped directly into Ultra Tech Liquid
Plant Mixing vessel, thus protecting it from the external environment and contamination.

b) Sodium Ligno Sulphonate Powder.

Sodium Ligno Sulphonate powder is taken from Vendors who are strictly matching our stringent
quality parameters. Before starting the supply, we take the Third Party certificate from
recognized Labs to ensure we get the desired quality product.
It comes in 25 Kg PP bags which are stored on wooden pallets.

c) TEA

TEA is in liquid form and in available in local.

It comes in 200 Kg drums.
TEA is taken from Vendors who are strictly matching our stringent quality parameters. Before
starting the supply, we take the Third Party certificate from recognized Labs to ensure we get the
desired quality product.

5
 d) Biocide

Biocide is in liquid form and in available in local

It comes in 200 Kg drums.
Biocide is taken from Vendors who are strictly matching our stringent quality parameters. Before
starting the supply, we take the Third Party certificate from recognized Labs to ensure we get the
desired quality product.

Raw material consumption:

The approximate consumption pattern of raw materials is as follows:
Production quantity Unit
Raw materials
1000 % KL / month
DM Water 699 69.9 MT / month
SodiumLigno
200 20 MT / month
Sulphonate Powder
TEA 95 9.5 MT / month
Biocide 6 0.6 MT/ month

Raw material Input:

DM Water is stored at DW Water tank where the Tanker carrying DM water is unloaded.
The DM water from the tank is directly transferred to Liquid Plant Mixing vessel by properly
weighing through Weigh Balance.

Sodium Ligno Sulphonate powder is charged in Mixing vessel once required quantity of DM water
is taken in the vessel.
The powder is charge slowly to ensure uniform mixing so that no lumps are generated during
charging & in the process. Required quantity of Surfactant is charged to ensure good quality
product is obtained.

After Surfactant is uniformly mixed, then TEA is charged slowly to ensure it is mixed properly.

After uniform mixing is done Biocide is charged by weighing proper quantity.

Batching and Mixing

Collection and weighment of DM Water is done before charging in vessel.

All other Raw material is charged by proper weighing through accurate Weigh Balance.

Liquid Plant- Packing Unit:

Liquid is packed in 200ML, 1L & 5L HDPE Bottles, 10L & 20L Pails, 50L & 100L Carboys.
We are using Semi-Automatic Filing machine, comprising of Auto cut off Control valve, Load
cell for proper weighing.
200ML, 1L & 5L bottles are packed in cartons to ensure good quality product is delivered at
Customer end.

End product used for “Water Proofing Agent”

6
 Process Flow Chart

Sodium Ligno
Sulphonate
TEA
Biocide Powder
DM WATER

Mixing
Vessel

Storage Vessel 1
Storage Vessel 2

Filling Stations (Weigh metric filling)

Packing Plant

7
 Section V

Quality Control System

The quality control of the Liquid plant products is ensured at various stages from selection
of raw material to manufacturing process.

a) Raw Material Selection & Use

Selection of the raw material will be done from the approved sources meeting
specification to use them. The sources are identified and quality of DM Water is
tested with help of external agencies or consultants.

The other chemicals used are taken from reputed Vendors.

b) Manufacturing

Manufacturing of the Liquid plant products is done using SS Mixing vessel & Flow
meters which has latest technologies and features.

The mixing of raw material is done with control parameters & for set time to ensure
good quality product.

The product quality is monitored while manufacturing through highly sophisticated Lab
equipment’s.

8
 C) Seal & Dry SBR.

This product is produced by mixing Apco 651 Liquid in DM water in Mixing vessel at room
temperature and is simply a cold blending process

Process Description

Raw Material used for Liquid Plant

The principal raw materials for Liquid Plant are De mineralized Water and Additive.
Some basic information about each of these key materials is detailed in this. Right from selecting
the raw materials to batching and mixing, packaging and transporting — UltraTech ensures
flawless operation in every stage. Clearly, it's all about putting together the right ingredients for
that perfect recipe.

a) De Mineralized Water. (DM Water)

De Mineralized water is taken from Vendors who are strictly matching our stringent quality
parameters. Before starting the supply we take the Third Party certificate from recognized Labs
to ensure we get the desired quality product.
It is stored at plant in dedicated Tanks, which in turn is pumped directly into Ultra Tech Liquid
Plant Mixing vessel, thus protecting it from the external environment and contamination.

b) Apco 651

Apco 651 is available in liquid form. It is available in local.

It comes packed in 200Kgs Carboys.

