1

A

PROJECT REPORT

ON

AQUAGEL CHEMICALS PVT. LTD.,

VARSANA, GANDHIDHAM (GUJARAT).

SUBMIT BY SUBMIT TO

Nirav.j.Gangar ABHA MA’AM

KRANIGURU SHYAMJI KRISNA VERM KACHCHH

UNIVERSITY,BHUJ

Academic year(2011-2012)

YEAR

2011-2012

DNV INTERNATIONAL EDUCATION ACADEMY

THIS IS TO CERTIFY THAT

MR./MISS ………………………………………………………………

Of………………………………….. Class, Roll No……………………

Exam No………………………………………………has satisfactorily

Completed his/her term work.

In ……………………………………..............................................for

The term ending in ………………………………………..2011-2012

Date :-…………………

Teacher’s sign


CERTIFICATE

ACKNOWLEDGEMENT

My word cannot express the gratitude and respect that I have for all the

people who are directly or indirectly connected with this research project.

But I am really thankful to each and every person without whom Iwould not

have been capable of making such project report.

I am thankful to all other department of Aquagel Chemical Pvt. Ltd and their

staff for their feedback, cooperation, support and ever-useful guidance.I

would also like to thank Mr. Prahlad Charola-Clerk, Mr. Mahesh Ghedia, Ms.

Farzana and other staff of the Office of the Personnel & (Admin.) for their

cooperation and support.

I am also very much thankful to all the respondents for their kind

cooperation and feedback.

INDEX


SR.NO. PARTICULARS PAGE NO.

1. COMPANY PROFILE 6

1.1 Name of the company

1.2 Registered office

1.3 Year of Establishment

1.4 Branches

1.5 Brief History

1.6 Vision

1.7 Mission

1.8 Organization structure

1.9 Location view

1.10 SWOT Analysis

2


1. COMPANY PROFILE


1. COMPANY PROFILE

1.1 Name of the company -

“ AQUAGEL CHEMICAL PRIVATE LIMITED”

1.2 Registered office – 40, G.I.D.CChitra, BhavnagarGujarat, India – 36

1.3 Year of Establishment-

28th may,2002

1.4 Branches-

Survey No. 159Varsana. BhimasarPadana Road,GANDHIDHAM (KUTCH) – INDIA


1.5 BRIEF HISTORY OF AQUAGEL CHEMICAL PVT. LTD.

Aqua gel Chemical Pvt. Ltd. Was established on 21st may, 2002 with collaboration of Hindustan

unilever ltd. It is in process of manufacturing goods only without interference in sales.

Aquagel Chemical Pvt. Ltd. was established with the investment of 105 cr.of capital and

expenditures. It had started its first commercial production on 17th January, 2003. It is located

near Gandhidham in the village called varsana on national highway 8A.

Aqua gel Chemical Pvt. Ltd. Is a 2P unit of Hindustan unilever ltd., which has its production

process of detergents and toilet soaps? It does only the work of manufacturing and has yearly

market, thus sales are zero, and Hindustan unilever ltd. Does the sales. Thus, this firm has only

the target of achieving the objective of manufacturing.


1.6 Vision:

Our factory shall strive to become a world class manufacture to provide total customer

satisfaction, by providing all products to set company standards, in a safe manner at an optimum

cost, in a congenial work environment, establishing itself to be the most significant contributor to

personal wash and home care business growth, by providing leading edge in innovation and by

building a culture of complete ownership amongst out people.

1.7 Mission:

Based on our guiding tents of leaderships team spirit commitment Enterprise and innovation.

Aquagel is committed to serve society by providing quality products and services and is

dedicated to long team growth and will practice highest standards of integrity and are for people.

Size of the units : “Large scale Industries” From of the organization : “Private limited Company”


1.8 Organization structure-

Aqua gel Chemicals Pvt. Ltd. is manufacturing unit, is producing Goods for the Hindustan

Unilever Ltd. an India’s largest fast moving consumers goods company. The fundamental,

Principle determining the organization structure force speed and flexibility in decision-making

and implementation with empowered Manager’s across the Company’s nation. Wide operation

Hindustan Unilever Ltd. and group companies have about36,000 employees, including 1350

Managers.

