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REPORT ON SUMMER TRAINING HELD AT DCW LIMITED, SAHUPURAM

1. INTRODUCTION

An Internship is a period of work experience offered by an organization for

a limited period of time. They are typically undertaken by students and graduates
looking to gain relevant skills and experience in a particular field. Typically an
internship consists of an exchange of services for experiences between the trainee
and the organization.

Internships are used to determine the interest in that field after the real-life
experiences. In addition, an internship can be used to create a professional network that
can assist with letters of recommendation or lead to future employment opportunities.
Internship provide trainee to participate in a field of his choice to receive hands on
learning about a particular future career, preparing them for full-time work following
graduation. Internship is one of pre-job experience where the trainee got practical
knowledge of the corporate world. A successful Trainee can look forward to progressing
further as a leader.

According to Anna University Regulation, the internship is must for a student

for four weeks. Internship period is helpful for enhancing knowledge related to the
company. During internship period trainee come to know about various processes carried
out in the company. It is a good opportunity for the trainee to get managerial skills
through the training.

2. AIM

The aim of the summer training or internship is to develop skills in the

application of theory to practical work situations.

 To develop skills with techniques directly applicable for the career.

 To get depth knowledge of the formal functional activities of a participating

organizations and to know various other functional activities.
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3. INDUSTRY PROFILE
3.1.INTRODUCTION
The chemical industry comprises the companies that produce industrial chemicals.
Central to the modern world economy, it converts raw materials (oil, natural gas, air,
water, metals, and minerals) into more than 70,000 different products. The plastics industry
contains some overlap, as some chemical companies produce plastics as well as chemicals.
Various professionals are involved in the chemical industry including chemical engineers,
chemists and lab technicians. As of 2018, the chemical industry comprises approximately 15%
of the US manufacturing economic sector.

Basic chemicals or "commodity chemicals" are a broad chemical category including

polymers, bulk petrochemicals and intermediates, other derivatives and basic industrials,
inorganic chemicals, and fertilizers.

Polymers are the largest revenue segment and include all categories of plastics and
man-made fibres. The major markets for plastics are packaging, followed by home
construction, containers, appliances, pipe, transportation, toys, and games.

The largest-volume polymer product, polyethylene (PE), is used mainly in packaging

films and other markets such as milk bottles, containers, and pipe.

Polyvinyl chloride (PVC), another large-volume product, is principally used to make

piping for construction markets as well as siding and, to a much smaller extent, transportation
and packaging materials.

Polypropylene (PP), similar in volume to PVC, is used in markets ranging from

packaging, appliances, and containers to clothing and carpeting.

Polystyrene (PS), another large-volume plastic, is used principally for appliances and
packaging as well as toys and recreation.

The leading man-made fibers include polyester, nylon, polypropylene, and acrylics,
with applications including apparel, home furnishings, and other industrial and consumer use.

Principal raw materials for polymers are bulk petrochemicals like ethylene, propylene
and benzene.
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3.2. PETRO-CHEMICALS

Petrochemicals and intermediate chemicals are primarily made from liquefied

petroleum gas (LPG), natural gas and crude oil fractions. Large volume products include
ethylene, propylene, benzene, toluene, xylenes, methanol, vinyl chloride monomer (VCM),
styrene, butadiene, and ethylene oxide. These basic or commodity chemicals are the starting
materials used to manufacture many polymers and other more complex organic chemicals
particularly those that are made for use in the specialty chemicals category.

Other derivatives and basic industrials include synthetic rubber, surfactants, dyes and
pigments, turpentine, resins, carbon black, explosives, and rubber products and contribute
about 20 percent of the basic chemicals' external sales.

Inorganic chemicals (about 12 percent of the revenue output) make up the oldest of the
chemical categories. Products include salt, chlorine, caustic soda, soda ash, acids (such as nitric
acid, phosphoric acid, and sulfuric acid), titanium dioxide, and hydrogen peroxide.

Fertilizers are the smallest category (about 6 percent) and include phosphates,
ammonia, and potash chemicals.

3.3. WORLD CHEMICAL PRODUCTION

The scale of chemical manufacturing tends to be organized from largest in volume

(petrochemicals and commodity chemicals), to specialty chemicals, and the smallest, fine
chemicals.
The petrochemical and commodity chemical manufacturing units are on the whole
single product continuous processing plants. Not all petrochemical or commodity chemical
materials are made in one single location, but groups of related materials often are to induce
industrial symbiosis as well as material, energy and utility efficiency and other economies of
scale.
Specialty chemical and fine chemical manufacturing is mostly made in discrete batch
processes. These manufacturers are often found in similar locations but in many cases they are
to be found in multi sector business parks.
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3.4. CHEMICAL INDUSTRY IN INDIA

The Indian chemical industry mainly produces basic types of chemicals as well as
knowledge type chemicals and specialty type chemicals as of 2018.[5] In India, Gujarat was the
largest state contributor to the chemical industry of India in 2018. [6] India also produces
products related to petrochemicals, fertilizers, paints, varnishes, glass, perfumes, toiletries,
pharmaceuticals, etc.

The India chemical industry is divided into six sub-segments. These sub-segments are
Basic Organic Chemicals, Specialty Chemicals, Chlor-alkali, Pesticides, Dyestuff, and
alcohol-based chemicals. India is a major producer of basic organic chemicals.

In India, the Council of Scientific and Industrial Research (CSIR) was established in
1942 with the aim of providing scientific and industrial research to maximize the scientific,
economic, and environmental benefits to the people of India.

