TRANING REPORT22

INDUSTRIAL TRAINING REPORT 1

CHAPTRER-1

INTRODUCTION TO CEMENT INDUSTRY IN INDIA

Cement industry in India has made significant contribution to the country’s economic

development. This is obvious because most of the development activities of the country

involve construction works using cement. South Indian Industry Limited installed the first

cement industry in Tamil Nadu in 1904 and then onwards number of factories manufacturing

cement was started. In our country there are 51 companies and 99 plants having installed

capacity of manufacturing 700 million KN of cement and with this installed capacity, the

Indian cement industry is the largest in the world after China, Russia, Japan and USA. It

accounts of about 4% of the world’s production. Some of the important highlights of Indian

cement can be summarised as follows.

1. The energy consumption is substantially higher than that in efficient plants abroad.

2. The energy protection activities require be improving and updating.

3. The new technologies i.e. high efficiency separator, roll press, vertical roller mill, pre

calcinators etc, have to be improved.

4. The requirements such as better packaging materials, bulk containers and ready mix

concrete technology deserve immediate attention.

DEPT OF MECHANICAL ENGG RIT KOTTAYAM


CHAPTER-2

HISTORY OF THE COMPANY

The Travancore Cement Limited was incorporated in the year 1946. The year of

commencement of Grey Cement in the year 1949. The licensed capacity of the plant was

50,800 Ts of cement per annum.

The master-mind behind setting up of this factory was that of late Sir.

C.P.Ramaswami Iyer, the then Devan of Travancore, who had realized the vital role of

cement in the industrial development of Kerala. The company was promoted by M\s. Essel

Limited, Bombay and the Technology tie up made with M\s. F.L.Smith & Co. Denmark.

During 1959, the company diversified into the production of White Portland Cement.

The installed capacity for the production of White Cement is 30,000 Ts per annum. Till 1974,

the company was manufacturing both White Cement and Grey Cement in the same plant,

disturbing the production of two over certain period in a year. Since 1974, the company

manufacturing white Cement alone, as the demand for white cement went up.

During the last 54 years of its existence, TCL has diversified its activities to relate

areas. Besides Super Shelcem brand Cement paint, the company has added to its products

ranges, Sheltex Acrylic Emulsion paint for interiors and exteriors and Shelprime Cement

Primer.

The Travancore Cements Limited is the only manufactured, perhaps in the whole

world, producing White Cement from a raw material other than conventional limestone. The

main raw material of TCL is lime shell, which is dredged out of Vembanad Lake, one of the

back waters in Kerala. The company has successfully executed a diversification project for

manufacture of Grey cement during the year 2000, with a capacity of 66,000 MT per annum.



CHAPTER-3

DESIGN OF STUDY

3.1 OBJECTIVE OF THE STUDY

To understand the functioning of organization as a whole.

To study the organizational structure.

To study various department of the organization and their function.

To know the organizational objectives and scope.

3.2 SCOPE OF STUDY

The scope of the study conducted includes the study of aims of the company, various

departments and their functions, various products and their production activities, quality

control procedures taken by the company and the work culture of the organization. The study

of the various departments would help in improvement their overall efficiency, by way of

identifying deficiencies.

3.3 METHODOLOGY

This study was conducted by visiting the head office of Travancore Cements Limited

at Kottayam from February 2009 to June 2009. The information’s and data’s were collected

by interacting with the managers, officers and workers and also made interviews. The further

details about the production were taken by the direct observation of the plant process. Also

some of the data’s regarding the past performance of the organization were collected by

referring the annual report of the company.



CHAPTER-4

PROFILE OF TRAVANCORE CEMENTS LIMITED

4.1 MILESTONES IN THE HISTORY OF TCL

Standard production of Vembanad Grey cement from lime shell in August 1949.

Standard production of Vembanad White cement from lime shell in August 1959.

Grey cement production stopped in 1976.

Diversified into cement paint super shelcem production in 1977.

Celebrate Silver Jubilee in 1982.

Become a government company in April 1989.

Celebrate Golden Jubilee in 1997.

Launched Shelprime Dry Cement primer in January 2000.

Diversified into Acrylic Emulsion Paint Sheltex for interiors and Exteriors in April

2000.

Diversified into Grey cement production from bought outclinker in 2000.

Become an ISO 9002 company in December 2000.

Started HRD centre in 2002. Started production of “Vembanad Wall Putty” in 2008.

TCL has implemented the Quality Management System and maintain best quality

throughout the production process. The row materials are taken by verifying quality and after

and every production process they are testing the quality of sample in the laboratory. Thus

customers are well satisfied with the products

4.2 LOCATION OF TCL

The cement plant is situated on the bank of Kodoor River and on the bank of the state

highway, M.C Road, 4KM away from the town of Kottayam in Kerala. The location of plant

makes it accessible by road as well as by water.



