Ashapura Minechem

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A PROJECT REPORT ON:
ASHAPURA MINICHEM Ltd.
BARAYA, MUNDRA-KACHCHH
PROJECT SUBMITTED TO:
K.S.K.V. KACHCHH UNIVERSITY
FOR THE PARTIAL FULFILLMENT OF BACHELOR OF BUSINESS
ADMINISTRATION PROGRAM
BY
HARIA MEET
ROLL.NO.9
UNDER THE SUPERVISION OF
ASST.LECTURER-VAIBHAVI GOR
VEERAYATAN INSTITUTE OF BBA & BCA.

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DECLARATION
I, Haria Meet, student of Veerayatan Institute of Business Administration and
Computer Application- BBA (S.Y.BBA-SEM-:IV) hereby declare that a report on an
industrial visit to ASHAPURA MINICHEM LTD. has been submitted for the partial
fulfillment of the requirement for the award of the degree of BBA, is a record of bonifide
project work carried out under the guidance of Assistant Lecturer:Vaibhavi Gor. I further
declare that the work reported in this project has not been and will not be submitted either in
part, or in full, for the award of any degree in this institute or any other institute or university.
Date: Signature of the candidate
HARIA MEET

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CERTIFICATIONOFGUIDE
This is to certify that a report on an industrial visit to
ASHAPURA MINECHEM LTD.
is submitted by HARIA MEET student of B.B.A. Sem-IV submitted to
Veerayatan Institute of Business Management & Computer Applications
Affiliated to K.S.K.V. Kachchh University in the Partial fulfillment of the
requirement for the completion of B.B.A. Sem-IV, 2015 – ’16.
I/c Principal Project in-charge
Mrs .Bhavna Ramjiyani Ms. Vaibhavi Gor
Date:
Place:

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ACKNOWLEDGEMENT
Project work is never the accomplishment of an individual; rather it is an
amalgamation of efforts, ideas, & co-operation of number of entities.
I would like to thank Veerayatan Institute of Business Administration & Computer
Applications for giving me a wonderful opportunity to work on a valuable project. I am
thankful to Mrs.Ritu Jain, administrator of our institution who had arranged the visit in a well
known industry and provided best facilities possible.
I am thankful to Asst.Lecturer-Vaibhavi Gor & Asst.Lecturer-Kunjan Mehta without
their guidance the completion of this project seemed to be a distant goal.
I am also thankful to the management of ASHAPURA MINICHEM LTD. i.e. to all their
workers and staff members, especially Mr. Manish Patel of the visited unit for the co-
operation and wonderful guidance, which helped me in understanding the working of unit in
detail.

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PREFACE
Our society is divided into castes based upon a supposed division between theoretical
knowledge and practical skill. In today’s world instead of cramming theoretical things alone,
practical things have also to be supplemented. The thought that aptitude at acquiring skills at
practical activities is different from aptitude at acquiring knowledge of truths affects our most
fundamental interactions with others.
Thus, BBA program aims at providing a practical insight to the student in the various
functions of business enterprises. It is the aspect which gives a learner an edge over other
programs in same area.
This course aims at bridging the gap between theory and practice by providing an opportunity
to the student to acquire basic understanding of the functioning of a business organisation. It
attempts to introduce a student to the various functional areas of management through
industrial exposure followed by report writing and viva-voce. It also aims to sharpen the
communicative skills of the student through practical training in some of the important skills
required to be mastered by middle and higher level managers.

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INDEX
Chapter No. Particulars Page.No:
Declaration 2
Certificate 3
Acknowledgement 4
Preface 5
1
1.1
1.2
1.3
1.4
1.5
ResearchMethodology
Introduction
Objectives of the Study
Significance of the Study
Limitations of the Study
ResearchDesign
7
8
9
10
11
12
2
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.2
2.3
Organisation Details
Company Profile
Key people of the Organisation
Employees-Workers
Mission-Vision Statement
Address
Financial Details
Corporate Social Responsibility
13
14-17
18
19
20
21
22
23-25
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.7
3.8
Data Analysis & Interpretation
Org. Location & Issues of Production
Plant layout
Org. Structure of Production Department
Process of Production
Benotnite
Ground Calcium Carbonate
Oil Refine Clay
Capacity Planning
Raw Materials Procurement & Purchase Decisions
Materials Handling & Stores Management
Effluent Treatment Plant Practises
26
27-29
30
31
32
33-37
38-42
43-46
47
48-49
50
51-52
4
4.1
4.2
4.3
Findings, Suggestions-Recommendations & Conclusion
Findings
Suggestions & Recommrndations
Conclusions
53
54
55
56
5 Biblography 57
6 Appendix 58

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CHAPTER: 1.
RESEARCH METHODOLOGY

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1.1 INTRODUCTION
“Minechem is a mod that explores chemistry and some basic physics in the Minecraft
world. With a bit of effort, it can decompose the everyday items around us into compounds
and elements. It can then combine and re-assemble the elements into compounds and
materials of their choosing.”
“MINECHEM” is nothing but a combination of two words-: mineral and chemical.
India's mining industry was the 4th largest producer of minerals in the world by volume, and
8th largest producer by value in 2009. In 2013, it mined and processed 89 minerals, of which
4 were fuel, 3 were atomic energy minerals, and 80 non-fuel. The government owned public
sector accounted for 68% of mineral produced by volume, in 2011-12.
By volume, the Indian chemical industry was the third largest producer in Asia, and it alone
contributed 5% of its GDP. India is one of the top 5 world producers of agrochemicals,
polymers and plastics, dyes and various organic and inorganic chemicals.
This Industrial report on the company ASHAPURA MINECHEM LTD. has been prepared to
make a detailed analysis on the operational functioning of the industry. It has mainly been
concentrated on the production and processing department of the industry. ASHAPURA
MINECHEM LTD mainly produces:
 BENTONITE
 KAOLIN
 GROUND CALCIUM CARBONATE
 PROCESSING OF ORC (OIL REFINE CLAY)
 BAUXITE
 OTHER MINERALS-: BARITES, CLAY GRANULES, QUARTZ, FELDSPAR
 VALUE ADDED PRODUCTS-: CALCINED BAUXITE, BLEACHING EARTH,
ALUMINA etc.
In this project detailed study has been made only on Ground Calcium Clay, Bentonite and
ORC.

