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PROJECT CONSULTANCY FOR THE MANUFACTURING OF DETERGENT

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Saturday, October 19, 2013

Detergent

Detergents, chemically known as alfa olefin sulphonates (AOS) are used as fabric brightening agent, anti-deposition agent, stain remover and as a bleacher. A detergent is a surfactant or a mixture of surfactants with "cleaning properties in dilute solutions". The sodium or potassium salts of long chain fatty acids are soaps while salts of long chain sulphonic acids are detergents, this compound have hydrophobic and hydrophilic nature. The detergent includes from about 5% to about 80% of an inorganic carrier, from about 1% to about 90% of a detergent surfactant, from about 0.1% up to about 15% of an acidulant which is selected from the group of acids and from about 0.1% up to about 30% of the discrete whitening agent particle

Detergents are either derived from petrochemicals, vegetable oils or animal fat. Builders, enzymes, antioxidants, fabric softeners, antimicrobial agents etc are the compounds added with detergents to enhance the property.

Composition of Detergent

1. Texapon

2. Na2SO4 to taste

3. NaHCO3 25%

4. NaCO3 7%

5. STPP / CMC taste

6. Perfume to taste

 

Role of Detergent

Detergents that are basically surfactants are the active cleaning agents that perform three major roles:

·         Penetrating and wetting fabric.

·         Loosening soils (assisted by the mechanical action of the washing machine).

·         Emulsifying soils and keeping them suspended in the wash solution.

·

Methods of manufacturing

Detergents can be manufactured by these methods like spray drying, agglomeration, dry mixing or combinations of these methods and blending process

 

Types of cleaning Detergents

There are three types of detergents

·         Anionic detergents

·         Non-Ionic detergents

·         Cationic detergents

·         Amphoteric detergents

·         Alkaline detergents

·         Caustic Materials

·         Acid Cleaners

·         Detergent Crystals

·         Solvent-Based detergent Wax Removers

Classification based on the physical form

·         Liquid detergent

·         Detergents cream 

·         Detergent powder

·         Hollowed detergent powder

·         Compact powder detergent 

Market structure

          Detergents, as a constituent of the overall FMCG industry, accounts for a near 12% of the total demand for all FMCG products estimated at over Rs 530 bn. Total market of synthetic detergents and scourers was valued at about Rs 90 bn in 2007-08. It represents an increase of 15% over that of preceding year. A major input for the production of detergents is a petrochemical, Linear Alkyl Benzene (LAB), while soaps rely more on an inorganic chemical, caustic soda, as a major input.

Bars make up for less than half of the market, while powders have more than a third of the market. Liquids have 12% presence in the market. The bar market is dominated by Hindustan Lever (now Hindustan Unilever - HUL) with a share of over 40% held by its brands - Rin, Wheel, 555, Shakti, OK. The super-premium market, making up for around 10% of the overall detergents market, is dominated by Surf Excel from HUL and Ariel from Proctor & Gamble (P&G). The two together have a near 75% market with the rest coming in from players like Henkel SPIC. In the sub premium segment, Nirma from Nirma Soaps and Wheel from HUL are the major brands with small presence from an array of brands like Trilo, Hipolin, Tide, Key, Chek and others.

The detergents market in India is dominated by HUL. Nirma is the second largest player with an overall market share of 19%. Nirma is more dominant in the states of Gujarat, Rajasthan, Punjab and Haryana, that is Northwest India. Nirma has the highest market share of around 40% in Gujarat. It has the highest market share in the mass segment, like toilet soaps.

Hindustan UniLever was the first to launch the powder detergent, Surf, as far back as 1959. The company had earlier commissioned a 30,000 tpa detergent unit at Haldia. This till then was the largest detergent manufacturing unit set up in India. Wheel is HUL's leading detergent brand and contributes around 50% to the revenues of the company's laundry business. It also set up a Rs 1.1 bn soaps and detergents manufacturing facility in Himachal Pradesh. The new unit has a capacity of producing 110,000 tonnes of soaps and detergents. It helped take the annual turnover of the country's largest fast moving consumer goods company past the Rs 163 bn mark in 2008.