The Indian Chemical Manufacture association, now called Indian Chemical

Association (ICC) was founded in 1938 in by P. C. Ray, Rajmitra B. D. Amin and other
Industries to promote the national chemical industry of India.

In India, the first pharmaceutical company set up was Bengal Chemicals and
Pharmaceutical. Bengal Chemicals and Pharmaceutical was set up by P.C Ray, professor of
chemistry at Calcutta University. After 9 years of settlement of this company, one more
company called Alembic Chemical works at Baroda (Now as Vadodara) in Gujarat was set up.

Before World War II, foreign companies had the domain in the drug industry of India.
After World War II, foreign company domain in drugs decreased and more Indian drug
companies were established. During this time, the Indian government established five drug
companies. The two of them are Hindustan Antibiotics Limited and Indian Drugs and
Pharmaceutical companies.

After India got independence from the British Raj in 1947, India established many units
of basic chemicals, dyes, textiles and fertilizers. In 1964, a downstream plant was established
in Mumbai.

In the 1980s and 1990s, the petroleum industry of India had grown faster with the
development of the gas cracker, along with related downstream industries for polymers,
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Synthetic fibers, aromatic and other chemicals. In early 1980, the IPCL had established a
plant-based on a cracker in Gujarat and Maharashtra.

India has been suppressed by inadequate supply and high import duties in the petroleum
industry, which led to private industry entry into the petroleum industry. Reliance industries
have set up many parts in PatalGanga (Maharashtra), Jamnagar (Gujarat), Hazira (Gujarat).
This led to an increased role of Reliance industries in the petroleum industry. This has led to
the entry of Reliance industries into the polyester business, such as purified terephthalic acid,
and polyethylene terephthalate resin. These new materials are used to make polyester fibre,
bottle and filementation .

3.5. GLOBAL VIEW

The United States is the top chemical producer in the world, accounting for
nearly one- fifth of world production. With chemical shipment reaching nearly $720
billion in 2010, the chemical industry provides over $226 billion to the U.S. GDP,
approximately 2% of the total. The industry exported a record $171 billion in chemicals
in 2010, accounting for 10% of all U.S exports. On a value-added basis, it is the second
largest U.S manufacturing sector. Most production of basic chemicals is concentrated
along the Gulf Coast, where petroleum and natural gas feed stocks are available in
refineries. Texas and Louisiana produces a majority of all primary petrochemicals.

Production of other products, such as plastics, pharmaceuticals, and fertilizers is more

widely dispersed among the states.

Chemical companies in the United States directly employees 784,000 people and
indirectly contribute 4.4 million jobs to the economy in chemistry-dependent industries.
In 2010, the average wage for an employee in the chemical industry was $81,900.

3.6. EFFECTS OF GLOBALIZATION ON CHEMICAL INDUSTRY

The chemical industry has been traditionally been developed in protected

environment. The globalization posed several challenges to the Indian Chemical Industry.
The Indian chemical manufacturers were not globally competitive and hence they
struggled to deliver quality as the import quality chemicals (KPMG, 2004). Another
challenge Indian Industry faced is the environmental regulations forced by the policy
makers due to the International pressure.
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Entry of Foreign Players like Dow chemicals, Akzo Noble and BASF has madethe
Industry more competitive. As explained by Mr.P.N.Shah, GM Larsen & Toubro Ltd,
the foreign players use the world-class technology which gives both, Cost effective as well
as better quality products. The import duty has been reduced after opening the economy. This
has made Indian Producers suffer. Especially, the smaller players were affected adversely.
The earlier years of 21st century saw closing of many small scale players in India. This
hinted Government of India to take up initiatives such as Cluster Development approach for
the development in India.

Prof. R.N.Shukla stressed upon the point that Indian Chemical Industry faces the
challenge of dumping which is also a resultant of Globalization. This has made the
import cheaper and local producers less competitive. This also resultant into shift of
focus towards export markets for the Industry. The lower capital and Labour cost make
Indian Exports competitive . The Stringent environment regulation in USA and Europe, the
exports market for dyestuff industry has hence seen tremendous growth in the past few
years. The rise of so many small export oriented manufacturers can be attributed to
this fact.

3.7. CAUSTIC SODA INDUSTRIES

The caustic soda industries in India and their forecasting for an future India’s
Caustic Soda plant capacity is forecasted to grow at a compound annual growth rate
(CAGR) of 6.1% from 3.751 million tonnes per annum (mtpa) in 2017 to 5.032 mtpa
in 2022 .

In fiscal year 2020, the production volume of caustic soda across India was around 3.1
million metric tons. The Indian chemical industry is highly diversified. With coverage of over
80 thousand products, the south Asian country was the sixth largest producer of chemicals in
the world and the fourth largest in Asia.

Caustic soda (sodium hydroxide) is a versatile alkali. Its main uses are in the
manufacture of pulp and paper, alumina, soap and detergents, petroleum products and chemical
production. Other applications include water treatment, food, textiles, metal processing,
mining, glass making and others. Around three-quarters of end use demand tracks GDP growth
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One of the largest consumers of caustic soda is the pulp and paper industry where it is
used in pulping and bleaching processes, the de-inking of waste paper and water treatment.
Global growth is confined to GDP levels.

The production of alumina from bauxite is a major end-use application for caustic soda.
Demand has been growing faster than GDP levels driven by the growth in the use of aluminum.
While consumption of caustic soda in alumina refining accounts for 11% of global demand,
this use consumes more than half of caustic soda globally traded.

