J.P.

S GLOBAL
ACADEMY

PROJECT REPORT ON:

PRODUCTION OF ALUM FROM SCRAP
ALLUMINUM

SUBMITTED TO SUBMITTED BY:

MR.MOHD. KHALID
AJEET RANA

XII
 HAPUR

PROJECT REPORT

ON

THE MANUFACTURING
 OF

“ALUM FROM SCRAP ALLUMINUM”

Guided By. Submitted By.

Mr. Mohd. Khalid Ajeet Rana

XII

CERTIFICATE

It is to certify that AMAN GOEL of Class-XII C/4 has

prepared this project report on Washing Soap. It is a self data
collected by her under my supervision & guidance. I wish her
bright future.

Guided By.
 Dr. Vimal Tyagi
M.A (Eco.) Ph.D

ACKNOWLEDGEMENT

With due pleasure I express my gratitude towards our principal

madam Mrs. Chanchal Saxena and Dr. Vimal Tyagi, our
project mentor, for providing me the encouragement and
necessary suggestions which has helped me a lot on completing
this project. He made me understand and learned important
terms of the project. My project has been success because of
their constant guidance.

AMAN GOEL
XII-C/4

INTRODUCTION

This project report has been prepared for the justification of

setting up a unit the “Manufacturing of Washing Soap-Laundry
Soap” at G.T. Road, Muzaffarnagar in the name and style of
Reno Laundry Soap is registered. The Registration No. of
Society is 359, 2002-2003. This project highlights the basic
details about the land and the building, market profitability etc.

MANAGEMENT
This is registered society with the registrar of the firm and
societies wide registration No. 359, 2002-2003. Society is
having following persons in their management committee.

a. Mr. Pankaj Aggarwal President

b. Mr. Punit Aggarwal Secretary

PRODUCT AND ITS USES

The product “Soap” is a traditional washing compound made by
oils and fats and caustic alkali.

This soap is used for household cleaning of clothes as well as in

Laundries.
 MARKET POTENTIALS
Now a days, a number of synthetic detergents are available at
very common rates in the market but the use of soap has not
decreased.

The least rather there is a good soap for the growth of soap
industry the increase in population as well as there are a no. of
people like to use cheap soaps in place of detergents.

PRODUCTION TARGET
Production targets of washing soap (Laundry Soap)
Quality : 300 M.T.
Value : Rs. 2,70,00,000

BASIS AND PRESUMPTION

A.The estimates are drawn for production capacity generally
considered techno-economically viable for modern type of
manufacturing activity.
 B.The information supplied is based on a standard type of
manufacturing activity utilizing conventional techniques of
producing optimal level of performance.
C.Cost in respect to land and building, machinery and
equipments, raw material and the selling price of finished
product etc. are those generally at the time of preparation
of the project profiles and may vary depending upon
various factors.
D. Whereas some names of manufactures/ suppliers of
machinery and equipment are indicated at the end of the
profile there are by no means exclusive or exhausted.

PRODUCTION DETAILS AND PROCESS OF

MANUFACTURING
There are three main conventional methods of producing soap
namely cold process semi-boiled process and full boiled process
or settled process.
The first two processes are particularly suitable for
manufacturer having small capital outlay. Cold process
essentially requires good quality oils and fats having
saponification value. The acute shortage of these oils at present
has resulted in a general shift towards the large scale adoption
by small scale manufacturers of semi-boiled process of making
soap. Semi-boiled process offers the following note worthy
advantages over the cold process.

1. Lower grade fatty stock can be employed for making soap.

2. Coconut, groundnut or other edible oils are essentially
although incorporation of small percentage of coconut oils
improves the quality of soap particularly leathering
properties.
3. Higher rate of production of soap makes the process
economical.
4. Rosin, fillers and boilers can be incorporated easily.

Full boiled process or settled process offers advantages in

comparatively large production and particularly when it is
desired to recover the glycerin as a by product of manufacturing
soap.
In this process the oiled charge is taken in the pan which is
heated by firewood or coal slowly to melt the fat charged (70 c
approx). Caustic soda solution of a required concentration is
then added in small quantities at a time. The moderate heat is
maintained and each addition of caustic soda solution is allowed
to react with the oil before next addition is made. A hasty
addition of the caustic soda solution may result in graining,
while judicious working will keep the mass in the form of a
smooth homogeneous emulsion. If the mass shows sigas of
separation or graining then further water should be added to
bring the enlarge to a homogenous or crossed state. Presence of
such oils, fats on enlarge having high free fatty acids contents
result in shift saponification proceed smoothly. It takes about
half hour depending upon the types of oil and fats used, when
the saponification takes a visible shape. After which the soap
charge is brought boiling state which is to be so controlled so
that the soap charge does not boil over and at the same time a
good boiling is ensured to complete the saponification process.

The soap charge passes through different stages on en-route to

complete saponification. The mask thickness gets increasingly
transparent and finally assumes a peculiar shiny translucent
surface free from forth. This stage is easily recognizable by an
experienced soap maker. During the last stage of operation, it is
advisable to reduce the fire under the pan considerable. After
the boiling operation is complete, then the fire is withdrawn and
the soap allowed to cool somewhat in the pan with occasional
stirring. If any colours are to be added to the soap. These should
be incorporated a little before slopping the oiling operation. The
perfumes, (if any) may be added after the soap charge in the pan
has become a bit cool. The soap is now transferred to frames
and allowed to set there, the settled soaped is taken our of the
frames by opening the frame and cut into bars and tablets mean
of a cutting machine and stamped with the help of stamping
machine.