4.3 BRANCHES AND OFFICES

The company has its registered office and factory at Nattakom, Kerala. Also it has

another registered office in Trivandrum, it has depots at Bangalore, Coimbatore and

Vijayavada.

4.4 PROMOTERS OF THE ORGANIZATION

At first TCL was under the control of private management till 1974 subsequently the

government of Kerala took over the management and now the government holding 50.13% of

the equally share capital. Another 25% of shares are provided by the Pyramid group of

company and the remaining shares are held by General public.

4.5 OBJECTIVES OF THE ORGANIZATION

The main objective of TCL is the production of Vembanad White Portland cement. It

is the first and foremost product of the company. By quality, it is the best whit cement

produced in India. The company is now engaged in the production of cement paint known as

‘Super Shelcem Cement Paint’ which is available in 42 different shades.

4.6 QUALITY CONTROL POLICY

TCL has implemented the Quality Management system and best quality throughout

the production process. The row materials are taken by checking its quality and after each and

every production process they are testing the quality of sample in the laboratory. Thus

customers are well satisfied with the products.

4.7 PROBLEMS FACED BY COMPANY

The main problem faced by the company is the storage of row materials. The

company has serve storage of lime shell which is the major row material for both the products

of the company. The difficulty in commencing mining operations for lime shell in the

company’s lease hold area at Vaduthala is affecting the lime shell availability. The issue is

being sorted out. Now the company is obtained lime shell from ‘Chithira’ lake. The

increasing use of oil and diesel is badly affecting the profitability of the company. Surplus

labour is the another major problem faced by the company.



4.8 PRODUCTS

The company is producing three types of products. They are,

1. White Portland Cement under the brand name “VEMBANAD”.

2. Cement paints under the brand name “SUPER SHELSEM” in 42 different shades.

3. Wall putty under the brand name “VEMBANAD”.

1. VEMBANAD WHITE PORTALAND CEMENT

It is the first place in Indian white cement market by its excellent quality and its

quality is at pas with that of the best available in the world market. As compared to others

brand it accounts for its superior whiteness and maintain its quality by using lime shells

instead of lime stone. The white cement is the best suited for housing and construction of

industries. Vembanad White Cement is quickly drying, process high strength and superior

aesthetic values. Also it is good for floor finish, plaster and ornamental works. The

miscellaneous application of white cement are in swimming pools, where it replaces the use

of glazed tiles with coloured shades under water, for moulding sculptures and statues, for

painting furniture’s. It is also used for ready mixed concrete and precast blocks and also

fixing marbles and glazed tiles. Today the company enjoys the highest 8042 e-1976

specification.

SPECIAL FEATURES

Lowest magnetic content and hence most durable white cement.

Brilliant whiteness.

High strength.

Super soundness.

Super finishing.

Excellent properties.

Ideal for manufacturing cement paints, mosaic tiles etc.



APPLICATIONS

Pointing brick works.

Road marking.

Cast stone finish.

External rendering.

Mosaic tiles.

Terrazzo flooring.

Primary coat for cement paints.

2. SUPER SHELCUM CEMENT PAINT

In 1977 TCL started manufacturing cement paints under the brand name

“SHELCEM”. It was rebranded as “SUPER SHELCEM” in 1986. Super Shelcem is a unique

technology formulation with the most durable “VEMBANAD” white cement. It is an

intimate mixture of Vembanad white cement, water proofing fungicides, oxide extends, non

fading oxide pigments and hardening agents. Cement paint is water biased paint widely used

for painting buildings.

Unlike other cement paints, Super Shelcem doesn’t require water curing after first and

second coat. Only initial wetting of the surface is necessary. This makes it ideal for exteriors

of multi storied buildings and sky scrapers. Also it is ideal for interiors since, tedious curing

after removing furniture can be avoided which means saving of labour. Once a wall is painted

with Super Shelsem , it looks and stays good for years un affected by weather and fungal

attack .

Super Shelsem carries ISI marks and the approval of Bureau of Indian Standards, is

E-1969. It is available in a wide range of colours of total 42 different shades in the market.

SPECIAL FEATURES

CAPACITY: Any previous deep shade made on the surface can be effectively

hidden with a single coat of Super Shelcem. The second coat completely covers the

dark patches and stains on the wall.



COVERAGE: Super Shelcem covers greater area than any other cement paint. 1Kg

covers 100 sq feet for a single coat or 65 sq feet for two coats.

ADHESION: Super Shelcem can be applied on a wide variety of surface like

cement plaster, concrete, brick work and plastered surface.

DRYING: Super Shelcem dries very quickly. While other cements paints requires

16 to 24 hours waiting time for applying the second coat, Super Shelcem need only

3 to 6 hours after the first coat.