India Caustic Soda market demand stood at 3.43 Million Tonnes in FY2021 and is
forecast to reach 5.52 Million Tonnes by FY2030, growing at a healthy CAGR of 5.43% until
FY2030. Caustic soda is an inorganic bulk chemical that is soapy in touch, strongly alkaline,
and odourless that finds application in various fields like pulp and paper manufacturing, viscose
yarn, staple fiber, aluminium, textiles, soaps & detergent, dyestuffs, drugs and pharmaceuticals,
petroleum refining, etc. Increasing demand from the textile and alumina sectors due to rising
investments in these sectors by the Government of India is likely to drive the overall Caustic
Soda demand in the country

India is a surplus in Caustic Soda production volumes with most of the plants operating
at around 85% efficiency. However, the increase in cheaper imports has forced domestic
manufacturers to curtail their margins predominantly due to the high input and logistics costs
involved within the country. Although disruptions in overseas trade and nationwide lockdown
weighed on the overall Caustic Soda consumption in Q4 FY2020, strengthened Caustic Soda
demand from hand wash and soaps manufacturing industries supported the industry outlook
during the Coronavirus outbreak. In addition to that, the extension of Anti-Dumping Duty on
the imports of Caustic Soda from the U.S. and Saudi Arabia, as per the petition filed by the
Alkali Manufacturers Association of India (AMAI) in FY2017 has given a strong boost to the
domestic Caustic Soda Industry.

3.8. AN OPPORTUNITY FOR PHARMACEUTICAL SECTOR

Traditionally, chemical companies were organized along commodity and specialist

chemical lines with some hybrid companies in between. The emergence of Life science
has created new business opportunities. Many chemical companies have reinvented
as life science companies in at the start of 21st Century. The industry has also seen
many companies changing character from commodity player to service providers
working very closely with their customers to serve the final end user. In any case,
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the character of chemical industry has been different in the last decades. As Mr.Mukesh
Ambani said at the India Chem 2006, “The challenges is the inflexible attitudes,
concentration as core skills, assimilation of new skill sets and capabilities and working
with customers in a partnership made. I believe that the chemical industry is at the
doorsteps of a new technology revolution that will dwarf earlier information technology
revolution, the world have seen.” He also noted that the chemical industry adopted
physics in the 20th century. It will embrace biology in the 21st century. Hence, the
most exciting opportunity for the chemical industry has been in life science and notably
biotechnology as well as molecular science. Chemical industry has the opportunity of
using the biotechnology platform to bring about new products, energy efficient and
pollution free process and alternatives bio routes to conventional products in the coming
years.

The developing countries are facing problems like Declining R&D productivity,
Shrinking R&D pipeline, and famous drugs losing patents, competitive pressure & scarcity
of new breakthrough molecules. These factors present significant opportunities for
low cost destinations like India.

3.9. FUTURE OUTLOOK

Indian Chemical Industry envisages being USD 100 billion in size of 2015 as
per “Call to Rebrand Chemical Industry” (2008). While the pharmaceutical sector has been
relatively unaffected by the global slowdown, other factors are facing a challenge due to
low demand as Prof. R.N. Shukla said “the Knowledge Chemical require aggressive
growth strategies to grab the exciting business opportunities that has been put forward.
It also requires high investment in Research and Development. The Specialty chemicals
must sought after collaborative strategies such as cluster development and institutional
recreation. Significant focus on cost reduction in Basic Chemical segment is desired. All
the segments also need to focus on Economic of Scale.

Chemical Industry must also adhere to stringent Health and Safety regulation
required by the foreign players for collaboration and trade. The infrastructure support
from the government is also sought for the impetus to the industry. A massive brand
revamp is also required for achieving the vision of USD 100 billion turn over.
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4. COMPANY PROFILE - DCW LTD

4.1. MISSION STATEMENT

It is our endeavor to become a chemical powerhouse by growing in globally

competitive market with focus on the environment and community by optimizing use of all
available resources

4.2. VISION STATEMENT

To Innovate & to Integrate Emphasis on the 4R's - Reduce, Reuse, Recycle & Recover

 Enhance Stakeholder value

 Diversify in Synergistic Business

 To be a responsible social citizen

4.3. DCW LTD HISTORY

DCW Ltd (formally Dhangadra Chemical Works Limited.) the Company is
renowed Sahu Jain Family, Was Incorporated in January 1939 to take over India's first
Soda Ash factory in Dhanghadra, Gujrat.

Its ownership was aquired in 1949 by padmabhushan Late Shri Sahu Shriyans
Prasad Jain - The founder. Since then, DCW has expanded, diversified and mordernized its
operations and its now public Limited Company with a diversified range of products for
supply to customers in both, domestic and international markets.

Over the years its corporate logo, the "Horse Shoe" has earned respect and recognition
and now is widely ackowleged as a symbol of excellence.

Under the stable and astute leadership of the management, DCW has generated great
success to emerge as one of India's fastest growing multi-product multi-location chemical
companies. DCW is a industry pioneer with strong presence in the Chlor-Akali, Synthetic
Rutile and PVC business segments, with a successful record of innovation and in pioneering
new products and processes. Its competitive edge is furthur enhanced by the diversity of its
product portfolio.
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The corporate Office of the company is located in Mumbai, India’s Commercial

Capital . The business is steered by Dr.Shashi Chand Jain, as Chairman & Managing
Director and Mr. Sharad Kumar Jain, as Vice Chairman & Managing Director. Under their
able and astute leadership, DCW has come a long way to emerge as India’s respected
multi-national.

