PROPOSED DESIGN OF A 100 TON

DETERGENT POWDER
PLANT/FACTORY TO BE LOCATED AT
BRGY. CONCEPCION, BATS. CITY
COMPANY NAME: Bright Wash Manufacturing Inc. Co.

Company Profile

Bright wash is a manufacturing plant that is specialized on making detergent

powders. It is a sole proprietorship of the Perez Family. The company seek to build a
reputable brand known for quality detergent products.To deliver high-quality detergents
to the market that significantly exceed existing products of cost, efficiency,durability,

environmental safety and user friendly in order to protect public health and welfare.Our
company is passionate for its products as well as its people while it reflects our
philosophy of providing top quality detergent.

Organizational Chart

Company Owner

Plant Engineer

Supervisor

Quality Control Admin Officer

Security and Safety Inventory Staff

Officers

Warehouseman Operators/Factory Technicians

workers
 PRODUCTS: 130kg/container detergent powder

Raw Material

Raw Material Wt %
Supplier
linear alkylbenzene 19 Shandong Baovi Energy Technology Co.,
sulfonate Ltd.
Soda Ash (light) 30 Dewas (Madhya Pradesh, India), “Big Ideas
Global”
Zeolite 8 Gongyi City Meiqi Industry & Trade Co., Ltd.
Sodium Silicate 2 Guangzhou Billion Peak Chemical
Technology Co., Ltd.

Sodium Sulphate 5 Mary Wang Shandong Zhi Shang Chemical

Co., Ltd.
Sodium Chloride 7 Shanxi Linfen Dyeing Chemicals (Group)
Co., Ltd.
Dolomite 4 Vadodara, (Gujarat, India), “Annexe Chem
Private Limited”
Tinopal 0.8 Adinath Industries,
Madanganj, Ajmer, Rajasthan
Inorganic ingredients 4
Savinase 0.1 Merck KGaA, Darmstadt, Germany
perfume 0.5 Robin Chemicals Private Limited
Rabale, Navi Mumbai, Maharashtra
Anti foam powder 1 Dongguan Defeng Defoamer Co., Lt
Av-50granules (shading 1 Shanghai Orcheer Material Techno
powder)
SLES Granules 3 Shandong Zhi Shang Chemical Co
Container 770
Total Including other 100
minors
BASIS OF CAPACITY

Since he per capita detergent consumption in Philippines is around 3.7kg per year and
for the year 2018, the projected population of Batangas City based from CY 2015
POPCEN of the Philippine Statistics Authority (PSA) is 344,488 with a population
growth rate of 1.46%.

Therefore:
𝑝𝑜𝑝𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝐵𝑎𝑡𝑎𝑛𝑔𝑎𝑠 𝐶𝑖𝑡𝑦
plant capacity = 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑝𝑒𝑟𝑠𝑜𝑛 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟

𝟑𝟒𝟒,𝟒𝟖𝟖 𝒑𝒆𝒓𝒔𝒐𝒏
=𝟑.𝟕 𝒌𝒈/𝒑𝒆𝒓𝒔𝒐𝒏/𝒚𝒆𝒂𝒓

Plant capacity = 93,104.86486 kg per year

Plant capacity will be up to 100 Ton per year

Plant Layout/Location
INITIAL COST ESTIMATE

Land

It is needed to build our plant and buildings. The land is not lease, it is owned by the
company. This is situated at Concepcion,Batangas City having 400 sq. meters. The
land area will cost:

Estimated cost of land is Php 2518 per sq. meters

Therefore:

20 m x 20 =400 sq. meters x Php 2518 per sq. meters = Php1,007,200

1 Ribbon Blender 1
Php294,086/unit

2 Vibrating Screen 1 Php 208,000/unit

5 Weighing Scale 1 Php 6500/unit
7 Material Handling Equipment 14
Php
182,000/unit
8 Conveyor 1
Php 57,200/unit

9 Forklift 1
Php
442,000/unit
10 Generator 1
Supplies Quantity Price per Unit

Office Tables 2 Php6,000 Php12,000

Office Chairs 6 Php2,000 Php12,000

COMPUTER 2 Php10, 000 Php20,000

TELEPHONE 1 Php2, 000 Php2, 000

AIRCON 1 Php20, 000 Php20, 000

FIRE 2 Php1, 800 Php36,000

Indirect Materials Retail price
EXTINGUISHER
Laboratory equipments(SS Trays/Plastic 50,000
Trays/
MINI Enameled Trays,
TRUCK 1 Plastic Buckets,) Php80, 000 80,000
Waste disposal plastic bags 91/pc
TOTAL Php182,000
 ANNUAL COST ESTIMATE

Raw Material Wt % Retail price Supplier

linear 19 Php15.08 / Php286,520 Shandong Baovi Energy
alkylbenzene kg Technology Co., Ltd.
sulfonate
Soda Ash (light) 30 Php Php533,520 Dewas (Madhya Pradesh,
17.784/kg India), “Big Ideas Global”
Zeolite 8 Php Php1,816,000 Gongyi City Meiqi Industry
1,352/kg & Trade Co., Ltd.
Sodium Silicate 2 Php49.4/kg Php98,800 Guangzhou Billion
Peak Chemical Technology
Co., Ltd.