3. VEMBANAD WALL PUTTY

Vembanad Wall Putty was introduced in the last year, i.e. in 2008. It is dry powder

putty with Vembanad White Cement as the base. By the low content of MgO in Vembanad

White Cement, the putty when applied on the cement plastered wall and ceiling will ensure

durability, extra coverage and smooth finish. Vembanad Wall Putty can be applied on

freshly plastered surface also.

Like other products of TCL, Vembanad Wall Putty is also excellent in quality.

Before applying wall putty, one or two coats of Vembanad White Cement is recommended

to be applied on the newly plastered wall.

SPECIAL FEATURES

Quality tested Vembanad White cement is used for making wall putty.

Its production process goes through the strictest quality test.

It has a unique formulation.

It has more coverage than any other wall putty in the market.



CHAPTER-5

ORGANIZATION STRUCTURE



The Board Directors consists of five persons of which one is full time Managing

Director. Under the General Manager there are five Chief Managers, i.e. for Finance,

Personal, Production maintenance, Marketing and Purchase. The maintenance manager is

responsible for departments of dredger, civil and sanitary, water and general transport,

workshop and electrical. The production manager is responsible for the departments of white

cement plant, kilin, packing house, shelcem, lab and quality control. The purchase manager is

responsible for the departments of purchase, stores and shelcem. The finance manager is

responsible for the departments of accounts. Finally the personal manager is responsible for

the time office, personal department, office and guest house.



CHAPTER-6

PERSONNEL DEPARTMENT

DEPARTMENT STRUCTURE



It is the department which is connected to other departments in TCL. This department is

headed by Joint General Manager. Under him Joint Chief Manager followed by Junior

Executive and office assistance. The recruitment and selection of the personnel are owned by

this department. Another important function of personnel department is to loot into welfare of

its employees. Time office comes under this department. The function of time office is to

maintain leave register, attendance making, overtime confirmation etc. The above data is

forwarded to the accounts department for accounting the wages of employees.

1. EMPLOYEE POTENTIAL

In TCL are totally 595 employees, which include 24 officers. The officers of the TCL are

further classified into:

General Manager

Manager Grade

Special Grade

Class one Grade

Class two Grade

People working in the office, a security and a senior employee in the plant come under the

staff category. The grade of staff varies from 1 to 7. It being the lowest grade and 7 being

highest grade. Workers in TCL are classified into:

1. Permanent

2. Probation

3. Temporary

4. Casual

5. Apprentice

The grades of workers vary from A to E. E being the lowest grade A being highest.

1. TIMING



The office time of TCL is from 9 am to 5 pm. On Sundays the working time is from 9 am to 1

pm. The factory is working on the shift basis.

1. 3 continuous shift of 5 hours each

2. 2 special shift to 8 hours each

3. Special shift for special work of 8 hours

4. A general shift of 8 hours

3. MAN POWER PLANNING

Man power planning is a key economic resource of an organization. Man power planning is

the process by which a firm ensures that it has right number and right kind of peoples at right

places.

Man power planning includes a series of activities consisting of the following:

1. Forecasting

2. Anticipating man power status

3. Planning

4. SALARY AND WAGES

Salary and wages to be paid to the employees are determined on an agreement between CMI

and Trade Union. In TCL pay revision is done by every 4 years.

5. LEAVE PATTERN

There are 14 days of casual leave and 12 days of sick leave. For non-staff workers 18 days

of privilege leave are allowed and for officers 30 days.

6. RECRUITMENT AND SELECTION

Recruitments is done through direct application and through employment exchange.

Selection is mainly based on written test and interview. Selected person will have undergo a

period of training. The training period is usually six months and for higher post it may



extended to one year or more. Every worker is liable to be transferred from one department

to another and one job to another according to experience of work in the factory.

7. TRADE UNIONS

The recognized trade union. In the company are:

1. Travancore Cements Workers Union

2. Kerala Cement Workers Union

3. Travancore Workers Union

4. The Kottayam Cement Workers Union

8. CANTEEN

A fare price canteen is operating at the premises. The employees are given Rs. 30 per day of

attendance. Maximum Rs.900 per month is allowed by the company.

9. WELFARE FACILITIES PROVIDED BY THE COMPANY

Uniform 3 pairs of uniform once in two years

Foot wear allowance Every year

Umbrella Once in two years

Rain coat Once in three years

Washing soap Two half bars in a month

Toilet soap Two numbers in a month

Turkey towel Every year

10. COMPANY SCHOLARSHIP

Company is giving scholarship to the children of employees.

For S.S.L.C, P.D.C, to Degree & Diploma

Rs. 700/- for 1st highest rank. Rs 500/- for 2nd rank.



12. DEATH BENIFIT

Rs. 5000/- will be given to the department of the deceased employee to meet the expenses

in connection with funeral.