The Company has two manufacturing units. At Dhrangadhra, Gujarat State, it

produces Soda Ash, Ammonium Bicarbonate, Liquid Bromine and Bromide . At Sahupurum,
Tamil Nadu State, it produces Caustic Soda, Liquid Chlorine, Trichloroethylene, enamel
Paint and PVC resin . The Sahupuram Unit is also striving to commercialise Bio-tech
productslike Natural Spirulina, Salt, considered the essence of life, is a starting material of
DCW’s basic products.

4.4. MILESTONES

 1959 - Caustic Soda Plant Commissioned

 1965 - Liquid Chlorine Plant Commissioned

 1968 - Trichloroethylene plant setup- as India’s first unit for the product

 1970 - Upgrade Beneficiated IImenite (Synthetic Rutile) Plant went on stream

 1970 - PVC Resin plant 0 one of the first petrochemical Segment

 1978 - Utox Plant Setup

 1989 - Sodium Hypochlorite plant Set up- with twin Objectives of controlling
pollution and a product for bleaching

 1991 - 1*6 MW captive Power plant installed in the First place

 1993 - Iron Oxide (Synthetic Yellow) Plant Setup –a sunrise Product from a
drained wash liquor & a result of R&D
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1996 - 5*6Mw Captive Power Plant installed

1997 - Reverse Osmosis Plant come into Being

2001 - Ferric Chloride plant as an initiative for converting waste

 2002 - Natural Spirulina – a bio-tech product

 2002 - Paint Plant -An R&D venture

 2007 - Caustic Soda Plant conversion to Membrane Cell process from Mercury
process

2008 - 2x25MW Coal based Power Plant

2009 - Turnover crosses Rs. 1,000 Crore; 8.27MW Power plant using surplus steam

2010 - Iron Oxide

4.5. DCW MANUFACTURING WORK

4. 5.1.SAHUPURAM WORKS
Sahupuram works of DCW Limited is situated in TamilNadu on the Tuticorin –
Tiruchendur State Highway about 14kms north of Tiruchendur – the famous shore- based
temple town . The nearest harbour and broad – guage railway station is at Tuticorin City
about 30kms north of Sahupuram . The nearest commercial airports are at Madurai
(170kms) and Tiruvananthapuram (180kms) . The Bay of Bengal is about 5kms to the east
side.

The climate at Sahupuram is tropical with coastal land and sea breeze influences .
It is hot in the earlier part of the summer and cool and moderately humid in winter.
Annual Rain fall ranges form 450mm to 750 mm, mainly received during October to
December. The factory together with the township facilities and Salt fields covers a total
area of about 1012 hectares . There is also an installation near the Tuticorin Port for storing
Vinyl Chloride Monomer, the imported Raw material used in the manufacturing of PVC
resin. The factory works round the clock.
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4.5.2. AT DHRANGADHRA UNIT

DCW contributes significantly to the S.P. Jain Arts and Commerce College and the
Panjarapole Trust, which maintains old cattle. DCW also runs a Pre-Primary & Primary level
school at the labor colony providing free education to all students since 1945; the school is
running without Government grant. DCW maintains a club for the welfare of its employees. In
addition, the company also makes contributions to the Kidney Disease Research Centre for
hospital patients and to the Tiffin Seva Mandal for feeding the poor.

The climate at Dhrangadhra is tropical with Desert land. It is hot in the summer and
cool in winter. Annual rainfall ranges from 600 mm to 700 mm mainly received primarily
during June to September period.

4.5.3. AT MUMBAI

DCW has promoted The S.P. Jain Institute of Management and Research, a leading
management institute associated with the University of Mumbai, offering post-graduate
degrees in management. The institute founded by our Late Founder Chairman is now
recognized as one of the best in India. In Mumbai, DCW patronizes the ‘Shriyans Prasad
Charitable Trust’ & the ‘Dhrangadhra Chemicals Charitable Trust’ which is engaged for
charitable activities, namely, medical, educational and relief to the poor which has in turn
benefited a large number of people from different walks of life and by giving donations to
various Charitable Institutions throughout the country who are rendering similar type of
charitable activities. It also supports the ‘Sukhanand Ashram’ (Dharamshala Charitable Trust)
that owns a heritage building in the heart of Mumbai used as a rest place for the sick, weary &
poor travellers.

It also gives aid to members of public in case of medical, education, floods &
earthquakes throughout the country.

DCW has also contributed towards this S.P. Jain Sadhana School for the mentally
handicapped, an institution named after out late Founder Chairman. medical, education, floods
& earthquakes throughout the country.
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4 .6. ENVIRONMENT PROTECTION

Conscious of its obligations towards environment protection, the Management at DCW

has been investing money and efforts in progressively implementing pollution control
measures.

In this concept, DCW has chosen to first exploit the opportunities of cleaner production
techniques and then set pollution control measures only for residual pollution. This approach
not only results in resource savings, but also helps to cut down the treatment cost of pollutants;
in turn leading to lower cost of production.

DCW has been upgrading its process, plants and equipment to assimilate environmental
protection measures in a progressive manner in line with the universally accepted principles of

3Rs viz. Reduce, Reuse and Recycle.The Company is also effectively operating an advanced
wastewater treatment plant using Nano and Reverse Osmosis Process for effecting Zero
Effluent Discharge. Safety and Environment protection are given focused attention at both
plant locations, and have achieved significant results in energy conservation efforts; which
continue to be an ongoing initiative.

The Sahupuram Unit has embarked in implementing QHSE Management System and
acquired ISO 9001 QMS; OHSAS 18001 & ISO 14001 EMS standards.

