west godavari /east godavari cluster g...west godavari bishveshara rao 08829- 271213 shri satya sai...
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ACNielsen ORG-MARG
Situation Analysis for SME
Sector
Submitted to TERI
By
West Godavari /East
Godavari Cluster
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ACNielsen ORG-MARG
SUMMARY OF FINDINGS
West Godavari
• There are approximately 20 units in this cluster who are engaged in manufacture of
various types of firebricks.
➢ ANNUAL TURNOVER
Annual Turnover (In Lakhs)
8 8 8
3
6
7
4
1 11 1 1
2
3
2
0
2
4
6
8
10
2005-06 2006-07 2007-08
Upto 5 Lakh 5 to 8 Lakh 8 to 10 Lakh 10 to 12 Lakh Above 12 lakh
➢ PRODUCTION
Annual Production (In Tonnes Per Annum)
3
6
4
2
3
1
0
1
2
3
4
5
6
7
8
Upto 300 Tonnes 300 to 500 Tonnes 500 to 1000 Tonnes 1000 to 2000
Tonnes
2000 to 3000
Tonnes
Above 3000 Tonnes
2007- 08 Production
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ACNielsen ORG-MARG
➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per annum
Number of Units using the fuel
Electricity 1702670 20
Coal / Hard Coke 21840 Tons 20
Firewood / Husk 1560 Tons 7
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
Usage of Electricity (In Units consumed per annum)
20%
5%
25%
45%
5%
Upto 50000 Units
50000 to 75000 Units
75000 to 100000 Units
100000 to 125000 Units
Above 125000 Units
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ACNielsen ORG-MARG
• USAGE OF COAL / HARD COKE (IN TONNES PER ANNUM)
Usage of Hard Coke / Coal (In Tonnes / Annum)
10%25%
40%
15%
10%
Upto 500 Tonnes
500 to 1000 Tonnes
1000 to 1500 Tonnes
1500 to 2000 Tonnes
Above 2000 Tonnes
• USAGE OF LIGNITE FIREWOOD / HUSK (IN TONNES PER ANNUM)
Usage of Lignite Firewood / Husk (In Tonnes per annum)
14%
72%
14%
Upto 125 Tonnes
125 to 250 Tonnes
Above 250 Tonnes
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ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
Qty consumed per annum Number of Units using the raw material
Clay 25968 Tonnes 20
China Clay (Garg) 11196 Tonnes 21
• USAGE OF CLAY (IN TONNES PER ANNUM)
Usage of Clay (In Tonnes per annum)
10%
10%
65%
10%
5%
Upto 600 Tonnes
600 to 1200 Tonne
1200 to 1800 Tonnes
1800 to 2400 Tonnes
Above 2400 Tonnes
• USAGE OF CHINA CLAY (IN TONNES PER ANNUM)
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ACNielsen ORG-MARG
East Godavari
• There are approximately 25 kiln units in this cluster who are engaged in manufacture of
various types of firebricks / other refractory materials.
➢ ANNUAL TURNOVER
Annual Turnover (In Lakhs)
9
1211
4 4
6
1 1 11 1 1
43
2
0
5
10
15
2005-06 2006-07 2007-08
Upto 10 Lakh 10 to 15 Lakh 15 to 20 Lakh 20 to 25 Lakh
25 to 30 Lakh Above 30 Lakh
➢ PRODUCTION
Annual Production (In Tonnes Per Annum)
1
4
9
4 4
1
0
2
4
6
8
10
Upto 300 Tonnes 300 to 500 Tonnes 500 to 1000 Tonnes 1000 to 2000
Tonnes
2000 to 3000
Tonnes
Above 3000 Tonnes
2007- 08 Production
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ACNielsen ORG-MARG
➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per annum Number of Units using the fuel
Electricity 2057170 Units 25
Coal / Hard Coke 33084 Tonnes 25
Firewood / Husk 6480 Tonnes 13
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
Usage of Electricity (In Units consumed per annum)
4%
8%
24% 48%
16%
Upto 50000 Units
50000 to 75000 Units
75000 to 100000 Units
100000 to 125000 Units
Above 125000 Units
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ACNielsen ORG-MARG
• USAGE OF COAL / HARD COKE (IN TONNES PER ANNUM)
Usage of Hard Coke / Coal (In Tonnes / Annum)
4%
16%
48%
24%
8%
0%
Upto 500 Tonnes
500 to 1000 Tonnes
1000 to 1500 Tonnes
1500 to 2000 Tonnes
2000 to 3000 Tonnes
Above 3000 Tonnes
• USAGE OF FIREWOOD / HUSK (IN TONNES PER ANNUM)
Usage of Firewood / Husk (In Tonnes per annum)
23%
38%
31%
8%
Upto 250 Tonnes
250 to 500Tonnes
500 to 1000 Tonnes
Above 1000 Tonnes
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ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
Qty consumed per annum Number of Units using the raw material
Clay 43680 Tonnes 25
China Clay / Calcined Bauxite 19080 Tonnes 24
• USAGE OF CLAY (IN TONNES PER ANNUM)
• USAGE OF CHINA CLAY – Calcined Bauxite (IN TONNES PER ANNUM)
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ACNielsen ORG-MARG
Field Observations
✓ The units in West Godavari are spread across Chebrolu, Bhimdole, Dwarka
Tirumala, Timmaya Palem Road and run in general shift for 8 –10 hours.