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1.2 OBJECTIVES OF THE STUDY
Today’s generation is the backbone for developing the country, so they must have both
theoretical and practical knowledge.
 So the main objective of involving in an industrial study is to gain practical
knowledge about the thing or topics which we study in our curriculum.
 Other main objectives are:
→Develop understanding of the functioning and organisation of a business.
→Interact with other professional and non-professional groups.
→To learn various managerial designs of working and problem solving method.
→ Develop technical, interpersonal and communication skills, both oral and written
→To know how exactly theoretical knowledge is being imparted in real world.
→To know how rich India is in producing the minerals produced by this industry.
→To know how company has been interacting with few of the fundamentals of
economics.
→To know about the problems being tackled by the organization.
→To know how financially company does sound.

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1.3 SIGNIFICANCE OF THE STUDY
Significance of this study or project covers how useful the study may be useful to a particular
individual. The objectives and the significance of this study are almost same. The
significance of the study varies from person to person. It may be useful to person “A” in
some way while it may be useful to person “B” in some other way around. The significance
of this project has been shown how particularly will deal with my career and the things being
learnt in my daily curriculum of BBA.
Some of the significances of making study on ASHAPURA MINECHEM LTD. are as
follows:
→ First and foremost it allowed me to break to shell of the egg and come into practical
world and to learn how to imply the things which I have learned into the books of my
study.
→To know what are the problems being faced by the corporate world and what actions
are being taken by the management to face those problems?
→How capable the person should be? I.e. skills and talent required for acquiring the
job in the companies.
→To learn more about, how the company acts according to demand and supply of the
products they produce.
→It helps to learn about how to be capable enough to take accurate decisions at the
point of action, because each and every decision governs the future of the unit.

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1.4 LIMITATIONS OF THE STUDY
It is very difficult to make the defects in the creation of the god, in a similar way to find out
limitations of the industrial study is very difficult.
However there are few limitations or drawbacks which were faced during conducting the
study and also while preparing the report of the study being conducted.
Some of these limitations are:
→Due to increasing innovations in corporate world, and slower rate of change in our
studying curriculum hasn’t been able to keep up pace with industrial change and cope
the students with its changes
→Very short duration was being allotted to make a detailed study on the working of the
industry.
→Full detailed information was not being provided by the concerned guider of the
company.
→Some of the facts which were necessary for the completion of the project were not
been completely answered by the company staff.
→Some of the information which is to be acquired through secondary data was not
easily possible.
→ Details and process regarding the production of only 3 products were been explained
to us. So a complete study of the working of the unit was not possible.

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1.5 RESEARCH DESIGN
The research design refers to the overall strategy that you choose to integrate the different
components of the study in a coherent and logical way, thereby, ensuring you will effectively
address the research problem; it constitutes the blueprint for the collection, measurement,
and analysis of data.
Sources of data for the preparation of this project report are as follows:
→Primary data- Information regarding products being produced by the company, raw
materials procurement, production process, problems being faced by the production
department was being collected via personally asked questions and guidance been given.
→Secondary data- Data regarding the history of the company, its financial statements, its
plant layout, ETP Practices was collected from internet i.e. via Google and company’s own
website.

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CHAPTER: 2.
ORGANISATION DETAILS

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2.1.1COMPANY PROFILE
ASHAPURA GROUP OF COMPANIES

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Ashapura Minechem Limited is an India-based mine owner and exporter of bentonite.
The Company's bentonite products are used in the areas of iron ore pelletisation,
drilling, metal casting, construction and pet litter. The Company offers minerals, such as
bauxite, barites, kaolin and attapulgite. The Company's portfolio consists of approximately
25 minerals and 120 value added mineral solutions, such as bleaching clay, ceramic
proppants and clay catalysts, which are used in several applications, such as
manufacturing of aluminum metal, cement, foundries, oil well drilling, paper, paints,
edible oil purification, castables and hydraulic fracturing. The Company's plants are
located at Kutch, Gujarat; Baikampady, New Mangalore, and Jamnagar, Gujarat
Established in 1960 the Ashapura group is India’s largest muti-mineral solutions
provider. Its flagship company Ashapura Minechem Ltd. is listed on India’s premier
exchanges. The multinational group has mining & mineral processing facilities in Belgium,
Oman and Malaysia; in India it operates from Rajasthan,Gujarat, Maharashtra, Karnataka,
Kerala, Andhra Pradesh and Orissa.

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 When Late Shri.Navnitlal R. Shah, the Company’s ex-Chairman, returned to India
from Burma, he had confidence in his ability to convert opportunities to a profitable
venture. He started a partnership business in bentonite in the 60’s. By the early 80’s,
the business flourished due to the export of drilling grade of Bentonite to the Middle
East. The war in the Middle East forced the company to explore new applications.
Since then Ashapura never had to look back.
 SOME MAJOR MILESTONES:
 In 1960, Mr. N.R. Shah starts a partnership business in bentonite.
 In 1970, an Office and a factory was set up in Bhuj.
 In 1975, Chetan Shah, the Chairman’s son, joins the business.
 In 1980, the Shah family separated from their partners and also alternate uses of bentonite
explored like oil & water well drilling, iron ore palletization, metal casting, civil
engineering, bleaching clay etc.
 In 1982, the partnership firm was converted to a
Company. ASHAPURA MINICHEM LTD was
established
 In 1992, Ashapura Shipping Ltd. (ASL) established.
 In 1993, Ashapura Minechem Ltd went public with an
equity issue of 600,000 shares.
 In 1995, diversification into bauxite business.
 In 1997, Indo-American joint venture Ashapura Volclay Limited started to manufacture
value added Bentonite products.
 In 2001, Ashapura acquired 51% stake in M/s. Bombay Minerals Ltd.
 In 2004, Ashapura Group crosses Rs. 500 crores turnover.
 In 2005, Received in-principle approval from Gujarat Government for setting up Alumina
Refinery
 In 2006, started new global projects- Nigeria, Belgium, Malaysia and New domestic
projects - Port infrastructure, Kerala for Kaolin.