For the sustainable development on the Environmental Management System, the

effective tool in the QHSE Management System Objectives, various activities like Green Card
Audit System, Department Specific Awareness Programs on sharing environmental aspects
and its related pollution control measures have been vigorously carried out.

World Environment Day and National Conservation Day are celebrated on 5th June
and 24th November, respectively, every year. To mark the occasion, our employees carry out
a massive tree plantation in the Plant area and various other areas of the township. To
emphasize the eco-friendly culture, environmental awareness posters and stickers are
distributed on these occasions.

DCW has incorporated various air pollution control measures viz., state of art sodium
hypo chlorite plant for fugitive emission control, three field electro static precipitator for dust
control, cyclone separators and scrubbing system at various source emission locations.
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On the part of solid waste management, DCW has taken various initiatives to minimize
the waste generation and developed secure and safe landfill arrangements for safe storing of
solid waste.

The Sahupuram Unit has developed an effective and pleasing green belt, which would
be systematically extended to cover more areas in the plant and township.

4.7. RANKING AND AWARD

 Two leaves ranking for overall performances in environment impact in Indian

Caustic – Chlorine Sector.
 State Safety Awards.

 Capexcil Awards for Exports

 Appreciation Award for contribution to customers & Central Exercise

 Excellence / Distinguished Awards by quality circles in International/National

conventions of Quality Circle Forums of India
 State Industrial Relations Awards

 Best Export Excellence Awards ( Non Traditional Cargo)

4.8. PRODUCT PORTFOLIO

4.8.1. CAUSTIC SODA

Caustic Soda, chemically called Sodium Hydroxide (NaOH), is a basic product

widely used in diverse industrial sectors, either as a raw material or as an auxiliary
chemical. It is produced along with chlorine and is produced in two forms - lye and
solids. Solid Caustic Soda can be in the form of flakes or granules.

DCW produces Caustic Soda using the latest energy efficient and environment friendly
Mercury free state-of-art Membrane Cell Technology.

Application

Caustic Soda is mainly used in the manufacture of pulp and paper, newsprint, viscose
yarn, staple fiber, Aluminum, cotton, textiles, toilet and laundry soaps, detergents, dyestuffs,
drugs and pharmaceuticals, vanaspati and in petroleum refining.
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Package & Handling

Caustic Soda Lye can be stored and transported in tanks and tanker trucks. Caustic
Soda Flakes can be packed in 50 kg. & 25 kg. net HDPE Bags lined with HMHDPE liner and
Caustic Solid in 375 kg. net .MS Drums.

End User

Aluminium, Rayon, Paper, Soap, Vanaspathi, Petroleum, Textile, Dyes industries.

4.8.2. LIQUID CHLORINE

Chlorine is a by-product in the production of caustic soda. Being a gas and due
to its hazardous nature it cannot be transported over long distances. Therefore,
DCW produces other chlorine products from Chroline in its complex. Internationally,
Chlorine is a main product and caustic soda is the by-product but in india, caustic Soda
is a main product and chlorine a by- product as development of chlorine based products
has not occur.

Application

Chlorine is used in the manufacture of products like vinyls, pharmaceuticals,

water disinfectants, agrochemicals, additives in oil and detergents, refrigerants,
photographic chemicals, adhesives, inks and coatings. It also finds application in multiple
industries such as electronics and semi-conductors, food processing, automotives, and
public health. Chlorine is also used in themanufacture of Trichloro & Perchloro Ethylene

PACKAGE & HANDLING

Liquid Chlorine is packed in cylinders of capacity 900 kg net for domestic and
international market.

End Users
Manufacturers of Trichloro & Perchloro Ethyline, Refrigiration Sanitation,
Pesticides, Paper and pulp etc
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4.8.3. HYDRO CHLORIC ACID

Hydrochloric Acid (HCl) is a colorless and odorless solution of hydrogen chloride and
water. Once commonly referred to as muriatic acid or spirit of salt, this acid is a highly
corrosive chemical compound with several applications in industry. It is also found in diluted
amounts in the stomach of humans and animals as gastric acid.

DCW’s Hydrochloric Acid is a guaranteed Mercury Free acid with minimum 30%
concentration.

Application

Hydrochloric Acid is used in the pickling of steel to remove rust or iron oxide scale
from iron orsteel before processing, production of organic and inorganic compounds, pH
control & neutralization and regeneration of ion exchangers. Hydrochloric Acid is used in a
number of small-scale applications such as leather processing, purification of common salt,
household cleaning and building construction.

Package & Handling

Material is packed in HMHDPE Barrels . It can also be transported in rubber

lined tank trucks.

End Users

Chemicals, Acid Pickling, Metal cleaning and ore reduction.

4.8.4. UPGRADED BENEFICIATED ILMENITE (SYNTHETIC RUTILE)

Synthetic Rutile is a product containing min. 94% TiO2 of golden yellow colour
and without specific odour. It is a multi-stage manufacturing process employing
controlled reduction, oxidation and acid leaching

Application

Sythetic Rutile is used in pigments (for paints, coatings, Plastics etc) and welding
electrodes
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Package & Handling

Material can be packed and handled in HDPE bags or in bulk for transportation and
marketing.

End Users

Pigments, Welding Electrodes, Paints, Titanium Sponges etc

4.8.5. TRICHLOROETHYLINE

Trichloroethylene (TCE) is a non-flammable, colourless liquid with a somewhat

sweet odur and a sweet, burning taste.

Application

Metal de-greasing, dry cleaning, drying electronic parts; as extraction solvent for oils,
fats, waxes, refrigerant and as fumigant.

