An

Industrial Training Report

On

AMBUJA CEMENT LIMITED

(KODINAR)

Submitted By

JIGAR N. BHUVA

NOBLE ENGINEERING COLLEGE

ER. No. 150350106005

INTRODUCTION OF COMPANY

AMBUJA CEMENTS LTD.

Their people practice a simple philosophy.

“Give a man orders & he’ll
Do the task reasonably well
But let him set his own targets,
Give him freedom & authority,
And his task becomes
A personal mission:”I CAN”.
Ambuja Cement Limited is India’s one of the major Company in the cement
industry. Its first plant “Ambuja Cement” was begun in 1986 & is located near
the coastal town of Kodinar in the Saurashtra region of Gujarat. The area has
huge deposits of limestone, a key of ingredient in the manufacturing of high
quality of cement.

The plant with an installed capacity of 0.7MTPA (million tons per year)
was a huge success with some equipment changing and optimizing the existing
plant company had produced 1MTPA from the plant. Then another plant
“Gujarat Line-1” again with an installed capacity of 1MTPA was erected in the
same area and commissioned in 1992. Then a new unit “Gujarat Line-2” with an
installed capacity of 1 MTPA was erected in the same area and commissioned
in 1996. Then through continues improvement Ambuja unit and Gajambuja line
-1 have upgraded by 0.5 MTPA each. In addition to these plants Ambuja
Cement Ltd. has packing units at Surat (Gujarat) and Panvel (Maharashtra).
Loose cement is dispatched to these locations by sea-route.

Ambuja has large port facility at Muldwarka, near Kodinar. Ambuja

Cement Ltd. has seven ships to carry the bulk cement to the packing units. This
has brought substantial saving by bringing down the transportation costs, which
plays a major role in deciding prices. Bulk cement is also exported to Srilanka,
the island Mauritius and gulf Country. Ambuja Cement Ltd. has captive power
plant comprising of 58bmw DG sets and is self-sufficient.
 HISTORY & DEVELPOMENT

In India, manufacturing of cement was first started in Madras in

1904.First three companies were started in 1912-1913 and real beginning was
started. When the plans started there were 21 factories with an annual capacity
of 328 million tons. After 1949 the cement industry had a complete interference
of govt. the production, distribution and price of cement and this hampered the
growth of industry. It was only in 1977 that govt. announces 12% post tax
return on net worth, which was fair enough, and retention price would be fixed
to ensure it.

The rapid growth of the Indian economy has developed the basic
industries like cement, iron and steel and fertilizers have prospered. This is also
a result of the govt.’s incentives of developing such industries. At the time of
the installation of this plant, there was not any cutthroat competition in the
cement industry.

Thus, the above mentioned are the main reason, which encouraged this
organization to enter into the cement industry. The Ambuja Cement Ltd. is a
company, which has been promoted by the Gujarat Industrial And Investment
Corporation Ltd.

The company started its commercial production in October in 1986. Later

the company in order to expand its production setup and another plant in
Kodinar itself called Gajambuja Line-1 in 1992 followed by the third one
Gajambuja Line-2 in 1998 making the total production to reach approximately
three million tons per annum marks.
 FACTOR AFFECTING LOCATION

Location of unit is most important factor for to be consideration for

successful working of any organization. It also plays vital role in the
development of the unit. The total cost of manufacturing cost of any business
unit is higher due to the wrong selection of location of their business. The main
object of an industrial concern is to maximum profit through minimum of
production cost.

Ambuja Cement Ltd. is situated near Vadnagar village in Kodinar. The

location of the plant is very beneficial for its existences as the area is
surrounded by limestone, which is one of the basic raw materials in cement
production. Company is also benefited as the area of the plant site is near the
sea coast which facilitates the transportation through sea route. Ambuja has also
developed its own seaport for transporting cement to other destinations. This
has helped Ambuja Cement Ltd. to export their product easily through seaport
directly increasing the export of their goods.

Location factors are very much important in establishing a cement plant.

1. Input

In terms of input, about 1.5 tons of limestone is required to produce one

ton of cement. Hence location of the plant is based on the limestone
deposit. The major cash out flow come by way of royalty and cash
payments. India’s estimated total reserve of cement grinding stone is
about 90 billon tons.
2. Power

It is used in raw material grinding. Clinkerization of lime stone is done

in the kiln operation and then clinker is grinding with gypsum to form
cement. The older plant required 120 to 130 units per ton of cement
produced, while modern energy efficient plants consume 80 to 90 units
per ton. Cement manufacturing is continuous process, so quality of
power plants is important.