13. TOUR

Inside Kerala and outside Kerala

For staff and officers- one in an year

For workers-Two each

14. TRANSPORTATION

Free transportation facility provided to employees for coming and return after duty. For the

children of employees for attending education institution in and around Kottayam.

15. FACTORY DAY COMPLIMENT

Every year

16. SPECIAL ADVANCE

For medical treatment up to maximum Rs. 15000/- is allowed for all members and for

marriage expense up to maximum Rs. 25000/- is allowed.

17. LOAN SCHEME

Two wheeler/cycle loan is allowed for all employees and car/computer loan is allowed for

all officers.

18. COMPANY’S PPRODUCT AT CONCESSIONAL RATE

Super shelcem cement paint and Emulsion paint are sold to employees at factory gate price.

19. QUARTERS FACILITY

A limited number of employees are provided with quarters with free electricity and water.



20. RECREATION FACILITY

Recreation facility for indoor games, reading rooms with newspaper and periodicals, T.V

with cable facility.

21. TRAINING AND DEVELOPNENT

There are both internal and external training for workers and employees, and it is

conducted by the HRD centre under the supervision of the Personnel Development. Job

rotation is allowed only for officers. Conference, talks, workshops, etc. Are conducted as

part of training and development.

22. WELFARE FUND SUBSCRIPTION

Company is contributing Rs. 10/- per member towards monthly subscription.



CHAPTER 7

PURCHASE DEPARTMENT

DEPARTMENT STRACTURE



The purchase and store department plays an important role in the proper functioning of the

entire organization. This department comes under the material management. It has a

common department head and he look after all the activities relating to raw materials and

other general consumer thing.

ADVANTAGES OF PURCHASE DEPARTMENT IN TCL

1. Because of centralized purchasing of materials, favourable terms, eg. Trade

discounts or economic in transportations can be obtained because quality will be

large.

2. The purchasing department can be staffed with highly paid officials who are experts

in the art of purchasing the materials. Specialized knowledge and skill of this

persons can be utilized.

3. All records with regard to purchase are kept at one place under the supervision of

the purchase officer.

4. Helps in achieving following uniform purchasing policies, practices and procedures.

5. It avoids duplication of efforts and is helpful in achieving standard products.

1. FUNCTIONS OF PURCHASE DEPARTMENT IN TCL

The main functions of purchase department are

Placing order

Inviting quotations

Correspondence

Following steps are taken to perform the above functions

STEP 1: Purchase requisitions or indenting for materials

The purchase officer does not initiate any action for purchase of materials on his own

record. With the help of purchase requisitions the purchase officer come to know the types

of materials needed by the organization. A purchase requisition is a formal request for the

purchasing department to purchase materials.



STEP 2: Exploring the sources of supply and selection the supplier

A source of supply materials is to be selected after the receipt of purchase requisition. In

TCL, the process of choosing the supplier is not a hard task. The shopkeeper generally

mentions the name of the current suppliers, their price quotations, and the purchase

department also has a series of good suppliers. Choosing the right supplier from the

suppliers list involves a process of comparative statement of purchases. It is a statement

prepared by the purchase department.

STEP 3: Purchasing order

After choosing the supplier, the purchase department prepares order of the supply of sores.

The order is a written authorization to the supplier to supply the particular material or

materials. It is the evidence between the buyer and the supplier having the terms and

conditions of the purchasing order.

STEP 4: Receiving and inspecting materials

In large concerns, a separate Receipt and Inspection department independent of stocking

location should be set up to receive and inspect the materials. But in small concerns this

work is done by the stock keeper. In TCL, the stores department makes the general

purchase only. This contains 22 classes of items needed for various consumable

departments. When goods are received in stores the consuming department is informed and

the personnel’s form this department come to stores and inspect the quality etc.

STEP 5: Checking and passing bills of changes

After checking the bills are passed. Generally the payment terms of TCL are,

Against invoice or acceptance of stock a minimum 15 days credit.

In case of monopoly suppliers, they are sent/paid through banks.

2. CONDITIONS REGARDING RECEIPT OF GOODS

If the suppliers are within Kerala a time within 15 days of sending/inviting

quotations.



If supplies are outside Kerala a period within 20 to 30 days

The company makes local purchase itself within 2 to 3 days.

3. PURCHASE LIMITS

In TCL, they followed an authorized purchasing system. The purchase units are as follows

1) Below and up to Rs.5000, purchases are maintained by Junior Manager and

sanctioned by Chief Manager Purchase in charge.

2) Rs.5000 to Rs100000, Chief Manager should sanction it.

3) Rs.100000 to 5000000, it should be signed and approved by Managing Director.

4) Rs.5000000 and above, approved by sub Committee/Board of Directors.