Package & Handling

The Material can be packed in M.S. Drums, HM HDPE Barrels, Tanker Trucks, Cans
etc. for domestic and international marketing.

End Users

Metal Degreasing, Dry Cleaning, Refrigent, Fumigant etc

4.8.6. YELLOW IRON OXIDE

Metal de-greasing, dry cleaning, drying electronic parts; as extraction solvent for oils,
fats, waxes, refrigerant and as fumigant.

Application

Yellow Iron Oxide is used primarily as a pigment.

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Package & Handling

Material is packed in 25 kg capacity HDPE Bags. Handling is to be done carefully to

avoid generation of dust.

End User

Paint Industries

4.8.7. FERRIC CHLORIDE

Ferric chloried is an industrial scale commodity chemical compound . The color of

Ferric CHloride crystals depends on the viewing angle: by reflected light the crystals appear
dark green, but reflected light they apear purple-red. Anhydrous Ferric Chloride is
deliquescent, forming hydrated hydrogen chloride mists in moist air.

Application

Indutrially Ferric Chloride is used in sewage treatment and production of drinking water

. Amongst other unconventional uses, It is also used as a drying reagent in certain reactions,
used in making print circuit boards and test pitting and crevice corrosion resistance of stainless
steel and other alloys

Package & Handling

Material is packed in 280 kg capacity HMHDPE Barrels. It also filled in lorry tankers
and transported for sale in domestic market

End User
Effluent Water & Sewage, Textile, Etching and chlorinating Etc

4.8.8. UTOX

Utox is a pigment with 89-92% Titanium Dioxide (TiO2) content. It is pale yellow in
colour and odourless. Utox is manufactured by recovering the fine particles of Titanium
Dioxide from the liquor blown down during the leaching process of Ilmenite
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Application

Utox is mainly used in industrial paints and power coatings.

Package & Handling

Material is packed in 25 kg capacity HDPE bags. Handling is to be done carefully to

avoid generation of dust.

End User

Paint Industry

4.8.9. POLY VINYL CHLORIDE

DCW produces Poly Vinyl (PVC), a white powder from vinyl Chloride Monomer by
suspension polymerization process. PVC is a thermoplastic resin, which in versality of
processing and application surpasses all other thermoplastic materials. This unique polymer is
one of the oldest established plastics.
Application

PVC finds applications in insulation of cables, in pipes and hoses, agricultural

products, windows and profiles, flooring tiles used in the building industry, blister packaging,
filmsand sheets, foamed leather cloth, custains, tarpaulins, and also for medical use - for IV,
blood bags, etc. The versality of its properties is such that new areas of application are being
continously developed.

Package & Handling

Material is packed in 25 kg capacity HOPE woven bags inserted with LOPE liner.

End User

Pipe industry, Automobile & Sanitary Fitting, wires and cables,Bottles containers,
Transparent films and flexible hose.
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4.8.10. SODA ASH

Soda Ash, also known as Washing Soda or Sodium Carbonate (Na2CO3), is a sodium
salt of carbonic acid. It most widely occurs as a crystalline heptahydrate, which readily
effloresces to form a white powder, the monohydrate. It is synthetically produced in large
quantities from salt and limestone in a process known as the Standard Solvay Process. As a
Chemical Manufacturer, DCW produces premium quality Soda Ash enabling our customers to
produce high-quality products.

Application

Soda Ash is primarily used for manufacture of detergent powder, cake and glass. It is
also used in oil well drilling, in hygiene and cleaning products. Soda Ash is also used in effluent
treatment, water treatment, in pulp and paper manufacture, in dyes, dye intermediates, brine
purification, ore refining, cooling agents, pesticides, drug intermediaries, paper, chemicals etc.

Package & Handling

The Material can be packed in M.S. Drums, HM HDPE Barrels, Tanker Trucks, Cans
etc. for domestic and international marketing.

End User

Caustic Soda & Soda Ash Industries, Manufacturers of chlorine, Hydrochloric Acid
and other Sodium Component

4.8.11. SODIUM BICARBONATE

Sodium Bicarbonate (NaHCO3) is a white, extremely pure substance. It is not only non-
toxic and biodegradable, but also human and environment friendly. Since it has long been
known and is widely used, the salt has many related names such as Baking Soda, Bread Soda,
Cooking Soda, Bicarbonate of Soda. Colloquially, its name is shortened to Sodium Bicarb,
Bicarb Soda, or simply Bicarb.

Application

Sodium Bicarbonate is an all-purpose product that can be used in a variety of sectors,

such as Foods and Animal Feeds, Domestic Applications, Personal Hygiene and many others.
 21

It is mainly used for cooking (baking), neutralization of acids and bases, medical applications
and personal hygiene products. Since Sodium Bicarbonate acts as a neutralizing agent, is
soluble and is slightly abrasive, it is the ideal product to safely remove persistent odours and
stubborn stains.

Package & Handling

Material is packed in HMHDPE Barrels . It can also be transported in rubber

lined tank trucks.

End User

Pigments, Welding Electrodes, Paints, Titanium Sponges etc

4.8.12. AMMONIUM BICARBONATE

Ammonium Bicarbonate (NH4HCO3) is a white, crystalline powder with a slight odor

of Ammonia that can dissolve in water to give a mildly alkaline solution.

Application

Ammonium Bicarbonate is used in the food industry as a raising agent for flat-baked
goods (e.g. gingerbread).

Package & Handling

Ammonium Bicarbonate is packed in 25kg HDPE bags. Do not breath dust.