Raw material consumption:

The approximate consumption pattern of raw materials is as follows:

Production quantity Unit
Raw materials
100 % MT / month
DM Water 25 25 MT / month
Apco 651 75 75 MT / month

Raw material Input:

DM Water is stored at DW Water tank where the Tanker carrying DM water is unloaded.
The DM water from the tank is directly transferred to Liquid Plant Mixing vessel by properly
weighing through Weigh Balance.

Apco 651 is charged slowly by weighing proper quantity ensuring uniform mixing.

9
Batching and Mixing

Collection and weighment of DM Water is done before charging in vessel.

All other Raw material is charged by proper weighing through accurate Weigh Balance.

Liquid Plant- Packing Unit:

Liquid is packed in 200Gms, 1Kg. & 5Kgs. HDPE Bottles, 10Kgs. & 20Kgs. Pails, 50Kgs.
Carboys.
We are using Semi-Automatic Filing machine, comprising of Auto cut off Control valve, Load
cell for proper weighing.

200Gms., 1Kg. & 5Kgs. bottles are packed in cartons to ensure good quality product is
delivered at Customer end.

End product used for “Water Proofing Agent”

Process Flow Chart

DM Water Apco 651

Mixing
Vessel

Filling Stations (Weigh metric filling)

Packing Plant

10
 Section V

Quality Control System

The quality control of the Liquid plant products is ensured at various stages from selection
of raw material to manufacturing process.

a) Raw Material Selection & Use

Selection of the raw material will be done from the approved sources meeting
specification to use them. The sources are identified and quality of DM Water is
tested with help of external agencies or consultants.

The other chemicals used are taken from reputed Vendors.

b) Manufacturing

Manufacturing of the Liquid plant products is done using SS Agitators and in Syntax
Tanks.

The mixing of raw material is done with control parameters & for set time to ensure
good quality product.

The product quality is monitored while manufacturing through highly sophisticated Lab
equipment’s.

D) Seal & Dry Flex.

Process Description

Raw Material used for Liquid Plant

The principal raw materials for Liquid Plant are De mineralized Water and Additive.
Some basic information about each of these key materials is detailed in this. Right from selecting
the raw materials to batching and mixing, packaging and transporting — UltraTech ensures
flawless operation in every stage. Clearly, it's all about putting together the right ingredients for
that perfect recipe.

De Mineralized Water. (DM Water)

De Mineralized water is taken from Vendors who are strictly matching our stringent quality
parameters. Before starting the supply, we take the Third Party certificate from recognized Labs
to ensure we get the desired quality product.
It is stored at plant in dedicated Tanks, which in turn is pumped directly into Ultra Tech Liquid
Plant Mixing vessel, thus protecting it from the external environment and contamination.

11
Additive

Additive 1

Additive 1 is available in liquid form. It is available in local.

It comes packed in 200Kgs Carboys.

Additive 2

Additive 2 is cement based product.

It comes packed in 10Kg Plastic Pouch.

Raw material consumption:

The approximate consumption pattern of raw materials is as follows:

Production quantity Unit
Raw materials
50 % MT / month
DM Water 4 8 MT / month
Additive 1 11 22 MT / month
Additive 2 35 70 MT / month

Raw material Input:

DM Water is stored at DW Water tank where the Tanker carrying DM water is unloaded.
The DM water from the tank is directly transferred to Liquid Plant Mixing vessel by properly
weighing through Weigh Balance.

Additive1 is charged slowly by weighing proper quantity ensuring uniform mixing.

Additive2 is directly given in Carton with Liquid part which is mixed at the time of application.

Batching and Mixing

Collection and weighment of DM Water is done before charging in vessel.

All other Raw material is charged by proper weighing through accurate Weigh Balance.

Liquid Plant- Packing Unit:

Liquid is packed in 5Kg and 10 Kgs. HDPE Bottles,

Powder comes in Plastic Pouch Packing of 10Kgs.
We are using Semi-Automatic Filing machine, comprising of Auto cut off Control valve, Load
cell for proper weighing for Liquid component.

Product is packed in 2 SKU’s 15Kgs. And 30Kgs.

SKU 15 Kg consist of 5Kg Liquid Bottle and 10Kgs. Pouch both packed in Single Carton.
SKU 30 Kg consist of 10Kg Liquid Bottle and 10Kgs two Pouches both packed in Single
Carton.

12
Process Flow Chart

DM Water
Additive 2

Mixing
Vessel

Packing Plant

13
 Section V

Quality Control System

The quality control of the Liquid plant products is ensured at various stages from selection
of raw material to manufacturing process.

A) Raw Material Selection & Use

Selection of the raw material will be done from the approved sources meeting
specification to use them. The sources are identified and quality of DM Water is
tested with help of external agencies or consultants.