4. STORE LOCATION LAYOUT

The location of stores department could be carefully planned out and it should be housed

in a position which is very near to receiving department so that transportation charges at a

minimum. In TCL, stores department is very near to the consumable department.

5. STOCK LEAVEL

In stores, items are divided into three levels namely

1) Maximum level

This represents the maximum quality of materials which must be maintained in

hand at all items. While fixing this level, TCL considers following facts

Rate of consumption of materials.

Amount of capital available.

Storage space of available.

Cost of maintaining store.

Risk of obsolescence.

Re-Order quantity.



2) Minimum level

This represents the minimum quantity of materials which must be maintained in

hand at all items. This quantity is so fixed that the production may not be held up due to

shortage of materials. While fixing this level, TCL considers the following.

Normal rate of material consumption.\

Lead time.

Re-Order level.

3) Re-Order level

It is the point at which the stock of particular material reaches the re-order quantity.

The storekeeper should invite the purchase requisition for fresh suppliers of that material.

While fixing this leave TCL considers following factors,

Maximum delivery time

Maximum rate of consumption

Minimum level

6. FUNCTION OF STORE KEEPER

One of the duties of the store keeper is to send requisition for materials for replenishment

in time so that the production may not hamper for want of materials. The store keeper

requisites the items need which are generally depending on the consumption pattern of

various departments.



7. ADVANTAGES OF CENTRALIZED STORES

1. Better control can be exercised over stores because all stores are housed in

one department.

2. Better layout of stores is possible.

3. Investment in stock is minimized.

4. Economy in cosy

5. Economy in staff and concentration of experts in one department will leda

to development in high technical skill.

6. Less botherisation Inventory checking are required,

8. STORES RECORD

The Bin card and Karde-X card are the two important stock records that are kept in TCL

for making a record of various stores.

9. BIN CARD

A bin card makes a record of the receipts and issue of materials and is kept for each item

of stores carries. Quantity of stores received are entered in the receipt of stocks are

recorded in the issue column of the bin card is usually hangs up or placed in shelf, rack,

or bin where the materials have been kept.

10. KARDE-X CARD

This card is used in TCL by store keeper in addition to the bin cards for storing list of

stock of items.

TCL does not maintain a store ledger, instead of this all the details are stored using

software in computer. The existing system is a FoxPro biased system.



CHAPTER 8

PRODUCTION DEPARTMENT




The production and service department control and coordinate the production process can

be mainly divided into three stage; they are slurry preparation, clinker making, and clinker

grinding. The total numbers of workers in these three stages are 75 with 17 employees in a

shift.

1. PROCESS OF MANUFACTURING

The two main process of Travancore Cements Ltd. Are Vembanad White Portland Cement

and Super Shelcem Cement Paint. Here we are discussing the manufacturing of Vembanad

White Cement and Super Shelcem Cement Paint.

The TCL produces Vembanad White Cement using the Rotary kiln and wet process

technology which is patented by F.L Smidth and company Denmark.

2. RAW MATERIALS

Vembanad White Cement is manufacturing from natures gift of rare raw materials which

are unique in consistent purity. The company is using high quality raw materials and wet

process in order to maintain the quality of its products. The main raw materials are lime

shell, white clay, white sand and Crystal gypsum.

a. LIME SHELL

Lime shells are found as under water depots in the Vembanad lake. Chemical analysis of

lime shells reveals that almost 99% accounts for calcium carbonate (CaCo3). While the

presence of usual impurities like iron and magnesium compounds are negligibly

insignificant.

Vembanad white cement has the distinctive feature of being only cement that is

manufactured form lime shell.

b. WHITE CLAY

white clay are crude china clay is obtained from southern parts of Kerala, particularly from

Trivandrum district. These white clay depots of Southern Kerala are famous for their purity

and high ceramic properties. The milky white clay, which is in paste form, go into the



manufacturing process of Vembanad White Cement, is almost 85% pure Hydrated

Aluminium Silicate.

c. WHITE CLAY

The white sand is obtained from the coastal areas of Chertala in Kerala, which is accounts

of purity up to 95%.

d. CRYSTAL GYPSM

PRODUCTION PROCESS OF VEMBANAND WHITE CEMENT

The basic cement making process consist of collecting the row materials, grinding them to

a fine stage, blending them to a uniform composition and heating them to the point of

sufficient fusion when the cement compounds are formed. Portland cement is the product

obtained by cooling and grinding the clinker thus formed with gypsum to a fine powder.

Production process can be mainly divided into three stages:

Slurry preparation

Clinker making

Clinker grinding

The different processes under these main stages are:

1. Dredging

2. Unloading station

3. Wash mill

4. Shell-sand grinding(Ball mill)

5. Slurry making(Raw mill)

6. Slurry section

7. Clinker making(Kiln)

8. Clinker grinding(Cement mills)



1. DREDGING

The main raw material for the production of Vembanad White Cement is lime shell an

underwater deposit in Vembanad Lake, is dredge and brought and brought to the company

by means of power bargers.