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Rs. 2500 crore Kutch alumina refinery project receives final approval from Gujarat
Government.
 In 2007, Began setting up a project at Oman.
 In 2010, New Initiatives in Indonesia to explore value added Minerals.
 In 2014, Private Equity Fund Cistenique came in as a JV partner in Ashapura Volclay Ltd
in place of Volclay Inc. USA.
ASHAPURA MINICHEM LTD is among the top six global producers of bentonite and
owns 3500 acres of bentonite mines and 5500 acres of bauxite mines.
ASHAPURA GROUP OF COMPANIES have the following units or subsidiaries under
their control:
 Ashapura Minichem Ltd.
 Ashapura Volclay Ltd.
 Ashapura International Ltd.
 Ashapura Claytech Ltd.
 Ashapura Shipping Ltd.
 Ashapura Minerals Ltd.
 Ashapura Export Ltd.
 Bombay Minerals Ltd.
 Ashapura Minichem Ltd (UAE)
 Ashapura Foundation.

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2.1.2 KEY PEOPLE OF THE ORGANISATION
 Shri Chetan Shah Chairman (Non-Executive)
 Shri Rajnikant Pajwani (Whole Time Director & Chief Executive Officer)
 Shri Ashok Kadakia (Non-Executive Independent Director)
Ashok Kadakia is an Industrialist with over 3 decades of experience in Chemical
Industry.
 Shri Abhilash Munsif (Non-Executive Independent Director)
 Shri Harish Motiwalla (Non-Executive Independent Director)
 Team of Senior Executives :
 Mr. Rajnikant Pajwani (CEO AND WTD)
 Mr. Hemul Shah (CEO) - International Projects and Investments
 Mrs. Geetha Nerukar (CEO) – Bentonite, Kaolin, and Allied Products.
 Mr. Sachin Polke (Vice-President) – Company Secretary
 Mr. Vipul Saxena (Vice-President) – HR
 Ms. Surekha Sathe (Vice-President) – IT & Systems

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 Mr. Dipak Vora (Vice-President) – AVL Accounts
2.1.3 EMPLOYEES AND WORKERS
Ashapura is a people-driven company. They believe their employees are their biggest
assets and they treat them as they would their best customers. They nurture talent and
appreciate and reward hard work and loyalty. Several of their managers have grown in
the organization through their commitment and team spirit.
 As of June 2006, ASHAPURA GROUP OF COMPANIES had 5824 personnel
working with them, which included 3000 employees working with the management
and staff category and approximately 2824 contract labours at their manufacturing
units from their various labour contractors.
 As of January 2016, ASHAPURA MINICHEM LTD. had around 600 people which
included both blue and white collar workers.

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 When it comes to the payment to the personnel, a project engineer in Ashapura
Minichem Ltd gets salary including bonus from Rs.164,413 – Rs.455,008 plus bonus
extra which in all varies according to skills, responsibility and working of the project
engineer.
2.1.4 MISSION & VISION STATEMENT
 MISSION :
“We will live up to our name… We will consistently work to realize
hopes…ours and those of our stake holders - customers, business associates,
shareholders, employees, community, governments…
Hopes fulfilled give rise to new hopes resulting in continuous improvement in the
pursuitof excellence.”

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 VISION :
“To emerge as a world class company and preferred partner to diverse
industries through proactive customer support, innovation and
cuttingedgetechnology.”
“Our standards of integrity, reliability and social responsibility will
become benchmarks for other companies to emulate. The
commitment, zeal and team spirit of our human resources will
enable ustotransform this vision toreality.”
2.1.5 ADDRESS
 Corporate office :
ASHAPURA GROUP OF INDUSTRIES
Jeevan-Udyog Building, 278- 3rd Floor,
Dr.D.N. Road, Fort,
Mumbai-400001, INDIA
Tel- +91-22-6665 1700
 ASHAPURA MINICHEM LTD :

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ASHAPURA MINECHEM LTD
Plot No.253/3, Bhuj-Mundra Highway,
Village-: Baraya, Taluka-: Mundra-370421, INDIA
Tel- +91-02838-274 512
2.2 FINANCIAL DETAILS
2.2.1 Balance sheet
(Rs crore)
Mar ' 15 Mar ' 14 Mar ' 13
Sources of funds
Owner's fund
Equity share capital 17.40 17.40 16.60
Share application money - - 3.68
Preference share capital - - -
Reserves & surplus -287.58 -161.69 -316.89
Loan funds
Secured loans 65.98 74.10 200.08
Unsecured loans - - 1.39
Total -204.20 -70.20 -95.14
Uses of funds
Fixed assets
Gross block 231.47 226.83 216.33
Less : revaluation reserve - - -
Less : accumulated depreciation 89.54 78.35 67.65

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Net block 141.93 148.47 148.68
Capital work-in-progress 8.94 11.15 4.79
Investments 39.00 38.70 38.70
Net current assets
Current assets, loans & advances 519.73 508.52 493.35
Less : current liabilities & provisions 913.81 777.04 780.67
Total net current assets -394.08 -268.52 -287.32
Miscellaneous expenses not written - - -
Total -204.20 -70.20 -95.14
Total Income - Rs. 7586.86963 Million (year ending Mar 2015)
Net Profit - Rs. -1239.371693 Million (year ending Mar 2015)
Other details:
Bankers Axis Bank, Bank of India
2.3 CORPORATE SOCIAL RESPONSIBILTY ACTIVITIES
 The company actively seeks opportunities to share its success with the communities in
areas where it operates. Their slogan says 'Value beyond Mining' but they are
committed to Value beyond Profits as they plough back funds into social welfare
schemes in Kutch. They have a long way to go in this area and they are determined to
make a difference in the lives of the less fortunate.
 The company is authorized to contribute to Charitable, religious, and other funds not
directly relating to business of the Company and or welfare of its employees from time to
time in any financial year up to the extent of Rs.5 crores or 5% of its average net profits
as determined in accordance with the provision section 349 and 350 of the said act during
the three financial years immediately preceding, whichever is greater.
 It has 3 foundations which looks after all the social activities. Its 3 foundations are:

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 Heralaxmi Memorial Foundation-
 It provides medical awareness and medical facilities to public on charity basis
in Mumbai and Kutchh.
 At present it is running two mobile medical vans at Lakhpat taluka covering
52 villages and on an average 2500 patients
every month are getting examined
 Two more vans will be introduced for other
talukas
Awareness is spread through medical camps, publishing
books, CDs, seminars.
 Ashapura Foundation:
 This is looking into special activities such as water harvesting, agricultural
development, animal care, women and child care, empowerment, promotion of
education, relief and rehabilitation, rural development covering 92
inaccessible villages.
 These programmes are funded by the foundation, Ministry of rural
development, Water and Sanitation
Management organisation, United
Nations Development, Prime Minister
Relief Fund for Drought Proofing
Programme.
 Hiralaxmi Memorial Craft Park (Kutchh Navnirman Trust):

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 A noble effort was made in memory of Lt. Smt Hiralaxmibai at Craft Park
to restore, preserve, promote, and uplift the artisans to display their arts and
sell their products to get their value.
 Every year sale amounts to Rs.50 lakhs which directly goes to artisans, in
addition the trust gives stipend to encourage them
 Last year the trust had made arrangement of lodging and boarding for 52
artisans from Kachchh to organise exhibition in Mumbai. It was a great
success.

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CHAPTER: 3.
DATA ANALYSIS
&
INTERPRETATION
[PRODUCTION DEPARTMENT]

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3.1 Organisation Location & Issues of Production
3.1.1 ORGANISATIONAL LOCATION:
ASHAPURA MINECHEM LTD. being a subsidiary of ASHAPURA GROUP OF
COMPANIES is being set up at Pragpar near Mundra in Kachchh.
Its main reason of being stationed here was to avail various facilities being provided by the
Govt. of Gujarat during the decade of 90’s.
 Its main intention was mainly to exploit the mineral resources available in plenty in
the region of the Kachchh of Gujarat.
 The plant was being located near the coastline of Kachchh i.e. near Mundra port so
that the import and the export of goods through ocean routes to various countries.
 To avail the facilities of the SPECAIL ECONOMIC ZONES such as:
 Less amount of Duties and Taxes
 Cheap Electricity
 Availability of proper water and transport facilities etc.
At the time of its establishment i.e. during the decade of 90’s the phase of globalization and
liberalisation was in full force, so to click at right point and also to avail new market
opportunites and expand its market share in the north and central western part of India it was
set up at the location stated earlier.
Today the condition of the company is that, the company is enjoying all the benefits of the
more than developing industrial sector of Gujarat especially more of Kachchh. Its location is
so well planned that it performs all its production related activites in less or minimum errors.

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3.1.2 ISSUES OF PRODUCTION:
Though the company is enjoying its all benefits of being set up as industry in Kachchh
mainly related to the production of commodities but still it is not being able to run in full
fledge as it would like to do because of the several factors hindering the process of
production and the development of the company.
Some of the issues which a company mainly a production department of ASHAPURA
MINECHEM LTD are as follows:
 One of the most challenging issues in ASHAPURA MINECHEM LTD is the lack of
assessment of resources available in Kachchh. A number of areas remain unexplored and
the mineral resources in these areas are yet to be assessed. Due to which the company is
importing majority of its raw materials from other countries.
 Another issue that is being faced by the company is that the company is not able to
procure efficient skilled and specialized employees from the region required to comply
with all the production processes of the company. The number is very few which are
available to the company from the local region.
 As the company has to procure employees from other states or regions its cost of maintain
them increases because the company has to provide them better living facilities to them
and to their families, obligating to several provisions made for them in the laws.
 It mainly procures its materials from south-western Asian countries and the location of
the port of Kandla near the company in North western region of the country makes the
time-period of receiving the products long and the company cannot produce at all its
efficiency.

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 Other operational inefficiencies can be gained in the areas of lab automation, information
management, and data analysis. The need for rapid data capture and timely, accurate
analysis of sample data to determine ore boundaries and drilling targets is a huge
challenge in ASHAPURA MINECHEM LTD.
 Another important issue is the efficient and safe disposal of company production
effluents. Mining processes produce large volumes of waste, some of it highly toxic. This
waste can result in acid mine drainage and groundwater contamination, and needs close
monitoring to ensure that it has been neutralized before being returned to the earth. As the
regulations governing the disposal of mining waste materials become stricter, elemental
analysis is becoming more important in the effort to reduce the release of harmful
chemicals.

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3.2 LAYOUT OF THE PLANT
ENTRANCE
OFFICE QUARTERS
CANTEEN
FUEL PUMP
PARKING AREA
BENTONITE PLANT
OIL REFINE CLAY PLANT
KAOLIN PLANT
GROUND CALCIUM
CARBONATE
PLANT

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3.3 Orgnisational Structure of the Production Department
GENERAL MANAGAER OPERATION
WORKS MANAGER
BARAYA PLANT
DY.MANAGER
PRODUCTION
DEPT. GNRL. MNGR
QUALITY ASSURANCE
VICE PRESIDENT
HR & ADMIN
C.E.O.
1.Dpt. Manager of Pro
a.Supervisor
b.Job& Tractor Opt.
c.Helper-Fitter
d.Welder
2.Ass. Management
Store
3. Inch. Maintenance
4.Exe. Auto Store
5.Auto Machine
6.Officer
7.Electrician
8.Data entry
9.Dpt. Auto Engineer
1.Production Incharge
2.SupervisorProduction
3.Maintenace Foreman
a.fitter,welder,helper
4.Store Officer
5.Auto Foreman
a.Mechanic
b.AutoElectronic
c.AutoHelper
6. Incharge Electrician
7. Driver
8. WeighBridge
Operator
1.Dpt. Manager Q.A
a.Asst. Manager
2.Assistant
Manager(office at port)
3.Lab officer
a.SeniorAsst. & Lab
Asst- Lab Helper
Dpt. Manager
1.Assistant Manager
Admin-
a.security
b.Mechanic
c.LMV drivers
2.Office Administration
a.Peon
b.AssistantAdministrator
3.Exe. Licensing
4.GuestHouse
Incharge