✓ The units in East Godavari are located in Rajhamundry and spread across
Morampudi and Dowel swarm within an radius of 5 kms from Rajamundry.
✓ All the units in this cluster are having grid connection - commercial and power
availability is not a problem except some small power cuts of 30 – 40 mins daily.
✓ All the units are semi mechanized in nature and use there own technology; there is
no sourcing of technology.
✓ The units are manufacturing various grades of firebrick from Fire clay, which is
widely used as refractory insulating bricks for maintaining consistent temperature.
✓ Used in lining furnaces, kilns, fireboxes and fireplaces. These are built primarily to
withstand high heat and also find applications in extreme mechanical, chemical, or
thermal stresses.
✓ The major equipments are Draught Kiln, which is normally called locally as DD
Kiln, besides this a Grator, Muller Mixer, hammer press and motors of 7.5 & 12.5
hp are being used. In each unit in case of West Godavari wherein the plants are
operating at 30-50 tpm capacity are having 2/3 DD kilns whereas in East Godavari
wherein the plants are operating at 400 to 500 tpm are having 7/8 DD kiln.
✓ The major equipment being the DD Klin is fabricated locally.
✓ The energy cost in the total cost of production is ranging between 30 % to 35%,
which comprises of Electricity, Hard Coke Fire wood where as the raw material
cost which consists of clay as well as bauxite ore.
✓ The units are not running throughout the year because of marketing / order
problems
✓ The major manufacturing process is as under
▪ The most important aspect is the mixing ratio as well as content of
aluminum oxide and iron oxide in bauxite ore.
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ACNielsen ORG-MARG
✓ Both the locations are manufacturing firebrick of varied alumina content, besides this the units using China Clay / Bauxite ore are also manufacturing Pickle Jars and other articles.
Clay / China Clay - Bauxite Ore
Mixer + Grater - crushing make powder, add water make an paste
Hand molding / Hammer press
Draught Kiln - temp 1260 to 1300
Cooling & firebrick is ready.
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ACNielsen ORG-MARG
Draught Kiln
Draught Kiln
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ACNielsen ORG-MARG
Draught Kiln
Exit point
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ACNielsen ORG-MARG
Fire clay brick frame
Fire clay brick frame
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ACNielsen ORG-MARG
Fire clay brick frame
Mixer/Crusher
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ACNielsen ORG-MARG
Hammer press
Pressing machine
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ACNielsen ORG-MARG
Ball clay pickle jar frame
Finish products
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ACNielsen ORG-MARG
SERVICE PROVIDERS
Equipment Supplier Contact Nos Remarks
M/s Amic Industries (P) Ltd 86-D, Dr. Suresh Sarkar Road, Calcutta-700014
A.R. Engg. Refractory Rajamundhry East Godavari
08883- 2467357 Fabricator for Kiln
Gerranjali Engg. Refractory 8, Morampudi, East Godavari
08883 -2533103
Heat Flow Engineering Polasanpalli Elure West Godavari
08829- 222273
Raw Material
Shri Laxmi Clay Mines Dwarka Tirumala West Godavari M. SATYANARAYAN
09393262301
Vijay Laxmi Minerals Dwarka Tirumala West Godavari Bishveshara Rao
08829- 271213
Shri Satya Sai Clay Mines Dwarka Tirumala West Godavari A.M.Venkateshwara Rao
08829 - 271545
Godavari Clay Mines East Godavari
09392064444
Association
B.Shyama Prasad President West Godavari
09390410011
Er. M.Satayanarayan President West Godavari
09390400054
Ceramic Association G.A.Raju President East Godavari
09848253664
George Babu Vice President East Godavari
09247605859
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ACNielsen ORG-MARG
BANKERS
✓ The major banks in the area wherein the units are sourcing finance are ▪ State Bank of India, RAJAMUNDHRY ▪ Andhra Bank , RAJAMUNDHRY ▪ State Bank of India, Tirumala ▪ ANDHRA bank, Tirumala
✓ Out of total 45 units operating in this cluster 25% of the units are not having any bankers , rest are having the bankers for CC limits as well as loan purpose for Kiln.
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