The other chemicals used are taken from reputed Vendors.

B) Manufacturing

Manufacturing of the Liquid plant products is done using SS Agitators and in Syntax
Tanks.

The mixing of raw material is done with control parameters & for set time to ensure
good quality product.

The product quality is monitored while manufacturing through highly

sophisticated Lab equipment’s.

E) Seal & Dry High Flex.

Process Description

Raw Material used for Liquid Plant

The principal raw materials for Liquid Plant are De mineralized Water and Additive.
Some basic information about each of these key materials is detailed in this. Right from selecting
the raw materials to batching and mixing, packaging and transporting — UltraTech ensures
flawless operation in every stage. Clearly, it's all about putting together the right ingredients for
that perfect recipe.

De Mineralized Water. (DM Water)

De Mineralized water is taken from Vendors who are strictly matching our stringent quality
parameters. Before starting the supply, we take the Third Party certificate from recognized Labs
to ensure we get the desired quality product.

14
It is stored at plant in dedicated Tanks, which in turn is pumped directly into Ultra Tech Liquid
Plant Mixing vessel, thus protecting it from the external environment and contamination.
Additives

Additive 1
Additive 1 is available in liquid form. It is available in local.
It comes packed in 200Kgs Carboys.

Additive 2

Additive 2 is cement based product.

It comes packed in 10Kg Plastic Pouch.

Raw material consumption:

The approximate consumption pattern of raw materials is as follows:

Production quantity Unit

Raw materials
50 % MT / month
DM Water 2 4 MT / month
Additive 1 18 36 MT / month
Additive 2 30 60 MT / month

Raw material Input:

DM Water is stored at DW Water tank where the Tanker carrying DM water is unloaded.
The DM water from the tank is directly transferred to Liquid Plant Mixing vessel by properly
weighing through Weigh Balance.

Additive1 is charged slowly by weighing proper quantity ensuring uniform mixing.

Additive2 is directly given in Carton with Liquid part which is mixed at the time of application.

Batching and Mixing

Collection and weighment of DM Water is done before charging in vessel.

All other Raw material is charged by proper weighing through accurate Weigh Balance.

Liquid Plant- Packing Unit:

Liquid is packed in 5Kg and 10 Kgs. HDPE Bottles,

Powder comes in Plastic Pouch Packing of 7Kgs.
We are using Semi-Automatic Filing machine, comprising of Auto cut off Control valve,
Load cell for proper weighing for Liquid component.

Product is packed in 2 SKU’s 12Kgs. And 24Kgs.

SKU 12 Kg consist of 5Kg Liquid Bottle and 7Kgs. Pouch both packed in Single Carton.
SKU 24 Kg consist of 10Kg Liquid Bottle and 7Kgs two Pouches both packed in Single
Carton.
End product used for “Water Proofing Agent”

15
 Process Flow Chart

DM Water
Additive 1 Additive 2

Mixing
Vessel

Packing Plant

16
 Section V

Quality Control System

The quality control of the Liquid plant products is ensured at various stages from selection
of raw material to manufacturing process.

a) Raw Material Selection & Use

Selection of the raw material will be done from the approved sources meeting
specification to use them. The sources are identified and quality of DM Water is
tested with help of external agencies or consultants.

The other chemicals used are taken from reputed Vendors.

b) Manufacturing

Manufacturing of the Liquid plant products is done using SS Agitators and in Syntax
Tanks.

The mixing of raw material is done with control parameters & for set time to ensure
good quality product.

The product quality is monitored while manufacturing through highly

sophisticated Lab equipment’s.

Section VI

Equipment details of production machine & Utility

1) Seal & Dry ILW Plus SS high speed Agitator 5KL- 10 HP,3 Phase
2) Seal & Dry ILW Plus SS high speed Agitator 5KL- 10 HP,3 Phase
3) Seal & Dry SBR Liquid slow speed Agitator 1.5 KL-1 HP,3 Phase
4) Seal & Dry 5 Plus liquid slow speed Agitator 1.5 Kl-1HP,3 Phase
5) DM Water storage tank 5KL -2 Nos
6) Seal & Dry ILW Plus storage tank-5kL 2 Nos
7) DM water transfer pump-5HP,3 Phase
8) Seal & Dry ILW liquid transfer pump-5HP,3 Phase
9) Seal & Dry SBR liquid transfer pump-1HP ,3 phase
10) Seal & Dry 5 Plus liquid transfer pump-1HP,3 Phase
11) Plant light load-2HP
12) Liquid filling stations-1HP

17