Sodium Sulphate 5 Php41.6/kg Php208,000 Mary Wang Shandong Zhi

Shang Chemical Co., Ltd.
Sodium Chloride 7 Php21.6/kg Php151,200 Shanxi Linfen Dyeing
Chemicals (Group) Co., Ltd.
Dolomite 4 Php1.44/kg Php5760 Vadodara, (Gujarat,
India), “Annexe Chem
Private Limited”
Tinopal 0.8 Php1,040/kg Php832,000 Adinath Industries,
Madanganj, Ajmer,
Rajasthan
Inorganic 4 Php1/kg Php4000
ingredients
Savinase 0.1 Php124.433 Php12443.36 Merck KGaA, Darmstadt,
6/ml Germany
perfume 0.5 Php720/kg Php360,000 Robin Chemicals Private
Limited
Rabale, Navi Mumbai,
Maharashtra
Anti foam powder 1 Php80.6/kg Php80,600 Dongguan Defeng
Defoamer Co., Lt
Av-50granules 1 Php Php414,360 Shanghai Orcheer Material
(shading powder) 414.36/kg Techno
SLES Granules 3 Php468/kg Php1,404,000 Shandong Zhi Shang
Chemical Co
Container 770 Php900/pc Php693,000 Elroinissitrading
pcs.
Total Including 100 Php6,900,203.36
other minors
Electricity
Communication Php11,988
Total
 WATER TANK

Average Water Consumption for using lavatory and flush 35 Gallons x 2 per Person per

Day

For 32 Employees : 2240 Gallons

For 7 Days : 15680 Gallons

Average Water Consumption for using shower 17.2 Gallons per Person per Day

For 32 Employees : 550.4 Gallons

For 7 Days : 3852.8 Gallons

Average Water Consumption for drinking .0977437 Gallons per Person per Day

For 32 Employees : 31.277984 Gallons

For 7 Days : 218.945888 Gallons

Assuming that the plant will consume 15 gallons per day for maintenance etc.

Total Water Consumption for 7 Days : 105 Gallons to Liters

Water Consumption for using lavatory and flush : 15680 Gallons

Water Consumption for using shower : 3852.8 Gallons

Water Consumption for drinking : 218.945888 Gallons

Water Consumption for maintenance. : 105 Gallons

19856.74589 Gallons

75165.9598839 Litres
 DIMENSIONS: 165" Diameter x 242" Height

Price:Php1,091947

TDH =27 m

Q= 4 hrs. x 20 000 gallons/hr = 80 000 gal/hr = 0.08412 𝒎𝟑 /s

WP = (0.08412 𝒎𝟑 /s)(9.81)( 27 m)

= 22.28 KW
𝟐𝟐.𝟐𝟖 𝐊𝐖
𝑷𝑴𝑶𝑻𝑶𝑹 = 𝟎.𝟖𝟓

= 18.938 kW

20 kW Submersible pump

Price: 39,260

https://www.alibaba.com/product-detail/submersible-water-
pump20kw_60374234866.html?spm=a2700.7724857.normalList.9.792a767
3uqQp2r
Ribbon Blender

Model NO. HT-WP200

Capacity 200set/Month

Layout Type Horizontal

Operating type Continuous Operating

Machine Type Automatic

Specification1370*834*1647mm

Total Weight 400kg

Power Supply 3 P 380V 50Hz

Total Power: 4kw

ZhengzhouHonest Machinery Co., Ltd.

Vibrating Screen

https://www.alibaba.com/showroom/detergent-
powder-vibrating-screen.html

Model NO. DZSF-1025-1s

Power 2*0.75

Dimensions 2203*1320*900

Production Capacity 999 Sets Per Month

Weighing Scale

Conveyor

Power(W):0.3kW - 2kW
https://www.alibaba.com/product-detail/Belt-conveyor-
price-small

conveyorbelt_60605772444.html?spm=a2700.7724857.norm
alList.113.50e035bdMnvJXG
Material Handling Equipment

Capacity:1000 Liter

https://www.indiamart.com/proddetail/chemical-storage-ibc-
container-20410406548.html

Forklift

Overall Dimensions:3380*1150*2000
Loading Capacity:500-3500kg
Max. Lifting Height:3995
Production Workflow

The production process is the following:

 Ordering the raw materials from the suppliers

 Receiving the raw materials from the suppliers
 Storing the raw materials in the warehouse if still not needed
 Prepare the raw materials needed for the production.
 first of all powder raw materials are screened in the required quantity and
mixed uniformly. After this, acid slurry with dye is slowly poured on the
mixture and mixed in a ribbon blender. The machine is run for about 15
minutes and then material is taken out, screened if required and packed
in plastic bag.

START

RAW MATERIALS
RECEIVE STORAGE

PREPARATION

SCREENING

MIXING

IF FAILED,
SCREENING
INSPECTION
& TESTING

PACKAGING

WAREHOUSING

WAREHOUSING