Wear suitable protective clothing. In case of insufficient ventilation, wear suitable respiratory
equipment. If you feel unwell, seek medical attention and show the label when possible. Avoid
contact with skin and eyes.

End Users

Manufacturers of Trichloro & Perchloro Ethyline, Refrigiration Sanitation,

Pesticides, Paper and pulp etc
 22

4.9. DEPARTMENT DETAILS

4.9.1. HUMAN RESOURCES DEPARTMENT

Number of Workers: 1275 (staffs & workmen)

 The Unit Employees are around 1275 consisting of staff & workmen. Suitable
Services, technical and administrative, have been organized to support the
manufacturing activities.
 The Plant management is professional in outlook.

 The Unit has a positive work culture and employees are committed.

 Adequate welfare measures have been extended to employees to improve their

quality of life .
 Management-Union relation have been built on mutual trust and understanding
and have remained cordial.
 The works has always acknowledgement the potential of its employees and
importance of team work. Employee training and development efforts are given
strong emphasis in knowledge and skill enhancement .
 Large number of employees have been trained and motivated to contribute
towards improvements in quality, productivity and in turn manufacturing cost
through quality circles, quality improvement teams, 5s and cost improvemet
programs.
 A few quality circles have won recognitions at International and National levels
for their achievements in solving problems in their work place.
 The Indian Society for training and Development (affiliated to International
Federation of Training and Development Organisations, Manila) has a chapter at
Sahupuram which is actively engaged in promoting the cause of people
development .
 The Chapter has won repeated recognitions from the National Office for its
sustained performances.
 23

4.9.2. FINANCIAL DEPARTMENT

Finance is one of the major pillars of any organisation and an essential ingredient to a
successful business.

Finance Department is the part of an organization that is responsible for acquiring funds
for the firm, managing funds within the organization and planning for the expenditure of funds
on various assets. It is the part of an organization that ensures efficient financial management
and financial control necessary to support all business activities.

Roles and Responsibilities of A Finance Department

The contributions of finance department to any company and how these contributions
positively affect organisational performance will greatly depend on factors such as the extent
to which the owner/ manager is involved in his company. The roles and responsibilities of a
finance department include but are not limited to:

Bookkeeping

It involves the day-to-day recording, analysis and interpretation of a company’s

financial transactions. This will include the tracking of all expenses (purchases, payments etc.)
and sales of finished products. In some start-up companies, this role is often carried out by a
bookkeeper who might be replaced by more specialized payables and receivables clerks as the
company grows or expands its operations.

Management of Company’s Cash Flow

It is the duty of the finance department to manage all cash flows into and out of a
company and ensure that there are enough funds available to meet the day-to-day running of
the company. This area also encompasses the credit and collections policies for the company’s
customers, to ensure that vendors and creditors are paid correctly and on time; and that the
company is also paid correctly and as when due.

Budgets and Forecasting

In this function, the finance department works with managers to prepare the company’s
budgets and forecasts and also give feedback with regards to the financial standing of the
company. This information can be used to fulfil the cash needs of each department, plan
 24

company staffing levels, plan asset purchase and expansions at minimum cost before they

become necessary. The finance department can also use past records from respective
departments to make better budget and forecast over long-term and short-term time horizons.

Advising and Sourcing Longer-Term Financing

It is the duty of the finance department to advise companies on the best financing mix
that could yield the company the best profit and also help them source longer-term financing
at the lowest cost such that there is a profit level of liquidity.

Management of Taxes

Running a company involves paying tax, and it is the duty of the finance department to
handle tax issues. This includes creating good corporate relationships with government by
remitting PAYE (Pay As You Earn) to the relevant authority, and ensuring that implementation
of tax matters are done within the framed policies.

Management of Company’s Investments

Apart from analyzing and selecting new investments, it is also the duty of the finance
department to manage company’s existing assets. The finance department should be concerned
with current assets apart from fixed assets. The company’s working capital needs to be
managed efficiently in such a way as to maximize profitability relative to the amount of funds
tied up since it has more implication on the firm liquidity than its fixed asset.

Financial Reporting and Analysis

Financial reporting and analysis is the function that takes raw accounting entries and
transforms them into meaningful, usable and comparable financial statements. The finance
department contributes to organizational growth by measuring and reporting on regular bases,
key numbers that are vital to the success of the company. This will likely include a summary
of all funding sources, expenditures and reserves available for future use (excluding those
already committed and budgeted for current period) some non-financial information. And are
usually communicated to managers in a logical and understandable format.
 25

4.9.3. RESEARCH AND DEVELOPMENT DEPARTMENT

The role of an R&D department is to keep a business competitive by providing insights

into the market and developing new services / products or improving existing ones accordingly.
The future growth of the business sits in a large part with the R&D department. The R&D
department will have a range of responsibilities

DCW Progress in Research & Development

Staying ahead implies being constantly on the move, keeping track of technology
and market needs and being innovative. The R&D wing at Sahupuram is credited with
the following significant in-house efforts

 Bench scale process developed for ilmenite ore beneficiation was scaled up &
engineered entirely by DCW (1970)
 Development of “UTOX” from waste liquor of digesters in ilmenite plant - a
partial replacement to TiO2 in plant industry (1978)
 Replacement of graphite anodes with metal anodes in Caustic Soda cells
giving Substantial energy savings (1979-82).
 Filling sandy wasteland with polyethylene to avoid seepage of conc.brine
resulting in 60% increase in salt production (1979-83)
 Re-engineering BI process to manufacture synthetic Rutile with >95% TiO2
with low Silica and Alumina contents(1992-93)
 Development of the process of de-mercurisation of mercury-bearing water
effluent (1985)
 Development of process to manufacture Yellow FeO2 Pigment using waste
leach Liquor from BI Plant(1992-1993)
4.9.4. PURCHASING DEPARTMENT

Purchasing is the process of buying or acquiring goods and services to make supply
chain management more efficient. Goods, materials, and equipment procured in this process
play a key role in improving the quality of products/services produced by the organization.
Functions Purchasing Department

 Identify requirements for goods, materials, and services at particular time.