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3.4 PRODUCTION PROCESS
Production process is a process wherein the raw materials of the final products go through
various stages of production wherein they are converted into final products.
As far as ASHAPURA MINICHEM LTD is concerned the production process is lightened up
to 3 products which are:
 BENTONITE
 GROUND CALCIUM CARBONATE
 OIL REFINE CLAY
RAW MATERIALS PROCESSES FINAL PRODUCTS

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3.4.1 BENTONITE
Bentonite is a commercial term for the montmorillonite group of clay mineral, also known as
smectite. The term specifically applies to highly colloidal, plastic clay. It has the unique
characteristic of swelling to several times its original volume when placed in water and of
forming thixotropic gels with water even though the amount of clay is relatively less. It is
formed by alteration of volcanic ash in situ.
Raw Bentonite may consist of other clay minerals like halloysite, kaolinite and illite. The
physical properties of pure montmorillonitic Bentonite and admixture of the clays vary.
Bentonite composed of montmorillonite, having different structural, chemical and
exchangeable cat-ions exhibits different physical properties. For example, Na-Bentonite has
greater swelling property and plasticity than Ca-Bentonite. While Ca-Bentonite is most
common, Na-Bentonite is found in few localities.
Bentonite varies in colour from white to grey, yellow, green, blue
and black but more often yellow or yellowish green. The weathered
outcrops develop a characteristic cellular, popcorn or frothy
structure because of swelling and shrinking on wetting and drying.
The Bentonite in field has a waxy appearance.

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Among the sporadic occurrences of Bentonite in India, Gujarat has almost all the
Bentonite resources. Three fourth of the deposits in Gujarat are in Bhavnagar and
Kutch districts only. As many as 162 leases are in Kutch and 86 are in Bhavnagar.
Bentonite occurs in lenses, pockets or in oval shaped bodies 3 to 10 m thick, covered by a
residual soil layer 1.5 to 3 m. The soil is sticky, appears frothy and gives a soapy feel.
Reddish brown hard laterite or red soil, at times pinkish due to presence of manganese,
underlain by grey white aluminous clay or bauxite are observed in higher grounds.
Ashapura is India’s largest and one of the top five players in Bentonite globally.
The Company has extensive reserves of high quality Sodium and Calcium Bentonite
which are mined & processed carefully into several grades. These are in different forms
such as dried & crushed lumps, granules, powder to micronized powder, catering to diverse
needs of clients. Our Bentonite products cater to a wide range of industries starting from the
conventional usage areas of Iron Ore Pelletisation, Drilling, Metal Casting, Construction, Pet
Litter etc. to value added areas such as paper, detergents etc.

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 USES OF BENTONITE :
 Pelletising: As a binding agent in the production of iron ore pellets.
 Construction and Civil Engineering: Bentonite in civil engineering
applications is traditionally used as a thixotropic, support and lubricant
agent in diaphragm walls and foundations, in tunnelling, in horizontal
directional drilling (HDD) and pipe jacking.
 Oil & Water Well Drilling: Its role is mainly to seal the borehole walls,
to remove drill cuttings and to lubricate the cutting head.
 Oils /Liquor/ Food Markets: Bentonite is utilized in the removal of
impurities in oils where its adsorptive properties are crucial in the processing of edible
oils and fats (Soya / palm / canola oil).
 Agriculture: As an animal feed supplement, as a pelletising aid in the
production of the animal feed pellets, as well as a flowability aid for
unconsolidated feed ingredients such as soy meal.
 Fillers for Pharmaceuticals, Cosmetics and Medical Markets:
Bentonite is used as filler in pharmaceuticals and due to its
absorption/adsorption functions, allows paste formation. Such
applications include industrial protective creams, calamine lotion, wet compresses, and
anti-irritants for eczema.
 Detergents: Laundry detergents and liquid hand cleansers/soaps rely
on the inclusion of bentonite, in order to remove the impurities in
solvents and to soften the fabrics.
 Water Proofing: The Kutch Bentonite has excellent filtration loss
properties, which makes it ideal for all water proofing uses and in
environment protection.

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PROCESSING OF BENTONITE IN ASHAPURA MINECHEM LTD.
(for Ph value testing 100ml of water is mixed in bentonite, then the water is taken and
checked in laboratory its Ph value)
(Milling of the bentonite is done through the 7 mills available in the company)
MAKING RAW BENTONITE
AVAILABLE
HOPPER (MATERIAL STORAGE)
SPREADING OF BENTONITE
TESTING OF PH VALUE OR SCALE
Ph soda/sodium is mixed
MILLING OF THE TESTED PRODUCT
PACKAGING OF THE GRINDED
BENTONITE

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Explanation of the process of Bentonite processing
 As always the first step in any production process is to procure raw materials for the
transformation of the raw materials into finished or semi-finished products.
Over here ASHAPURA MINICHEM LTD procures raw or granular bentonite from the
local area such as MATA NA MADH or from other states, regions or countries.
 After the procurement of the raw materials, it is stored in hooper
 From hooper the bentonite is being spreaded on the belts and firstly its ph value is tested.
 After the testing of the ph value necessary amount of the sodas/sodium are being added
in accordance to the value of ph scale.
 The next important step is of milling of granular bentonite into grinded or
powdered form. The company completes its grinding process through the 7 mills
available in the unit.
 The last step of whole process is of packaging of the grinded bentonite.