Nirma became the leader in the powder detergent market by its unique new low-priced product in direct confrontation with Hindustan Lever. It captured about 43% share of the low priced detergent market. It, introduced new products like soaps, shampoos and toothpastes under the same umbrella brand. Nirma has cornered a 19% of the detergent market to emerge as the second largest player after HUL.

Henkel Spic is a 47% subsidiary of German detergent leader, Henkel AG. It has a wide product portfolio consisting of detergent powders, bars, dishwash bars, liquids and cleansers, with a good presence in the southern market. Recent product launches have been reasonably successful. However, its all-India market shares are not very significant both for its powder brands (Henko Megastar, Henko White Giant) and for bars.   

How beneficial Niir Project Consultancy Services (NPCS) can be:-

 

NPCS can provide project consultancy services to any budding entrepreneur, who wants to get knowledge on manufacturing of Detergents. Our Consultancy can provide the complete report covering topics like Plant Economics, Production Schedule, Land & Building, Site Development Expenses, and Working Capital Requirement etc.

NPCShelps in establishing business prospective in the manufacturing of Detergents and cleaning powder.  Our detailed project report can be modified as per requirement of cost and capacity of the project. We have a state-of-the-art experience in preparing projects report on different subjects as per need.

Detailed project report contains:

·         Introduction

·         Properties

·         BIS (Bureau of Indian Standard) Specifications & Requirements

·         Uses & Applications

·         Present Indian Market Position

·         Expected Future Demand

·         Export & Import Statistics Data

·         Names and Addresses of Existing Units (Present Manufactures)

·         List of Plant & Machineries

·         Miscellaneous Items and Accessories

·         Instruments, Laboratory Equipments and Accessories

·         Electrification, Electric Load and Water

·         Maintenance, Suppliers/Manufacturers of Plant and Machineries

·         Process of Manufacture

·         Flow Sheet Diagram

·         List of Raw Materials

·         Availability of Raw Materials

·         Requirement of Staff & labour

·         Personnel Management

·         Skilled & Unskilled labour

·         Requirement of Land Area

·         Built up Area

·         Plant Layout.

 

Along with financial details as under:

•        Assumptions for Profitability workings

•        Plant Economics

•        Production Schedule

•        Land & Building

Factory Land & Building

Site Development Expenses

 

•        Plant & Machinery

Indigenous Machineries

Other Machineries (Miscellaneous, Laboratory etc.)

 

•        Other Fixed Assets

Furniture & Fixtures

Pre-operative and Preliminary Expenses

Technical Knowhow

Provision of Contingencies

 

•        Working Capital Requirement Per Month

Raw Material

Packing Material

Lab & ETP Chemical Cost

Consumable Store

 

•        Overheads Required Per Month and Per Annum

Utilities & Overheads (Power, Water and Fuel Expenses etc.)

Royalty and Other Charges

Selling and Distribution Expenses

 

•        Salary and Wages

•        Turnover Per Annum

•        Share Capital

 

Equity Capital

Preference Share Capital

 

•        Annexure 1          ::        Cost of Project and Means of Finance

•        Annexure 2          ::        Profitability and Net Cash Accruals

Revenue/Income/Realization

Expenses/Cost of Products/Services/Items

Gross Profit

Financial Charges    

Total Cost of Sales

Net Profit After Taxes

Net Cash Accruals

 

•        Annexure 3                    ::        Assessment of Working Capital requirements

Current Assets

Gross Working. Capital

Current Liabilities

Net Working Capital

Working Note for Calculation of Work-in-process

 

•        Annexure 4                    ::        Sources and Disposition of Funds

•        Annexure 5                    ::        Projected Balance Sheets

ROI (Average of Fixed Assets)

RONW (Average of Share Capital)

ROI (Average of Total Assets)

 

•        Annexure 6                    ::        Profitability ratios

D.S.C.R

Earnings Per Share (EPS)

Debt Equity Ratio

 

•        Annexure 7                    ::        Break-Even Analysis

Variable Cost & Expenses

Semi-Var./Semi-Fixed Exp.