MEM - Manufacturing & Engineering Manager

QC - Quality Control

HR - Human Resources

CM - Commercial Manager VP - Vice-president

Sampling frame:

Sampling frame includes –Stockholders of ACPL (Chairman and Councilor)Top level management (City engineer, Chief auditor, Chief accountant etc.)Head of Departments (Technical, Legal, Computers, etc.)Middle level employees (Dy ex. Engineers, Assistant Engineers etc.)Lower middle level employee (Surveyors, Clerks, etc.)Lower level employee (Laborers )Element the individual respondent


1.9Location view –

Install production plants:

Sulphonation plant commissioned in March 2003

RO Plant commissioned in May, 2003

DFA Plant commissioned in August, 2003

GLY Refinery plant commissioned in December, 2003

PSM plant commissioned in January, 2004

TSP – Cascades = 4 nos (1 Binacchi, 3 stuff stampers)


1.10SWOT ANALYSIS

· Strength:○ Flexibility in operations.

○ Strategically located.

○ Fiscal benefits site (HUL point of view)

○ Harmonious Industrial relations.

○ Integrated factory.

○ Willing people.

○ High volume factory.

· Weakness:○ Low skill of workmen.

○ Low competency of manager & officers.

○ Underexposed employees.

○ High attrition level.

○ High dependence on contract workmen.

○ Dependence on fuel price for captive power generation.


Opportunity:

○ To make it lowest depot delivered cost.

○ To convert it into a vibrant factory.

○ To friend more volumes.

○ Huge opportunity for low cost automation.

○ Putting right people at right job.

○ To build safe culture from scratch.

○ Refinement of quality culture.

○ Development of second line management

Threats:

○ People’s perception of future of the factory.

○ No competent second line management.

○ Hindrance in operations because of manpower shortage.

○ High fuel price.

○ 5 earthquake zone area.


2. SOAP PROCESS

2.1 PROCESS OF TSP (TOLIT SOAP PLANT)

Step 1 - Oil preparation


The oils used most commonly are, as in the Colgate-Palmolive process, tallow and coconut

oil. These are blended together and dried in a vacuum chamber. Once the oils are dry,

bleaching earth is sucked by the vacuum into the chamber to remove any coloured impurities.

The spent earth is landfilled and the oils stored ready for saponification.

Step 2 – Saponification

The mixture of bleached oils is mixed with spent lye from the washing stage (see below) and

a caustic soda solution. The mix is heated and then left to settle into two layers. The neutral

lye (which is now rich in glycerine) is pumped off and the mixture of soap and unreacted oils

which has risen to the top is left in the pan. More caustic liquor is added to this and the mix

reheated to saponify the remaining free oils.

Step 3 – Washing

The crude soap is then pumped to a divided pan unit (DPU) where it is washed by a

countercurrent of lye. This lye is a mixture of fresh brine solution and nigre lye (see below). The

washed soap comes out the far end of the DPU and is sent to the fitting pans, while the lye

comes out the near end and is pumped back into one of the saponification pans.

Step 4 – Fitting

Here the remaining unwanted glycerine is removed from the soap by reboiling with water,

NaCl and a small amount of NaOH solution. The electrolyte concentration in the water is

such that the soap and water to separate out into two layers. The top layer is ’neat’ wet soap,

which is pumped off to be dried. The bottom layer is known as the ’nigre’ layer, and consists

of a solution of soap, glycerine and NaCl. This is left in the pan, reboiled with further salt

and left to stand, forming a soap crust over a lower layer of nigre lye (salt and glycerine).

This soap is left in the pan and is mixed with the next intake of washed soap, while the nigre

lye is pumped back to the DPUs to wash the next batch of crude soap.

Step 5 – Drying

Moisture is flashed off under vacuum in the same manner as was described above for the


Colgate-Palmolive process.

