B-PLAN FOR RECYCLE PAPER MILL WASTE- BRICK INDUSTRY 1.

Introduction, Uniqueness of Idea: Brick is one of the important materials for construction industry. The needs to conserve traditional building materials that are facing depletion resulted in the development of sustainable alternative solutions. Research was carried out in VNIT by Dr. S.A.Mandavgane and Dr. R.V.Ralegoankar to make bricks using recycle paper mill waste. The use of this waste as brick material is a sustainable solution to solid waste management provides alternative raw material and an additional source of revenue. This Reuse of recycle paper mill waste for manufacturing light weight bricks is a new technology which can be used for sustainable development of construction industries. 2. Product detail and capacity: Our product is basically a brick manufactured using recycle paper mill waste (90% by wt) and cement (10%) as raw materials. Salient features of our product are: exhibits a compressive strength (according to ASTM C 67-03a) which is three times greater than the conventional clay bricks. Satisfies the requirements in BS6073 for a building material to be used in the indoor structural applications. bricks under pressure shrink but do not exhibit sudden brittle fracture even beyond the failure loads. light weight, shock absorbing capacity. Environmental friendly and low cost Low cost hand operated mixing and molding machinery is used for manufacturing Low thermal conductivity

The use of these bricks as a building material is very beneficial to the customers due to its low manufacturing cost, decrease in cost of transportation because of its light weight and also due to its good strength and long lasting nature. 3. Location: The place chosen for setting up the brick manufacturing industry is Nagpur since the major raw material required here is Recycle Paper Mill Waste. It is well connected with railways and is a major junction for roadways. 4. Technology and Know-how: Hand operated hydraulic press has been used to make bricks of dimensions 230*105*80 mm3. RPMW and cement contents are placed in a specially

designed and fabricated mixer and mixed for 2 min. In order to obtain more homogeneous mixes, the water is sprayed by air pump onto the mixes while the mixer is turning and is mixed for 5 min. Afterward, 3200 gm of 70% mix is added to the steel mold and is pressed till its initial moisture is removed. The brick is taken out and kept for solar drying till its moisture further reduces by another 15 3%. The semi-dried brick is further pressed till its moisture content is reduced by 10 2% and then kept for final sun drying. The technology has been patented by Dr. S.A.Mandavgane. 5. Present Scenario of the industry or business: There is a great demand for bricks in developing countries like India due to increasing urbanization. The estimated demand is about 180 billion bricks per year and short-fall in the production is to the tune of 40 billion bricks per year in India. Threat from the competitors is very less as it is a new technology and has not penetrated the industries yet. 6. Oppurtunity: Market targeted is Builders, Consultants, Architects and Government 7. Market Strategy: Listing on websites like Indiamart.com, justdial.com, construction.indiabizclub.com, and others. Discounts on large buying and Trade promotion Publicity through advertisements in newspapers, magazines, radio and television 8. Financial Strategy and Break even analysis: No. of working days in a year No. of shifts per day No of hours in a shift No of bricks produced per day Financial analysis: A. FIXED CAPITAL: i. Land(1200sq m) Building area(80sq m) Working area shed(150sq m) Boundary wall+gate Solar lighting system Rs.600000 Rs.800000 Rs.600000 Rs.100000 Rs. 25000 - 300 -1 -8 - 5000

TOTAL

Rs.2125000

ii.

Machinery: Mixer+ Hand operated brick making machine Rs.600000 Office furniture Trollies TOTAL Rs.50000 Rs. 20000 Rs. 670000

B. WORKING CAPITAL 1. Salaries: Manager (1) Production engineer (1) Skilled Workers (2) Unskilled Workers (20) Chowkidars (2) Peon (1) Cashier cum clerk (1) TOTAL Perquisites (15%) TOTAL SALARY 2. Raw Materials: Cement(255 bags) Recycle paper mill waste TOTAL 3. Utilities: Power Water TOTAL 4. Other Contingent Expenses: Postage and stationary Telephone Transportation Rs.500 Rs.2000 Rs.2000 Rs.3000 Rs.1000 Rs.4000 Rs. 61200 Rs. 0 Rs. 61200 Rs. 10000 Rs. 8000 Rs. 10000 Rs. 60000 Rs. 4000 Rs. 2000 Rs. 4000 Rs. 98000 Rs.14700 Rs. 112700

Repair and maintenance Advertisement and publicity TOTAL

Rs.500 Rs.1000 Rs.6000

Total recurring costs per month (1+2+3+4) = Rs.183900 For 2 months = Rs.367800 C. TOTAL CAPITAL INVESTMENT Fixed Capital= Rs.2795000 Working Capital(2 months)= Rs.367800 TOTAL = Rs.3162800 D. COST OF PRODUCTION PER YEAR Total recurring cost = Rs.2206800 Depreciation on building (5%) =Rs.75000 Depreciation on machinery (5%)=Rs.30000 Depreciation on office furniture and trolleys=Rs.7000 Interest on capital investment(5%)= Rs.158140 TOTAL= Rs.2476940 Accordingly S.P. per brick was fixed as Rs.2.75 whereas conventional brick costs Rs.3.5. TOTAL TURNOVER = Rs.4125000 Net profit per year = Rs.1648060 E. BREAK EVEN ANALYSIS: Time when total revenue and total expenses are equal ie. Zero profit is: Total Capital Investment = 1.9years Net profit per year 9. Future plans: To convert our industry from small scale to medium scale, to gain popularity in the main cities and thereby to increase the number of branches. 10. Exit strategy: As our manufacturing process is completely ecofriendly (using waste from recycle paper mills and solar lighting system) it can be easily funded by the government. It can also be overtaken by Recycle paper mills since the waste produced from these mills is utilized adding additional amount to their revenue.