Profit Volume Ratio (PVR)

Fixed Expenses / Cost 

B.E.P

 

•        Annexure 8 to 11 ::        Sensitivity Analysis-Price/Volume

Resultant N.P.B.T

Resultant D.S.C.R

Resultant PV Ratio

Resultant DER

Resultant ROI

Resultant BEP

 

•        Annexure 12        ::        Shareholding Pattern and Stake Status

Equity Capital

Preference Share Capital

 

•        Annexure 13        ::        Quantitative Details-Output/Sales/Stocks

Determined Capacity P.A of Products/Services

Achievable Efficiency/Yield % of Products/Services/Items 

Net Usable Load/Capacity of Products/Services/Items   

Expected Sales/ Revenue/ Income of Products/ Services/ Items   

 

•        Annexure 14        ::        Product wise domestic Sales Realization

•        Annexure 15        ::        Total Raw Material Cost

•        Annexure 16        ::        Raw Material Cost per unit

•        Annexure 17        ::        Total Lab & ETP Chemical Cost

•        Annexure 18        ::        Consumables, Store etc.,

•        Annexure 19        ::        Packing Material Cost

•        Annexure 20        ::        Packing Material Cost Per Unit

•        Annexure 21        ::        Employees Expenses

•        Annexure 22        ::        Fuel Expenses

•        Annexure 23        ::        Power/Electricity Expenses

•        Annexure 24        ::        Royalty & Other Charges

•        Annexure 25        ::        Repairs & Maintenance Exp.

•        Annexure 26        ::        Other Mfg. Expenses

•        Annexure 27        ::        Administration Expenses

•        Annexure 28        ::        Selling Expenses

•        Annexure 29        ::        Depreciation Charges – as per Books (Total)

•        Annexure 30        ::        Depreciation Charges – as per Books (P & M)

•        Annexure 31        ::        Depreciation Charges - As per IT Act WDV (Total)

•        Annexure 32        ::        Depreciation Charges - As per IT Act WDV (P & M)

•        Annexure 33        ::        Interest and Repayment - Term Loans

•        Annexure 34        ::        Tax on Profits

•        Annexure 35        ::        Projected Pay-Back Period And IRR

 

In order to get consultancy services for manufacturing of Detergent and to know more about the cleaning powder and surfactants, you may visit: http://goo.gl/YidKyL to know every bit of information regarding manufacturing and market structure of the Detergents.

Source: NPCS Team

ABOUT NPCS

NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
  • Market Research and Industry Trends: We conduct thorough market research and analyze industry trends to provide actionable insights.
  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
  • Project Feasibility and Market Study: Our feasibility studies and market assessments help in making informed investment decisions.
  • Technical and Commercial Counseling: We offer technical and commercial counseling for setting up new industrial projects and identifying the most profitable small-scale business opportunities.

Publications

NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

  • Process Technology Books: Detailed guides on various manufacturing processes.
  • Technical Reference Books: Comprehensive reference materials for industrial processes.
  • Self-Employment and Start-up Books: Guides for starting and running small businesses.
  • Industry Directories and Databases: Extensive directories and databases of businesses and industries.
  • Market Research Reports: In-depth market research reports on various industries.
  • Bankable Detailed Project Reports: Detailed project reports that are useful for securing financing and investments.

Our Approach

Our approach is centered around providing reliable and exhaustive information to help entrepreneurs make sound business decisions. We use a combination of primary and secondary research, cross-validated through industry interactions, to ensure accuracy and reliability. Our reports are designed to cover all critical aspects, including:

  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
  • Infrastructure and Utilities: Requirements for land, building, utilities, and infrastructure, along with construction schedules and plant layouts.

Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

Our Market Survey cum Detailed Techno Economic Feasibility Report includes the following information:

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
  • Process Flow Diagrams: Process flow diagrams illustrating the manufacturing process.

Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.

Annexures

Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.

Testimonials

Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.

FAQs

Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.