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3.4.2 GROUND CALCIUM CARBONATE
"GCC" is usually referring to ground limestone, a calcium carbonate material having the
calcite crystal structure. Limestone formations are formed by natural precipitation, a process
that occurs slowly. This is part of the explanation why the
material in limestone products is completely converted to
the CaCO3 form. By contrast, depending on the conditions
of its production, precipitated calcium carbonate may
contain some residual calcium hydroxide. Because of the
hardness of limestone, the grinding process is energy-
intensive. Anionic dispersants, including phosphates and
acrylates, are used as grinding aids and to make the
resulting slurry more stable in a colloidal sense.
GCC can be obtained from high-quality limestone sources, yielding a product of very high
brightness.
Products Technical Details:
Products Name Ground Calcium Carbonate
Place of Origin: India
Application: fertilizer, glass, cement, painting industry.
Chemical Composition: CaCO3 98%min
Shape: Powder
whiteness: 90-97%
Model Number: GCC5
Limestone is formed either by direct crystallization from water
(usually seawater), or by the accumulation of sea animal shells
and shell fragments. In the direct crystallization case calcium
ions in the seawater combine with atmospheric or dissolved
carbon dioxide to form calcium carbonate, which being
insoluble, precipitates out. Over time, layers of the calcium
carbonate form, and with sufficient time and pressure from
overlying materials, are transformed to solid rock. The chemical composition of seawater and
its minerals

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USES OF GROUND CALCIUM CARBONATE:
 Adhesives & Sealants
GCC is often the main ingredient of sealants, fillers and ceramic tile
adhesives (CTA's), sometimes up to 80% of the formulation.
 fillers
 viscosity control
 Construction
GCC has long been used as filler in materials like asphalt, roofing felt and plasters.
Increasingly other applications are emerging in the new areas of specialist concretes &
grouts. Consistent particle size and handling characteristics are very
important.
 filler for concrete, grout & asphalt
 fillers in roofing materials
 Fertilisers
Calcium Carbonate has long been recognised as a useful addition to soil
for agriculture, stabilising the acidity of soil and providing essential
calcium for support of crops.
 calcium source
 filler
 Paints & Surface Coatings
GCC is used to bulk out or extend the resins & polymers in paints. Colour is obviously
important and GCC is used as an aid to pigmentation, and also to help control the finish (matt
or gloss).
 pigments
 extenders
 finish aids

41 | P a g e
 Plastics
GCC is widely used as a filler in plastic products, comprising up to 25% of the volume,
adding density, improving rheology and reducing cost. GCC is often
blended or "coated" with additives such as stearates to aid bonding
within the plastic.
 fillers
 improved rheology
 mechanical properties
 finish
 Paper
Fine grades of GCC are used extensively in paper manufacturing. Consistent particle sizing
and colour are essential. As an alkali material it reduces acidity of
paper, improving the durability of printed material.
 fillers
 coating pigments
 acidity control
 brightness
 Glass & Ceramics
GCC is an essential calcium component in the manufacture of container and flat glass. High
purity, consistent colour and low levels of impurities are essential. It
is a common ingredient in pottery glazes.
 calcium source (glass)
 kiln control (ceramics)

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PROCESSING OF GROUND CALCIUM CARBONATE
PROCUREMENT OF RAW MATERIAL
GROUND CALCIUM CARBONATE
CRUSHING (size of the GCC is 100mm-150mm)
MILLING UNIT (size of the GCC turns into 50mm-
60mm)
Syllo(milled GCC is stored in Syllo)
BALL MILL (50-60mm is converted intosemi-
powdered form)
SYLLO (semi-powdered form is stored)
CLASSIFIERS (Distinguished according to size and shape)
COATING OF
GCC
NON-COATED GCC
SYLLO(STORED)
PACKAGING

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EXPLANATION OF THE PROCESS
 The first step is the procurement of raw or grounded calcium carbonate from Malaysia.
 The next step is of crushing of the 100mm-150mm Ground Calcium Carbonate.
 Then the milled GCC is sent to milling unit where it is converted into 50-60mm of
size.
 50-60mm of the GCC is stored in Syllo
 From syllo the GCC is sent to BALL MILL through elevator.
 In Ball Mill the GCC is converted into semi-powdered form.
 Semi-powdered form is stored again in Syllo.
 From Syllo it is distinguished in classifiers according to its size and shape.
 Then the part of the production is coated with acid and other part remains un-
coated.
 Coated and un-coated production is stored in different syllos.
 Then the product finally from syllo is sent for packaging.

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3.4.3 OIL REFINE CLAY
OIL REFINE CLAY or also often called Fuller Earth / Activated Bleaching Earth, is a type
of clay mine in Asia, England, India, and the United of States. Once obtained from the earth,
this mineral-rich substance is processed and use for absorbing, bleaching, and filtering
properties.
Fuller's earth is any clay material that has the capability to decolorize oil or other liquids
without chemical treatment. Fuller's earth typically consists of palygorskite (attapulgite)
or bentonite.
Fuller's earth consists primarily of hydrous
aluminum silicates (clay minerals) of varying
composition. Common components
are montmorillonite, kaolinite and attapulgite.
Small amounts of other minerals may be
present in fuller's earth deposits,
including calcite, dolomite, and quartz. In some
localities fuller's earth refers to calcium
bentonite, which is altered volcanic ash
composed mostly of montmorillonite.
A type of Clay which is highly adsorptive and consists mainly ph hydrated aluminium
silicates. It is used as a bleaching agent, and as an
adsorbent in decolorizing and refining oils and fats.
Fuller's earth is a mineral substance characterized by the
property of absorbing basic colors and removing them
from oils. It is composed mainly of alumina, silica, iron
oxides, lime, magnesia, and water, in extremely variable
proportions and is generally classified as a sedimentary
clay. In color it may be whitish, buff, brown, green, olive, or blue. It is semiplastic or
nonplastic and may or may not disintegrate easily in water.