 Find reliable suppliers to meet these requirements

 Negotiate prices, build quality, and delivery terms

 26

 Set up the order quantities and making bid requests on supply contracts

 Coordinate delivery and storage operations

 Run quality control and product testing

 Manage budgets based on ROIs and payments

4.9.5. PRODUCTION DEPARTMENT

The production department is responsible for converting raw materials and other inputs
into finished goods or services.
Product Definition

Customer requirements, preferences and needs can change rapidly. Products in demand
in one season may exhibit low demand in the following season. A marketing department’s
research function sheds light on shifts in customer demand. Marketing and sales can help
translate customer demand into product specifications. These definitions can include color
choices, package sizes, feature modifications and even shifts to a new product line.

Set Production Quota Guidelines

Reports, meetings and strategy sessions among production, marketing and sales
personnel can help estimate production capacity needs and product changes. The marketing
department can help guide the timing and quantity requirements of production. Well-
orchestrated production scheduling can minimize waste and increase profits. For example,
marketing departments can alert production to a special promotion that will lead to an increased
demand for products. Production departments can increase production in advance of the
promotion to ensure sufficient product supply.

Quality
Sales personnel often see the constant trade-off between quality and price. When customers
are not as price sensitive, they may demand higher-quality products. At other times, customers
prefer low-cost items. Marketing and sales personnel help relay these preferences to the
production department. Production managers can then modify source materials, product offers
and specifications according to quality demands.
 27

5.SWOT ANALYSIS

SWOT Analysis is a process that identifies an organization’s Strengths, Weakness,

Opportunities and Threats.

Specially, SWOT is a basic analytical framework that assesses What an entity can and

cannot do, for factors both internal ( the Strengths and weaknesses) as well as external ( the

Potentical Opportunities and Threats ) Using environmental data to evaluate the position

of a company, a SWOT analysis determines what assists the firm in accomplishing its

objectives and what obstacles must be overcome or minimized to achieve desired results,

where the organization is today, and where it may be positioned in the future.

SWOT Analysis aims to identify the key internal and external factors seen as

important to achieving an objective. SWOT analysis groups key process of information

into two main catagories.

 Internal factors - the Strengths and weaknesses internal to the organization

 External factors – the Opportunities and Threads presented by the environmental

external to the organizations.

The SWOT analysis great for adopting and understanding of an Organization or

situation and decision making.

Detailed SWOT analysis of the company including key Strength and Weaknesses of

DCW Ltd, on which it can build its business along with potential opportunities and

threats in the near medium term future are detailed

 28

5.1. STRENGTHS

Strengths are the qualities that enable to accomplish the Organization’s mission.
These are the basis on which continued success can be made and continued/ Sustained.
The Company has adequate internal control system with the nature of its business and
size of its operations. Internal Audit is conducted on a regular basis by a reputed firm
of Charted Accountants.

The company holds a monopoly is some key product such as

Salt,Soda, PVC etc

Good R&D Department for new product development

Skilled & experienced workers

The Plant management is professional in outlook.

The Unit has a positive work culture and employees are committed.

Adequate welfare measures have been extended to employees to

improve their quality of life .
Has a Strong workforce of around 1275 employees

Availability of land for production

Safe and effective packaging facility

5.2. WEAKNESSES

Weakness are aspects of Business that detract from the value they offer or place then
at a competitive disadvantages. There is a need to enhance these areas in order to
compete with best competitors.

Need more investment in new technologies

Inherent nature of chemical leads to health issues of employee

Company must run 24X7 otherwise working capital requirement

will be high.
Huge dependency of the industry on raw material.
 29

5.3. OPPORTUNITIES

Opportunities are the qualities that enable to accomplish the organization’s mission.
These are the basis on which continued success can be made and continued/ Sustained.
The opportunities of DCW .

The globalization has increased India’s foreign trade and also forayed new
avenues in Pharmaceutical industry.
The Domestic demand for all the products manufactured by the company is
growing which gives opportunities to expand its production capabilities and
take benefit of the expanding market.
Company’s caustic soda,Synthetic Rutile and PVC units are near to Tuticorin
Port in Tamil Nadu and this gives opportunities to the company to easily export
its products. Company has opportunities to go for backward/ frontward integration
in the product’s it manufactures which can make the company more
competitive . .
Good reputation among customers.

5.4. THREATS

In Business analysis, Threats are anything that could cause damage to the
organization, venture or product.

Insurance cost are continually increasing

Tax rates for the products are also increasing

Government regulations and restrictions are regid.

The power and interest rates, and indirect taxes are high.

The low cost imports coming in to the country can be a threat

in future
 30

5. CONCLUSION

The summer internship training period provided opportunities to move

into the organizational world. The training was for a period of one month and during
this one month training program, the trainee came to understand the various departments,
how does it functions and their respective activities . To say in simple word it is just
a organizational study about the company. The summer training program helps to enhance
and develop skills, abilities and knowledge. It was a good experience and memories asthe
trainee not only have gained experience but also new knowledge.