SOURCES OF AVAILABILTY OF ROW

MARERIAL
a) Caustic Soda :
i. M/S DCM Chemical works, Delhi
 ii. M/S Akali and chemicals corporation Co., P.O.
Rishra Howrah (W.B.)
b) Oils and Fats :
i. M/S Ramesh Arun & Co., 467, Khari Bawli, Delhi
ii. M/S Birval Krishna Lal, Farash Khanna, Delhi
iii. M/S Dharam Das Tirth Das & Co., Lohori Gate Delhi
iv. M/S Goa Mal Hri Ram, Khari Bawli, Delhi
v. M/S Duni Chand Umroa Singh, Masjid Tevri Khan,
Delhi
vi. Oil Dealers in Calcutta, Madras, Bombayetc,
c) Rosin :
i. M/S Pran chemicals, Phatak Khabash Khan, New
Delhi
ii. M/S Vijay & Co., Behind Novelty Theatre, New
Delhi

PROCESS OF FLOW CHART

Oil change heated by coal or firewood
 Addition of caustic soda

Boiling of soap in boiling cattle

Stirring

Putting of soap in cooling frames

Cutting of soap with the machines

Stamping with the machines

Packaging

PLANT LAYOUT
 Watch
M
Room Worker’ s Room
A
I
N Godown

G
A
T
Office Manufacturing
E
Process

FINANCIAL VIABILITY
Plant Capacity : 340 MT
Working Days : 25 days/month (300 days p.a.)
No. of Shifts : One/day
No. of hrs in one shift : 7 hrs

QUALITY CONTROL & STANDARDS.

There BIS specification on laundry soap, washing soap. This
may be followed by the products to create the confidence
among the consumers.

LAND AND BUILDINGS

Land 200 sqm Rented

Office, Stores work 150 sqm 67,500

MACHINES & EQUIPMENTS

1 Boiling cattle hemispherical mild 5 nos. Rs.405000.00
 steel or cast iron, plate thicknees
1/8” 6.5 dia, 2.5’ depth
2 Cylindrical plans 3’ dia 4’ 4” height Rs.337500.00
1/3” thick welded at bottom with a
circular palte 3/16” thick.
3 Stirring paddles 5 ft long hollow 6nos. Rs. 40500.00
tube or road of light weight fixed at
right angles to be hemispherical 1/8”
thick iron plate of 12” to 15” dia
with holes (dia ½ )
4 Soap coding frames made ofr 1/8” 10 nos. Rs.405000.00
thick iron sheet (1/2 X 1/2) size

5 Soap cutting machine complete with 3 nos. Rs.101250.00

an adjustable device to very length
size
6 Soap stamping machine 2 nos. Rs. 54000.00

7 Chemical Laoratory Rs. 675000.00

8 Installation charges 10 % Rs. 202500.00

9 Office equipments, working table, Rs. 634500.00

racks etc.
Total Rs.2855250.00

STAFF AND LABOUR PER MONTH

A. Administative :
1. Accountant cum cashier 1 Rs. 47250.00
2. Store Keeper 1 Rs. 33750.00
3. Clerk cum typist 1 Rs. 33756.00
4. Watchman and peon 1 Rs. 20250.00
B.Technical
1. Chemist-Analyse 1 Rs. 54000.00
2. Skilled labour 3 Rs. 81000.00
3. Unskilled labour 8 Rs. 162000.00

Perquisites 15% of salary Rs. 64800.00

Total Rs. 361800.00

RAW MATERIAL PER MONTH

Rosin 105 MT, 15,500 MT fats oils

Such as Mutton Tallow/Towllow fatty acids Rs.708750.00

Mohua oil, neem oil, tobacco seed oil

Ricebran oil etc. 10.0 Mts. 2000/MT Rs.570000.00

Caustic soda solic/lye of 500 B.C. 1.7MT

15000 PMT Rs.688500.00

Sodium silicate and misc. chemicals Rs.830250.00

Total Rs. 2767500.00

UTILITIES PER MONTH

Power/Electricity Rs. 33750.00

Fuel Wood Rs. 168750.00

Water Rs. 20250.00

Total Rs. 222750.00

OTHER EXPENSES PER MONTHS

Rent Rs.1012500.00

Stationary, Postage, Telephone Rs. 20250.00

Insurance and consumables Rs. 33750.00

Transport, Packaging, Traveling Rs.303750.00

Advertisement and Publicity Rs.101250.00

Total Rs.560250.00

WORKING CAPITAL (PER MONTHS)

Total working capital for one month

=Total expenses over (over staff & labour per month)

+ (Raw material per month) + (Utilities per month)

+ (other expenses per month)

= Rs. 5938200

TOTAL RECURRING EXPENSES

Working capital for 3 months. Rs. 17814600

TOTAL CAPITAL INVESTMENT

Fixed Capital Rs. 2855250.00

Working capital Rs. 8907300.00

Total Rs. 11762550.00

COST OF PRODUCTION PER ANNUM

Total Recurring Expenses Rs. 106887600.00

Depriciation of machinery @ 10 % Rs. 201820.56

Depriciation on equipments @ 20 % Rs. 126900.00

Interest on capital @ 15 % Rs. 4436572.28

Total Rs. 111652893.12

SOURCES OF ABILITY OF MACHINER

a) M/S Jay Bhagat Engineer works, Lal Kuan, New Delhi
b) M/S Kulwant Singh, Near Guru Nanak Piao, G.T.Road,
Rnan Pratat Bagh, Delhi
c) M/S Mohinder Singh, Near Guru Nanak Piao, G.T. Road,
Rnan Pratat Bagh, Delhi
d) M/S corporate Engineer, 7-Chittranjan Avenue, Colcutta
e) M/S steel construction company Limited, Harding Road,
Baglore.