All over the world, sanitary wares are made from variety of materials each of them having certain advantages over the others, though sanitary wares made from ceramic has numerous advantages over ones made of other materials.
Sanitary wares are used for hygiene purposes, the product ranges from washbasins, closets, urinals, sinks, baths to hoppers. It resistance to weathering, chemical erosion, mechanical strength and resistance to abrasion. Its use in sanitation has preference over other materials.
Market potential:
The market for ceramic sanitary ware is very bright since its demand is increasing though at a high rate. The reasons are not farfetched, the huge housing and accommodation deficit in the country as individuals, private and public sectors are trying to bridge the gap in the housing sector.
The demand of ceramic sanitary wares is increasing day by day in rural and urban areas due to increased construction activities and changing sanitation habits. The small scale industries are manufacturing mostly white coloured opaque sanitary ware which has a large demand in the rural areas. A number of SMEs have also started manufacturing coloured variety of sanitary ware which is in great demand not only in the cities areas but has created a good export market also.
Manufacturing Process
The non-plastic raw materials like quartz, feldspar and some clay are crushed and ground to required fineness. They are unloaded in an agitator where more clay is added as per composition. The slip is screened, magnetided and kept in an agitating tank with addition of required flocculants. The wares are cast in plaster moulds. The wares are dried and finished and are kept on open racks for drying. The dried wares are tested for cracks and then applied glaze by spraying. It is then loaded in the kilns for firing at a temperature of about 1260OC. After firing they are sorted out and packed for sale.
Production Capacity (per annum)
Quantity: 1,200 M.T.
Value: N25200000
Motive power: 95 HP.
Monetary requirement:
Fixed capital
( i ) Land and Building
Land 2400 sq.mtrs. at N2000 per sq.mtr. N4800000
Building
Office, stores, laboratory 300 sq.mtr at N3500 per sq. mtr. N1050000
Working shed 900 sq.mtr at N3000 per sq.mtr. N2700000
Total N8550000
(ii) Machinery and Equipment Production Unit
Description Qty. Nos.
Ball mill size 6ftx6ft complete with porcelain lining and grinding media with 1.0 HP motor two (2) N400000
Ball mill size 3ftx3ft complete with porcelain lining grinding media with 5 HP motor four (4) N400000
Agitator vat dia 10.5 ft and height 10.5 ft. Complete with 5 HP motor three (3) N120000
Slurry pump cap.1000 ltrs. Per hr. with 5 HP motor one (1) N30000
Magnetic separator of permanent type one (1) N10000
Spray booths complete with complete with air compressor spray guns etc. four (4) N60000
Testing Laboratory equipment and apparatus N40000
Ceramic fibre lined, shuttle kilns, oil fired, capacity 5 tonnes complete with firing system, loading cars and setters etc. with one extra car each three (3) N3600000
Oil pipe fitting for furnace N80000
Oil storage tank and pre heating system L N60000
Deep well pump set with over- head storage tank (2 HP) N100000
Installation and erection charges N80000
Drying racks and working table, slurry container etc. N250000
Office equipment and furniture N100000
Total cost of machinery and equipment N5330000
(iii) Pre-operative (project deposits etc. and other unforeseen expenses) N1,00,000 cost, non-refundable,
Total fixed capital(i+ii+iii) N13980000
Working capital (Per month)
(i) Raw Materials Including Packing Requirements (per month)
China clay 13MT N2000 N26000
Ball clay/fire clay 40MT N800 N32000
Felspar powder 30MT N1400 N42000
Quartz powder 25MT N1800 N45000
Plaster of paris 8MT N2000 N16000
Other colours and chemicals N15000
Packing material N16000
Total N192000
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