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USES OF OIL REFINE CLAY
 Refining of Vegetable oils
 Refining of hydrogenated Vanaspati ghee oils, Margarine & shortening.
 Refining of Animal Fats like tallow oil, fish oil, lard oil.
 Refining of Mineral Oils like-:
 Insulating oil
 Rolling oil
 Lube oil
 Waste oil
 Industrial triglycerides and fatty acids used
for paints, varnishes and soaps
 Decolourising by removing colour pigments
like carotenoids, chlorophyll, Pheophytine
 Removal of gums (phospholipids), FFA and
soap contents and traces of heavy metals in
vegetable oils
 Reducing and Controlling different oil parameters like Peroxide value, Anisidine
value, UV-absorption value.FFA contents etc
.
 Purification of Aromatic Compounds in case of mineral oils & waxes and removal of
Sulphuric acid, Tars acid, Sludge, Sulfonic acid etc.
 Other Applications like-:
 Bleaching of Sulphur.
 In Effluent treatment plants.

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PROCESSING OF OIL REFINE CLAY
(Drying is done in order to dry up the moisture content is the material. Moisture is dried up
using HOT AIR GENERATION VIA COAL FIRING at 7000 CELCIUS)
(In water treatment process the ORC is dealt with the process of acid
calcinations at 700Celsius.)
PROCUREMENT OF CLAY/RAW
MATERIAL
CRUSHING OF ORC (0MM-10MM)
(Size is shortened to dry up the moisture fast)
DRYING
WATER TREATMENT
ADDING OF H2SO4 (to maintain Ph value)
MILLING
PACKAGING

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EXPLANATION OF THE PROCESS
 As usual the first step is to make available the raw materials i.e. oil refne clay or fuller’s
earth for its conversion into final product.
 The next step is to send the raw material through the crushing stage where it is converted
into 0-10mm particles.
 The next important step is to dry up the moisture present in the ORC. It is done by
HOT AIR GENERATION through COAL FIRING and the temperature to be
maintained in it is 700oC.
 Then through screw conveyor it is sent for water treatment for cooling down its
temperature. It is done through Acid Calcination where in temperature is reduced
to 70oC.
 The next step is to add H2SO4 to maintain the ph value of the product.
 Next step is to send the ORC for milling in milling unit.
 Last step is of packaging of the milled ORC

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3.5 CAPACITY PLANNNIG
Capacity planning is the process of determining the production capacity needed by an
organization to meet changing demands for its products. In the context of capacity
planning, design capacity is the maximum amount of work that an organization is
capable of completing in a given period.
In ASHAPURA MNICHEM LTD. the production was carried on according to the
market demand.
When it comes to the capacity of the firm to produce the total output, each of the unit in
it had different capacities according to the process of production of the product.
 Production of Bentonite: 1200 tons daily
 Production of Ground Calcium Carbonate: 1 hour- 2.5 tons
daily
 Production of Oil Refine Clay: 1 hour- 20 tons

49 | P a g e
3.6 RAW MATERIALS PROCUREMENT AND PURCHASE
DECISION
As far as this project is concerned, the procurement of raw materials is subjected up to 3
materials namely- BENTONITE, GROUND CALCIUM CARBONATE, & OLI REFINE
CLAY.
 When it comes to the procurement of bentonite, it is procured from nearby
regions of the unit such as MATANA MADH, OR from Bhuj i.e. from their own
mines as there are plenty of bentonite resources available in Kachchh.
 Ground Calcium Carbonate is made available from MALAYSIA, however it is
available in Rajasthan but the quality of it does not meet the standards and
GCC available from Malaysia is easier to process, has high quality and is bright
enough.
 OIL REFINE CLAY is made available from the state of TELENGANA i.e.
from Hyderabad (DHARUL).

50 | P a g e
RAW MATERIALS PURCHASE DECISION
1. Determine needs: Before you buy anything, it is necessary to know what you need to buy
and how much. It is important to remember that determining what you need involves not only
quantity, but quality decisions as well. Determining and specifying appropriate quality
requirements, in some situations, is a more difficult task than deciding what quantity to buy.
2. Select the supplier(s): When there are many suppliers to choose from, it is not simple to
choose those who will give the best value - not only in price but in service, and consistent
quality as well. Selection of suppliers may also mean finding more than one acceptable
vendor if the purchased product is so important that you would suffer substantial losses if it
were not available. In such a situation, in case the primary supplier cannot meet your needs as
a result of a heavy workload, strike, unavailability of raw materials, etc.
When deciding to use more than one supplier, you have to weigh these advantages against the
possible disadvantages of higher price and poorer service when you buy smaller quantities
from two vendors rather than larger quantities from a single, reliable one.
3. Negotiate the purchase: In addition to specifying quantities and obtaining agreement on
price, this can involve guarantees, method of payment, containers and packaging, delivery
dates and other details of the purchase. Proper documentation of the purchase agreement is
part of negotiation and assures that any questions or disputes that may arise will be settled in
line with your expectations.
4. Follow-up: Here you look at the quality of product and service as well as the accuracy of
quantities to determine what improvements, if any, are needed for the future

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3.7 MATERIALS HANDLING & STORES MANAGEMENT
Material handling involves short-distance movement within the confines of a building or
between a building and a transportation vehicle. It utilizes a wide range of manual, semi-
automated, and automated equipment and includes consideration of the protection, storage,
and control of materials throughout their manufacturing, warehousing, distribution,
consumption, and disposal. Material handling can be used to create time and place
utility through the handling, storage, and control of material, as distinct from manufacturing,
which creates form utility by changing the shape, form, and makeup of material.
The work of material handling is all done at the same place in ASHAPURA MINICHEM
LTD. i.e. all the manufacturing work, storing of manufactured work and also storing of raw
materials is done at the same place.
They don’t have a separate warehouse for the storing of raw materials or keeping the
manufactured products. They have made the arrangements to keep all at the same place.
 All the raw materials of bentonite, GCC, AND ORC are kept at their respective units
only. They have not maintained separate warehouses for them.
 The transportation of the finished products i.e. processed form of bentonite, GCC,
ORC is done via semi-automated and manually operated machines at the work place
and also the finished products are stored at the same work place. No special
warehouse is being maintained for their storing.
 The only transporation it involves is the raw materials from the distant places to the
unit and the processed form from the unit to the customers.

