White Cement

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Introduction
White cement, as the name indicates, is a kind of cement with white
color. White cement is similar to ordinary, gray Portland cement in all
aspects except for its high degree of whiteness. Obtaining this color
requires substantial modification to the method of manufacture, and
because of this, it is somewhat more expensive than the gray product.
The color of a structure is very important in the perspective of
architectural point of view.

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White cement produces a concrete with perfect and uniform color
throughout. It is possible to produces very light shades of pastels and
other colors by adding pigments with white cement which are not
possible with normally used gray Portland Cement. Besides, there are
various uses of White Portland Cement.

White cement is extensively used as an alternative to gray cement


owing to its value-added properties such as its ability to reflect heat
and improved aesthetic appearance. The demand for white cement is
higher among countries with hot environment conditions as more heat
is reflected from the resulting white concrete surface when compared to
standard gray concrete. In addition, it also serves as a readily available
concrete ingredient that works well in many applications.

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It offers aesthetic and performance benefits to pavements, buildings,
and other structures. It is also demanding in countries with advanced
economies, where it is often used for the construction of innovative
buildings and future landmarks. Furthermore, white cement serves as
an integral part in structural designing such as in high rise buildings,
bridges, and parking structures.

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Applications of White Cement:
1. Architectural Decorative Designs

White cement helps in making marvelous architectural designs. White


cement mixed with Colour pigments can give beautiful Colour
combinations while retaining the strength of the design structure.
They are used in false ceiling, decorative pillar structures, etc.

2. Designer Flooring

White cement, marble powder, marble chips / aggregates, Colour


pigments combined together gives you a freedom of creating exclusive
designer flooring.

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3. Tile Grouting

White cement is used for filling the gaps in ceramic tiles, vitrified tiles
and marble flooring. Mixing the white Cement with Colour pigments
can help you match the tile Colour by creating an illusion of a single
floor piece slab.

4. Sealants

They are used as sealants to fill in the gaps after installing ceramic
bathroom fixtures.

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Market Outlook
The white cement market is expected to register a significant growth
during 2018 to 2023 (the forecast period). This tremendous growth is
supported by the increasing construction activities in emerging
economies.

White cement is produced from non-iron containing raw materials such


as China clay and white limestone as well as with materials containing
a low content of coloring elements such as Fe, Mn, Cr, and Ti.
Moreover, white cement is manufactured in a separate kiln and is
therefore more expensive than standard Portland cement. The most
important property of white cement is its whiteness content. It is also
manufactured in strength classes of 325, 400, and 475.

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It exhibits excellent aesthetic, decorative, and hydraulic binding
features which improves its durability and strength as compared with
gray cement. Furthermore, white cement finds enhanced utilization in
the manufacture of architectural and decorative concrete, which is
further utilized in applications such as terrazzo tiles, paints, pavers, as
well as in pre-fabricated products such as artificial walls and tile
adhesives.

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White Cement Market Share, By Type, 2016
(%)

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At present, the global white cement market registers significant
growth, owing to the increase in major applications of white cement for
decoration. Moreover, growth in tradition of white buildings in
countries such as Spain and Italy also augments the market demand.
In addition, white cement-based prefabricated products such as tiles
and pavers coupled with growth of tile industry have effectively helped
to save time and labor, which further escalates the market growth. In
addition, the need for buildings with distinctive style of vernacular
architecture also boosts the production of global white cement.
However, the lesser strength of white cement in comparison with
ordinary Portland cement is expected to impede the market during the
forecast period.

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The white cement market can be segmented based on type, application,
end-user, and region. In terms of type, the white cement market can be
divided into white masonry cement, white Portland cement, and others.
White masonry cement is mixed with masonry grade sand to produce
mortar for usage in brick, block, and stone masonry construction. Portland
cement is manufactured using chalk and clay. It hardens quickly when in
contact with water. Other types of white cement are calcium aluminate
cement and calcium sulfoaluminate cement. White cement is used in
building and construction activities. It is combined with inorganic
pigments that tend to produce bright colored concrete and mortar. The
ability of white cement to be cast in any shape makes it ideal for usage in
monuments, sculptures, and restoration of archeological sites. Based on
end-user, the white cement market can be segregated into residential,
industrial, and commercial. White cement is widely used for construction
purposes in the residential industry. It is also employed in the development
of infrastructure.

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The Asia-Pacific construction sector is the largest in the world, and it
is increasing at a healthy rate, due to the rapid industrialization of
India, China, Japan, and Australia. Asia-Pacific is even anticipated to
exhibit highest market growth during the forecast period, due to the
presence of India, which is the second largest market for white cement
with emerging infrastructure growth.

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White Cement Market, by Geography (in %),
Global, 2017

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The growth of the global white cement market is driven by increase in
demand for white cement in countries with hot climates, owing to its
heat reflecting properties. In addition, rise in usage of white cement in
construction of designer buildings and future landmarks fuels the
market growth. Moreover, white cement finds extensive applications in
the developing economies such as India and China, owing to high
purchasing power, increase in per capita GDP, and rise in expenditure
by the governments.

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India White Cement Market Value, 2016-2023
($million)

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India exported about 6.22 million tonnes cement valued at `1,659
crore (including 2.85 million tonnes clinker, 2.28 million tonnes of
portland grey cement and 0.03 million tonnes white cement) in 2015-
16 to Sri Lanka, Nepal, Bhutan, Bangladesh and Myanmar, etc.