3. Coal
Coal is another major input, which along with electricity forms 40% of
total cost. There is a several coal shortage for the industry. The coal is
generally imported from certain African countries, which are unloaded at
companies’ Muldwarka port that is near to the factory site.

4. Labour

On growing modernization of plants, the requirement for skilled man

power has increased then that of unskilled man power. The cheap
availability of labor from the nearby areas has proved to be great help
for the company.

5. Transportation

It is a very important thing to be kept in mind while deciding the

location. It cost widely affects the overall cost. The seacoast is one of the
 important transportation modes for exporting companies. The company
has its own jetty at Muldwarka. This reduces cost of transportation for
the company.

CONTRIBUTION OF UNIT TO THE INDUSTRY

Ambuja Cement as a large scale manufacturing unit contributes to the

unit, contribution to the country, contribution to the society and government it
many ways.

Ambuja Cement is the most profitable cement company in India, and

one of the lowest cost procedures of cement in the world. Ambuja Cement can
now join hands with a distinguished organization that has been a fountainhead
of ideas and talent for the cement industry.

Ambuja cement foundation has made to improve the quality of life in

communities across the country. Ambuja cement foundation is give contribution
to water resource management, skill development training, agriculture, health
and education.

Its profited ring played an important role in the economic growth.

Ambuja Cement is helping it India as well as other countries also
 COMPANY PRODUCT &
MANUFACTURING PROCESS

Company Product:
Ambuja Cement produces many type of cement like as:

Rapid Hardening
cement

Sulphate
Resistance
Cement

OPC=43 Grade

OPC=33
Grade

OPC=53
Grade

Masonry

PPC
 Manufacturing Process:

Manufacturing means to make semi-finished goods into finished goods

and manufacturing process summation of all the steps making semi-finished
goods into finished goods.

Every manufacturing firm should have sound manufacturing process to

manufacture goods without sound. Manufacturing process, manufacturing cost
will be directly reflect in the profit if the organization.

The basic raw material required to produce cement are as follows:

1. LIMESTONE
2. RED CLAY
3. GYPSUM
4. COAL
5. FLY ASH
6. SILICA s

According to the mode of preparing the raw mix three different processes
can manufacture cement:

A. Wet Process
B. Semidry Process
C. Dry Process
MANUFACTURING PROCESS
1. MINING & CRUSHING OF LIMESTONE:

Limestone is the basic raw material to produce cement. It is mainly

obtain from the open cost mining. The limestone is hauled through dumpers up
to the 70 to 75 mm size. The crushing of limestone is done through hopper
crushed material passed on the conveyor belt in which the addictive material is
added to the material.

2. CRUSHING OF GYPSUM & COAL:

The second stage of cement manufacturing is to crush the gypsum & coal
by griddling machine.

3. MAKE A CINKER:

Clinker is a precondition to make cement. So to make cement of clinker

is needed. So, to make a clinker all crushed material like limestone, gypsum &
coal water with the help of elevator.

4. STORAGE OF CLINKER:

After a making of clinker it storage in a one place. It’s called silo. As per
the requirements clinker is send at required place weighing bin.
 5. DRYING OF CLINKER:

After making a clinker, it dried in heating machine at 1200-1400 degree

Celsius temperature. Minimum 1 hour required for drying the clinker.

6. STORAGE OF DRY CLINKKER:

After the drying a clinker it stored in a one place. It’s called silo. As per
the requirements, clinker is send at required place through conveyor belt.

7. CRUSHING THE CKINKER & ADDED THE

CHEMICAL:

Dried clinker is again crushed in the grinding cement mill. And chemical
is added as per the grad of cement. After adding the chemicals, this all things
are mixing in the raw mill. After this process all these mixing material is
transfer in to the ruler. Rulers exclude the wastage & clean to the cement.

8. PACKING:
Packing is the final step of cement manufacturing process. Clean cement
again stored in a silo and last as per the requirement it come in weight box
through conveyor belt. After this cement bag which have capacity to include 50
kgs. Cement in it.