The company has two dredgers, one hydraulic dredger and one mechanical dredger. The

capacity of two dredgers may about 30 tonnes/hour. The dredger can cut the lime shell

around 40 feet maximum depth. The dredger works on two powerful engines, a dredger

pamper engine and an auxiliary engine.

2. UNLOADING STATION

The shell brought by Barger from lake is unloaded here. Shell in barger is diluted with

about 60% of water by means of diluting pump for easiness of sucking. A sucking pump

draws water along with the shell to receiving tank near the rotary grill of screening plant.

The shell is then passed through the rotary grill and waste materials are washed out during

its rotation. Cleaned shell is either passed through the belt conveyors through hoppers or

stored out. There are two rubber conveyors (Conveyor 1-short and straight, conveyor 2-

long and inclined) for conveying the shell to the ball

3. WASH MILL

Before actually used for the process clay is mixed with water. This work is done in a clay

wash mill. Clay is put into the mill and about 65% of water is also added during the

grinding. During the hammering action of the weights provided in the wash mill clay is

made to slurry is pumped to the storage tank known as silo. From silo, it is taken for

process when required.

4. SHELL-SAND GRINDING

Slurry preparation is the fourth stage in the production process of whit cement. Slurry is a

mixture of shell, sand and clay with around of 40% of water.

For slurry preparation two grinding mills are used:

Roughing mill known as ball mill

Finishing mill known as row mill



Ball mill is a cylindrical shell of welded metal plates.

The shell around required amount of white sand and water is fed to the ball mill by rotating

feed table. When the mill rotates the materials are crushed down to the small particulars while

it passes through the ball. The materials coming out of the ball mill is diverted to a hammer

screen by means of slurry elevator. Fine material come out of the hammer screen is fed to the

row mill. The coarse material return to the ball mill for further grinding.

5. SLURRY MAKING

The row mill is hollow cylindrical shell, the inside of which is line with flint blocks. The

shell lining are avoided to reduce the contamination of slurry by iron. The grinding media is

used is Flint Pebbles. The mill is rotated by a motor at constant speed while passing through

the mill, the fine materials discharged from ball mill and clay pumped from clay silo are

finally ground and comes out as a party material known as slurry which then flows to slurry

pit.

6. SLURRY SECTION

Slurry discharged from the row mill is stored in silos by means of pipes. The chemical

composition of the slurry will be adjusted by this stage. There are three silos for storing the

slurry. From these silos slurry is pumped to the slurry basin. In the basin slurry is constantly

agitated with compressed air and stirring mechanism. From the basin, slurry is taken from

burning in the kiln.

7. CLINKER MAKING

kiln is a cylindrical steel lined with refractory bricks mounted at an inclination of 30˚ on

roller supports. The kiln having a length of 285 feet with diameter of about 9 feet and is

rotated at about 1rpm by an electric motor.

During the process of slurry passes through three stages:

1. Drying zone

2. Calcinations zone

3. Burning zone



In the drying zone about 99% of water content in the slurry will removed. In the calcinations

zone the removal of CO2 take place. After that the materials enters the burning zone. The

clinker is formed in the burning stage by fusing Diclacium Silicate, Tricalcium silicate, and

Tera calcium Alumino Ferrite at about 400˚ C. There after the clinker is cooled by flow of

air. Clinker come out of the cooler will be usually in the modular form.

8. CILNKER GRINDING

The cooled clinker is grinded is very finely to make white cement. Clinker grinding take

place in the cement mill. There are cement mill A,B&C with clinker grinding capacity of 60

tonnes, 50 tonnes, 50 tonnes respectively. The mills B&C are identical in nature. During

grinding, small quantity about 3% to 4% Gypsum is added. The Gypsum controls the initial

setting time of cement. If gypsum is not added, the cement wouldn’t set as water is added.

The gypsum act as retarder and it delays the setting action of cement. It thus permits cement

to be mixed with aggregate and to be placed in the position. The cement coming out of the

mill is conveyed to claufies by means of bucket elevator. In the separator, causes particles are

separated and they flow to the mill while fine particles flow to the Flaxo pump, which is

operated by compressing air. Using Flaxo pump cement is transferred to the cement silo

located at the packing house.

9. PACKING AND DISPATCHING

The white cement stored in silos is packed in paper bags in the packing house. Compressed

air is used for the free flow of the cement from the Silo and hopper located above the packing

machine. While the bag is filled with 50Kg materials discharges from the spout is

automatically transferred to truck through a fixed point belt conveyer and a movable belt

conveyer. The filled bags fall down from the spout to the wire net conveyor and are

transferred to truck through a fixed point belt conveyer and a movable belt conveyer .