OIL MIX


VACUUM DRYER

Bleaching NaOH earth

spent lye

PROCESS OF

MAKING fresh lye

SOAP

NaOH boiling fresh lye

crude soap

lye

fresh lye

washed soap nigre lye

nigra

wet soap

soap chips

Utilized capacity:

N.S.D. : 70,000 (TPA) Bar

60,000 (TPA) Powder


OIL BLEACHING

Saponification pan

Divided pan unit

Glycerine recovery

Fitting pan

Soap drying

Plodder worms

Soap noodles

Glycerine

Wet soaps andUnreacted oils

NaOH

T.S.P. : 50,000 (TPA) Pkt soap

D.F.A. : 30,000 (TPA)

1) Lifebuoy:

The flagship brand Lifebuoy contained to record double fight growth on the

back of Market share and volume gains. Lifebuoy, which was transformed for

of a carbolic soap in to modern toilet soapin 2002, has been growing over

since. During 2004, Lifebuoy wasrelaunched in the first quarter with a unique

shape improved purchasing and competitive price.


2) Rexona :

Rexona is another famous toilet shop brand; discover the secret of Rexona

with its nourishing coconut oil and cucumber soap bits. Itscreamy lather

gently purifies your skin, leaving it clear and fragrant.Rexona with cucumber

extracts, a natural way for clear flawless skin.

PROCUREMENT OF RAW MATERIALS .

SHREE EXPORT


3. HUMAN RESOURCE MANAGEMENT


3.1 NUMBER OF EMPLOYEES

Organizational Structure MAN POWERManagers 04Officers 18Staffs 115 Sub total 137Workmen 468 TOTAL 605

3.2 DAY AND NIGHT SHIFT

There are three sifts of 8 hours in ACPL.

3.3FUNCTIONS OF PERSONAL DEPARTMENT:There are mainly two types of function:

Managerial FunctionOperative Function

Managerial function:1. Planning

2. Organizing

3. Directing


4. Controlling

5. Staffing

Operative function:

1. Procurement

2. Development

3. Compensation

4. Integration

5. Maintenance

6. Record and Research

Safety briefing :

○ Smoking in the factory premises is prohibited.

○ Always walk on the designated pathways.

○ Please follow signs & Instruction.

○ While you are moving on the shop floor be aware of the forklift movement.

○ On hearing the siren please follow instruction of the host & leave the plant to assemble at the

Emergency assembly point.

○ On hearing the siren please follow instructions of the host & leave the plant to


4. FINANCE


4.1SOURCE OF FUND

HUL (HINDUSTHAN UNILEVER) provides the funds for the raw material for its products.

HUL purchase all the production from ACPL. And ultimate sales the product in the market.

Because ACPL is the third party of HUL

4.2 CSR (corporate social responsibility)

Asha Daan

HLL supports Asha Daan run in Mumbai by the missionaries of charity. Asha Daan is a home for

abandoned, handicapped children, the destitute and people affected by AIDS (HIV positive)

Project Shakti

The objective of project Shakti are to create income-generating capability for underprivileged

rural women by providing a suitable micro enterprise opportunity and to improve rural living

standard through health and hygiene awareness

Integrated rural development

Integrated rural development (IRD) programme in a backward district of Etah in the state of

Uttar Pradesh(north India), was started in 1976, adjacent to the company’s diary operations. In

1976, the IRD program started with 30 villages. As of now, it has been extended to above 500

villages. The basic activity in rural development implementation of program towards activity


such as farmer training, health of villagers, infrastructure development, improvement in

productivity and health of cattle in Etah.

Yashodadham village

HLL has reconstructed a village in Bhachau Taluka of Gujarat's Kutch district. The village,

which has been named Yashodadham, was dedicated to its 1100 residents in December 2002.

The residents belongs to Nani Chirai village, which was completed completely wrecked by the

devastating earthquake of January 2001. Yashodadham, spread over 25 acres, comprises 289

homes. HLL has also provided a school building, an exclusive playground for children and a

multi-purpose community centre, including a crèche, health centre, community room and village

administration office. All the structures are earthquake and cyclone-resistant


BIBLIOGRAPHY

The whole information is collected from the following recources.

1. Visit of the company

2. Www. [email protected]

With the costless of teachers

GLOSSARY

CM : Commercial Manager

TO : Time Office

TSP : Toilet Soap Plant

NSD : Non Soap Detergent

DFA : Distillation Fatty Acid

TPA : Tones per Annum

Dy ex : Deputy Engineer

QC : Quality Control

VP : Vice-president

MEM : Manufacturing & Engineering Manager

HR : Human Resources


1

Documents

Transcript of 1