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3.8 EFFLUENT TREATMENT PLANT PRACTISES
Effluent treatment plant performance is to reduce operating costs, comply with discharge
consent conditions and minimise environmental pollution is high on the agenda of many
industrial organisations.
This informative good practice guide deals with improving the performance of effluent
treatment plant to reduce operating costs and reduce environmental pollution. Most
companies operate effluent treatment plants to reduce the potential for pollution of receiving
waters and to comply with discharge consent conditions.
Effective management and control of the processes used
for effluent treatment helps you:
 Reduce operating costs and thus increase profits.
 Achieve more effective compliance with legislation.
 Improve your company's public image.
Effective effluent management
The five steps to effective effluent management are:
1. Characterize all effluents produced on-site;
2. Implement a waste minimisation programme to reduce the volume and strengths of
effluents;
3. Incorporate in-process conditioning and treatment, where appropriate;
4. Determine and install segregation facilities to tailor treatment options;
5. Optimise performance of ETP

53 | P a g e
 Practises inASHAPURA MINECHEM LTD.
Company has developed water management plans to minimize the potential for water
contamination, and to prevent the release of polluted water into the environment.
Surrounding surface and groundwater quality is monitored, and a number of treatment
processes can be used to ensure mine water meets regulatory standards prior to being
discharged.
Environmentally responsible practices, especially relating to water, have become central to
the viability and acceptance of a modern mining operation.
Water is carefully managed to prevent the release of contaminated water into the
environment.
Various control techniques are used to reduce the potential for water contamination and
minimize the volume of water requiring treatment. These techniques include:
 Intercepting and diverting surface water (rain and snowmelt runoff, streams,
and creeks) from entering the mine site by building upstream dams to reduce the
potential for water contamination from exposed ore and waste rock
 Recycling water used for processing ore in
order to reduce the volume of water requiring
treatment
 Capturing drainage water from precipitation at
the mine site through the use of liners and pipes
and directing the water to tailings dams in
order to prevent potentially contaminated
water from entering groundwater or flowing
off site
 Allowing the water to evaporate in ponds to reduce the volume of contaminated
water; in dry regions, enough water may be evaporated that no water needs to be
discharged, resulting in the containment of contaminates at the mine site
 Installing liners and covers on waste rock and ore piles to reduce the potential
for contact with precipitation and contamination of groundwater

54 | P a g e
CHAPTER: 4
FINDINGS, RECOMMENDATIONS-
SUGGESTIONS
&
CONCLUSIONS

55 | P a g e
4.1 FINDINGS
 Company has not maintained separate warehouses for storing of the raw
materials and finished products.
 Company has well equipped security system.
 Company has been importing raw materials even if it is available in our
country only because it aims to achieve higher quality of the products.
 Company has been taking care of the safety measures for its employees.
 Company has appointed most of the higher level personnel from non-Gujarat
regions.
 Company’s employees are very co-coordinative.
 Company has been exporting its high quality semi-finished goods across the globe in
countries like Nepal, Bangladesh, Nigeria etc.
 Company is able to comply with all its environmental constraints.
 Company produces its new products and markets it according to the demand in
market.
 Ventilation system is not good in the production units.
 Company has maintained its own fuel pump at its premise for its lorries and trucks.

56 | P a g e
4.2 RECOMMENDATIONS & SUGGESTIONS
 The company should improve its ventilation system, because one feels great
suffocation if he remains in there for few hours.
 The company should maintain separate warehouses for its products, because even a
small hazard in the production unit will affect raw materials as well
 Skilled and Qualified people are available in Kachchh as well. The company unit
should also appoint high level personnel from local region as well.
 They should try to reduce its cost of production as it has been importing raw
materials from foreign countries.
 Company should also see to it that all its employees are complying with the safety
measures.
 Company should keep producing or processing the raw materials so that its cost of
production decreases as it produces goods on large scale.
 Company should somewhat mechanize its GCC unit as after the milling of the GCC
takes place and is stored in Syllo, it requires manual work to transfer milled GCC
for its pacakaging.
CONCLUSION

57 | P a g e
By doing an extensive research over all the aspects I came to the conclusion that subject to
the mentioned conditions and circumstances the report is definitely economically and
socially viable.
I would finally like to conclude my report with a high feeling of having gained enormous
knowledge about ASHAPURA MINECHEM LTD. This includes thanks-giving not only
for the valued co-operation of Ashapura Minechem Ltd., but also my lecturers who gave me
such a wonderful opportunity to learn so much about the practicality of life. I could say
correctly for our professors that, “You inspire it; we develop and stand by it”.
Through this project, I have learnt how to deal with people in all circumstances and how to
maintain contacts. The important part was extracting as much information as possible, which
helped me to improve my potentials.
The theoretical studies conducted at the college as well as the fieldwork that I have learnt will
definitely help me in enhancing my academic career and come up as an efficient manager.

58 | P a g e
6. BIBLOGRAPHY
 The sources of information and data are:-
 Personally collected information and asked questions.
 BOOKS
 Bentonite Book [ A magazine that gives detail information about
the core products of Ashapura group]
 Akanksha Book [ A magazine that binds Ashapura company’s
all level of employees]
 WEBSITES
 www.ashapura.com
 www.moneycontrol.com
 www.wikipedia.com

59 | P a g e
7.APPENDIX
 Pro :Production
 Dpt: Deputy
 Asst: Assistant
 Mgt:Management
 LMV- Light MotorVehicle
 HMV- High MotorVehicle
 Exe- Executive
 GCC-Ground Calcium Carbonate
 ORC-Oil Refine Clay
 Oil Refine Clay = Bleaching Earth = Fuller’s Earth

Ashapura Minechem

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