CEMENT PAINT DEPARTMENT

Paint is a surface coating which decorates and protects the surface on which it is applied.

Paint is a mixture of four elements they are:

1. Solvents

2. Binders



3. Pigments

4. Additives

The total paint market is broadly categorized into four segments:

1. Architectural finish or decorative paints

2. Industrial finish-general industrial sector automobile sector

3. Heavy duty coatings

4. Marine paints

Decorative paints are largest market segment and constitute around 75% of the market share.

Super shelcem is self curing cement paint manufactured by TCL. It is an inmate mixture of

White Portland Cement, water proofing compounds as oxide extender, non fading oxide

pigments hardening agent and fungicide. Super Shelcem unlike other cement paints does not

require water curing after first and second coats. Unlike other paints, metal primer is no

require while using the paint. Only initial willing of the surface is necessary. This makes

Super Shelcem ideal for exteriors of multi storied building and sky scrappers. For interior too

Super Shelcem is ideal. It carries ISI marks and is available in a wide range of colours-40

shades to be precise.

Now wall putty is also produced in this department, but the major production is in Chertala

unit.



CHAPTER 9

MARKETING DEPARTMENT




INTRODUCTION

Marketing is defined as the process of identifying the needs and wants of the consumer and

producing goods and services to satisfy their needs and wants.

The marketing department of TCL is concerned the marketing of it s various products. The

department has various techniques to market their products. This department is headed by

general Manager Marketing, under him Junior Manager in marketing, superintendent

followed by sales superintendent and sales representatives.

MARKETING DISTRIBUTION CHANNEL

Company Depots Stockiest Dealers Customers

TCL have 40 stockiest of white cement, 300 dealers of paint, 2000 dealers for white cement

in Kerala and 70 stockiest and 50 dealers for white cement in Tamil Nadu.

MARKETING ACTIVITIES

TCL has a well established marketing department. There is an efficient sales force which is

under marketing. The whole system comes under the General Manager, TCL has got 14 sales

representatives throughout Kerala

PRODUCTS

The company produces two products and they have good markets. They are:

1. Vembanad white Cement

2. Super Shelcem Cement Paint

These products are well established and have good demand in the market. Vembanad White

cement has 70% market share and Super Shelcem Cement Paint has 30% market share in

Kerala. Vembanad white cement is also transported to Tamil Nadu. A sales representative

goes around the state for collecting the order than the networks. TCL also supplies to various

government agencies like PWD, FACT etc at special rates



PRICING OF PRODUCT

The price for 1Kg of Vembanad White Cement is Rs.11.90/-. For 50Kg of white cement is

Rs.580. For Super Shelcem Cement Paint 5Kg is priced at Rs. 114.25/- and for jute bag

Rs.60.80/-. These products are priced very high mainly because the raw materials particularly

lime shell and white clay is scared.

SALES PROMOTION

TCL has an advertisement budget of 25 lakhs per annum. Since the amount is too small the

company is advertising at a low level. Other promotional activities include, conducting

dealers meeting once in two years. In addition to these the company offers various incentive

schemes for its details according to their sales performance.

Due to very low advertisement budget the company does not engage in any large scale type

of advertisement activities. The company occasionally engages in advertisement through

news papers, magazines etc. the main modes of advertisement are displaying boards which

are positioned where they get maximum attention. They also use Asianet cable vision, wall

painting etc.

DISCOUNT ALLOWED BY TCL

TCL gives trade discounts of 10% and each discount of 4% for purchase of 250Kg and

above. The company allows 3% discount on freight allowances and 3% on special discount.

In every three months, the company gives 1% quantity discount for 200Kg, 2% for 500Kg.

They also give annual discount of 3%.

MARKET SHARE

The cement paint industry is divided into organized and unorganized sectors. The major

players are in the organized sector, however major of the brands come from unorganized

sector. TCL has 40% of market share of white cement and 33% for Super Shelcem Paint in

the cement industry of Kerala.

COMPETITION



The company is facing through competition from white cement from internal manufacturers

and also from imported white cement, JK White, Birla, RKC, etc. are the major competitors

in white cement sector. In the cement paint sector there are about 14 brands to compete with

Super Shelcem. The major competitors are Durocen, Trucem, Snowcem etc.



CHPTER 10

FINANCE DEPARTMENT




There are mainly three sectors in the finance department of TCL namely accounts section,

finance section and cash section.

ACCOUNTS SECTION

The most important task done by account section is the recording of day to day accounts.

Routine account functions like sales tax payment, receipts and payment of cash, cheques

etc. come under the preview of the accounts section. The employee payroll function is also

undertaken by the accounts section of finance department.

