A PROJECT REPORT ON AQUAGEL CHEMICALS PVT. LTD., VARSANA, GANDHIDHAM (GUJARAT).

SUBMIT BY Nirav.j.Gangar SUBMIT TO ABHA MAAM

KRANIGURU SHYAMJI KRISNA VERM KACHCHH UNIVERSITY,BHUJ Academic year(2011-2012)

YEAR

2011-2012

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CERTIFICATE
THIS IS TO CERTIFY THAT MR./MISS Of.. Class, Roll No Exam Nohas satisfactorily Completed his/her term work. In ..............................................for The term ending in ..2011-2012 Date :-

Teachers sign

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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.

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INDEX SR.NO. 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 PARTICULARS COMPANY PROFILE Name of the company Registered office
Year of Establishment PAGE NO.

Branches Brief History Vision Mission Organization structure Location view SWOT Analysis

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1. COMPANY PROFILE

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1. COMPANY PROFILE

1.1 Name of the company AQUAGEL CHEMICAL PRIVATE LIMITED

1.2 Registered office

40, G.I.D.C Chitra, Bhavnagar Gujarat, India 36

1.3 Year of Establishment28th may,2002

1.4 BranchesSurvey No. 159 Varsana. Bhimasar Padana Road, GANDHIDHAM (KUTCH) INDIA

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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.

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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

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1.8 Organization structureAqua gel Chemicals Pvt. Ltd. is manufacturing unit, is producing Goods for the Hindustan Unilever Ltd. an Indias largest fast moving consumers goods company. The fundamental, Principle determining the organization structure force speed and flexibility in decision-making and implementation with empowered Managers across the Companys 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

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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)
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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.

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 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:
Peoples 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.

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2. SOAP PROCESS

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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.
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Step 5 Drying
Moisture is flashed off under vacuum in the same manner as was described above for the Colgate-Palmolive process.

OIL MIX DNV INTERNATIONAL EDUCATION ACADEMY Page 15

VACUUM DRYER

Bleaching earth

OIL BLEACHING

NaOH

Glycerine

spent lye

Saponification pan

Glycerine recovery

PROCESS OF MAKING SOAP NaOH boiling fresh lye

Wet soaps andUnreacted oils

fresh lye

crude soap
Divided pan unit

lye
fresh lye

washed soap
NaOH Fitting pan

nigre lye nigra

wet soap
Soap drying

soap chips
Plodder worms

Soap noodles DNV INTERNATIONAL EDUCATION ACADEMY Page 16

Utilized capacity:
N.S.D. : 70,000 (TPA) Bar 60,000 (TPA) Powder 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.

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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

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3. HUMAN RESOURCE MANAGEMENT

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3.1 NUMBER OF EMPLOYEES

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

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 Function Operative Function Managerial function:

1. Planning
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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

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4. FINANCE

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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

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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 companys 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 crche, health centre, community room and village administration office. All the structures are earthquake and cyclone-resistant

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BIBLIOGRAPHY
The whole information is collected from the following recources. 1. Visit of the company 2. Www. Aquagel.hill-3p@unilever.com With the costless of teachers GLOSSARY

CM : TO : TSP : NSD : DFA : TPA : Dy ex : QC : VP : MEM : HR :

Commercial Manager Time Office Toilet Soap Plant Non Soap Detergent Distillation Fatty Acid
Tones per Annum

Deputy Engineer Quality Control Vice-president Manufacturing & Engineering Manager Human Resources

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