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Exports of Cement (Portland White) (By Countries)

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Major Queries/Questions Answered in the Report?

1. What is White Cement Manufacturing industry ?

2. How has the White Cement Manufacturing


industry performed so far and how will it perform
in the coming years ?

3. What is the Project Feasibility of White Cement


Manufacturing Plant ?

4. What are the requirements of Working Capital for


setting up White Cement Manufacturing plant ?

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5. What is the structure of the White Cement
Manufacturing Business and who are the
key/major players ?

6. What is the total project cost for setting up White


Cement Manufacturing Business?

7. What are the operating costs for setting up White


Cement Manufacturing plant ?

8. What are the machinery and equipment


requirements for setting up White Cement
Manufacturing plant ?

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9. Who are the Suppliers and Manufacturers of Plant
& Machinery for setting up White Cement
Manufacturing plant ?

10. What are the requirements of raw material for


setting up White Cement Manufacturing plant ?

11. Who are the Suppliers and Manufacturers of Raw


materials for setting up White Cement
Manufacturing Business?

12. What is the Manufacturing Process of White


Cement?

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13. What is the total size of land required for setting up
White Cement Manufacturing plant ?

14. What will be the income and expenditures for


White Cement Manufacturing Business?

15. What are the Projected Balance Sheets of White


Cement Manufacturing plant ?

16. What are the requirement of utilities and


overheads for setting up White Cement
Manufacturing plant?

17. What is the Built up Area Requirement and cost for


setting up White Cement Manufacturing Business?

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18. What are the Personnel (Manpower)
Requirements for setting up White Cement
Manufacturing Business?

19. What are Statistics of Import & Export for White


Cement?

20. What is the time required to break-even of White


Cement Manufacturing Business?

21.What is the Break-Even Analysis of White Cement


Manufacturing plant?

22.What are the Project financials of White Cement


Manufacturing Business?

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23. What are the Profitability Ratios of White Cement
Manufacturing Project?

24. What is the Sensitivity Analysis-Price/Volume of


White Cement Manufacturing plant?

25. What are the Projected Pay-Back Period and


IRR of White Cement Manufacturing plant?

26. What is the Process Flow Sheet Diagram of White


Cement Manufacturing project?

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27. What are the Market Opportunities for setting
up White Cement Manufacturing plant?

28. What is the Market Study and Assessment for


setting up White Cement Manufacturing
Business?

29. What is the Plant Layout for setting up White


Cement Manufacturing Business?

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Table of Contents
of the
Project Report

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Our Detailed Project Report contains
Introduction
Properties
Uses & Applications
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

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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

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 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.)

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 Royalty and Other Charges
 Selling and Distribution Expenses
 Salary and Wages
 Turnover Per Annum
 Share Capital
 Equity Capital
 Preference Share Capital

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Project Financials
• Project at a Glance Annexure

• Assumptions for Profitability workings ………………………..1


• Plant Economics…………………………………………………..2
• Production Schedule………………………………………………3
• Land & Building……………………………………………….……4
Factory Land & Building
Site Development Expenses

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• Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)

• Other Fixed Assets………………………………………..........….......6


Furniture & Fixtures
Pre-operative and Preliminary Expenses
Technical Knowhow
Provision of Contingencies

• Working Capital Requirement Per Month……………………….…7


Raw Material
Packing Material
Lab & ETP Chemical Cost
Consumable Store

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• Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses

• Salary and Wages …………………………………………....……..9

• Turnover Per Annum ……………………………………….....…10

• Share Capital…………………………………………………….....11
Equity Capital
Preference Share Capital

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

• Annexure 2 :: Profitability and Net Cash Accruals

 Revenue/Income/Realisation
 Expenses/Cost of Products/Services/Items
 Gross Profit
 Financial Charges
 Total Cost of Sales
 Net Profit After Taxes
 Net Cash Accruals

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• 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

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• 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

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• Annexure 7 :: Break-Even Analysis

 Variable Cost & Expenses


 Semi-Variable/Semi-Fixed Expenses
 Profit Volume Ratio (PVR)
 Fixed Expenses / Cost
 B.E.P

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• 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

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• 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

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• Annexure 14 :: Product wise Domestic Sales
Realisation

• 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

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• Annexure 21 :: Employees Expenses

• Annexure 22 :: Fuel Expenses

• Annexure 23 :: Power/Electricity Expenses

• Annexure 24 :: Royalty & Other Charges

• Annexure 25 :: Repairs & Maintenance Expenses

• Annexure 26 :: Other Manufacturing Expenses


• Annexure 27 :: Administration Expenses

• Annexure 28 :: Selling Expenses

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• 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

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Scope of the Report
The report titled “Market Survey cum Detailed Techno Economic
Feasibility Report on White Cement.” provides an insight into
White Cement market in India with focus on uses and
applications, Manufacturing Process, Process Flow Sheets, Plant
Layout and Project Financials of White Cement project. The
report assesses the market sizing and growth of the Indian White
Cement Industry. While expanding a current business or while
venturing into new business, entrepreneurs are often faced with
the dilemma of zeroing in on a suitable product/line. And before
diversifying/venturing into any product, they wish to study the
following aspects of the identified product:

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• Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period

We at NPCS, through our reliable expertise in the project


consultancy and market research field, have demystified the
situation by putting forward the emerging business opportunity
in the White Cement sector in India along with its business
prospects. Through this report we have identified White Cement
project as a lucrative investment avenue.

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How to Start a Cement Manufacturing
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