FINANCE SECTION

Finance section is mainly concerned with maintenance of accounts. The various functional

statements are kept in the computer as well as in the manual form.

CASH SECTION

The cash section is connected with the disbursement of cash.

ACCOUNTS POLICIES

The accounts of TCL are prepared in accordance with the accounting policies accepted in

India and in line with the relevant laws as well as the guidelines prescribed by the

department of company affairs and the Institute of Charted Accounts of India and in

accordance with section 211(3c)

SYSTEM OF ACCOUNTING

The company adopts the accrual basic in the preparation of the accounts.

FIXED ASSETS

Fixed assets are capitalized at coast inclusive of expenses. Depreciation is provided on all

fixed assets except machinery for erection and free hold land, on reducing balance method.

INVENTORIES



Raw materials, stores and spares and work in progress are valued at coast. Finished goods

have been valued at coast or market prise whichever is less and does not include excise

duty, except in case of stock at depots.

SALES

Sales are inclusive of excise duty and sales tax and are net of trade discount.

TREATMENT OF GRATUITY

The company has formed a Gratuity Trust and taken group gradually policy of Life

Insurance Corporation of India w.e.f.28/03/1995.

PROVIDENT FOUND

Contribution to P.F. are made monthly in accordance with the Employees Provident Fund

and Miscellaneous Provision Act 1952.



CHAPTER 11

MAINTENANCE DEPARTMENT

ELECTRICAL SECTION

The total number of employees working in the electrical maintenance section is 24, out of

which 12 employees are concerned with electrical maintenance of the plant and other 12

undertake the maintenance work of the power plant. The company has its own substation

for power supply. The main activities undertaken in the electrical section of the

maintenance department can be discussed as follows.

The electrical section is undertaking mainly three types of maintenance works, they are:

Breakdown maintenance

Preventive maintenance

Shutdown maintenance

1. BERAKDOWN MAINTENANCE

In case of any breakdown maintenance in the production departments, information’s

regarding the breakdown is given to the maintenance department, and subsequently

maintenance workers are sent to the production department to solving machine solving the

machine failures.

2. PREVENTIVE MAINTENANCE

Under this activity, a team of maintenance workers is sent directly to the production plants to

check out whether there is any failure in the machinery or not.

3. SHUTDOWN MAINTENANCE



When the plant is shutdown the employees in the production department sent a letter to the

maintenance department and successive steps are taken by maintenance department to solve

the failures.

MECHANICAL SCETION

All mechanical works are undertaken by the mechanical section of the maintenance

department. The company the company has a workshop under the control of this department.

There are nine sub divisions for the mechanical section. They are:

1. Fitter

2. Automobile section

3. Diesel machine section

4. Welder

5. Turner

6. Blacksmith

7. Carpenter

8. Khalasis

9. Tool section

Total number of workers in the mechanical section is 72, out of which 4 are changed hands

and foreman and an attender. The rest include the officers and other skilled workers.

CHAPTER 12

OTHER DEPARTMENTS

Instead of the above discussed TCL have some other departments. They are:

1. Laboratory department

2. Transportation department

3. Workshop department



4. Dredger department

5. Time office department

6. Civil engineering department

7. Security department

1. LABORATORY DEPARTMENT

TCL has its own laboratory which continuously striving to maintain the quality of the

products. There are three levels of testing conducted in the laboratory. They are:

a. RAW MATERIALS

The row materials are tested for ensuring the quality of the product even before

manufacturing.

b. PROCESS TESTING

Process testing is done before the grinding of lime shell, sand and clay.

c. INTERMEDIATE TESTING

In this level the slurry is tested for finding that whether it contains the right propotion of lime

shell, sand and clay. Then the slurry is taken to the kilin for burning.

2. TRANSPORTATION DEPARTMENT

Mainly water transportation facilities are used for bringing lime shell from Vembanad Lake.

The company has two dredgers for which one is hydraulic and other is mechanical. There are

six wooden bargers. Capacity of a barger is 70 tonnes approximately. Dredger is used for

cutting and sucking lime shell for the river bed. The bargers are use for transporting lime

shell to the unloading station.

There are four workers in a darger, a foreman, a change hand and two operators. The capacity

of two dredger is about 30 tonnes/hour. The cutter of the dredger is about 10 meter in length.

There are six workers in a barger, a srank, a lasker, and four helpers. Tthe company has six

steel bargers. The capacity of wooden barger is 70 tones and the steel barger is 400 tonnes.



3. WORKSHOP DEPARTMENT

The company has one workshop under the control of the mechanical maintenance

department. All machinery works and repairs are undertaken in the workshop. 76 memberes

are in the workshop.

4. DREDGER DEPARTMENT

The dredging of lime shell from Vembanad Lake is controlled by the dredger department.

There are 67 employees in this department.

5. TIME OFFICE


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