Acknowledgement

“EXPRESSION OF GRATITUDE IS THE LEAST, ONECAN DO IN RESPONSE TO THE FAVOURS RECEIVED.”

This project is the result of the help of the various people who rendered

their support and suggestions from time to time. I take this opportunity

to thank all of them with a deep sense of gratitude and reverence.

First of all, I wish to express my sincere thanks to Mr. S.K.Verma,

Assistant Manager, Kajaria Ceramics Limited, Sikandrabad, Distt.

Bulandshahar for the caring and guiding support and for giving a very

patient hearing whenever I needed. They directly made a significant

contribution to emerge this project report.

I would like to thank my family and friends who directly or indirectly

helped me in completing the summer training successfully.

ABHISHEKGOEL

3

PREFACE

As a part of the academic curriculum, all the students have to

undergo summer training at thee end of the semester in any

industry to get first hand experience on what they have studied

throughout the course.

I got an opportunity to undergo summer training at Kajaria

Ceramics Ltd., Sikandrabad (Bulandshahr) from 1st June, 2012

to 15th July, 2012.

4

EXECUTIVE SUMMARY

The summer training is undertaken under the guidance of

Mr. S.K. Verma, Assistant Manager (P&A),

Kajaria Ceramics Limited, Sikandrabad,

Bulandshahar.

It provides a comparative study of KAJARIA CERAMICS

LIMITED with some national and international companies in

the similar field.

5

ABOUT THE COMPANY

Kajaria Ceramics Ltd., was incorporated

in 1985 and was promoted by Kajaria

Exports ltd., and its associates. The plant was set up for

manufacturing Ceramic Glazed floor and wall tiles in technical

collaboration with M/s Todagres of Spain and imported major

equipments from Sacmi Imola and Omis Due of Italy.

KAJARIA CERAMICS LIMITED (KAJARIA CERAMICS

LTD.) was promoted by Shri Ashok Kajaria, an

engineer from U C L A in US.

6

KAJARIA CERAMICS is one of India’s leading ceramic floor &

wall tiles manufacturer with an installed capacity of 36.00

mn.sqm. as on 31 st March, 2012. A 30-fold growth since the

commencement of commercial operations in 1988.

Head quartered in New Delhi, the company has two ISO

9001:2000 certified manufacturing facilities in Sikandrabad and

Gailpur, producing ceramic glazed and floor tiles and polished

vitrified tiles in over 800 designs.

Kajaria ceramics is the largest exporter of tiles from India with a

global foot print across 20 nations; the domestic market is catered

by a robust pan-india distribution network comprising a prudent

mix of own exclusive outlets, dealers and sub-dealers. As on 31 st

March, 2011, there are more than 700 dealers and sub-dealers.

Kajaria earned the coveted business superbrand status in 2004,

the only tile company in the Indian Ceramic tile industry to be

given this accreditation fourth time in a row.

7

The Company started commercial production in August 1988 at

an initial installed production capacity of 12,000 metric tones per

annum [TPA]. In August 1990 it commissioned an additional

14,000 TPA thereby raising installed production capacity to

26,000 TPA. The second phase of expansion was commissioned

in December1991, enhancing the installed production capacity

from 26,000 TPA to 40,000 TPA. The third phase of expansion in

August 1994 enhanced the installed production capacity to 60,000

TPA and the fourth phase of expansion increase the installed

capacity to 80,000 TPA at Sikandrabad plant in 1996.

The capacity of this plant was further raised to 150,000 TPA in

2005 by setting up Dry Process based Plant. The company has

established its second plant at Gailpur, Bhiwadi, Rajasthan with a

capacity of 70,000 TPA in the year 1998.

The company has also started manufacturing POLISHED

VITRIFIED TILES in Sikandrabad as well as in Gailpur, Bhiwadi

plant.

8

The total production capacity of manufacturing facilities of

KAJARIA CERAMICS LIMITED, are as follows:

UNIT PRODUCTS INSTALLED CAP.

Gailpur Ceramic Glazed Tiles 14.10 mn.sqm

Gailpur Polished Vitrified Tiles 6.00 mn.sqm.

Gailpur Glazed Vitrified Tiles 6.80 mn.sqm.

Sikandrabad Ceramic Glazed Tiles 3.20 mn.sqm.

Sikandrabad Polished Vitrified Tiles 5.00 mn.sqm.

The company manufacturers printed and special affect Tiles and

have a wide product range in terms of design, sizes and shades. It

has consistently pioneered and brought in the latest international

quality product in India. Exclusive and valid showroom in-

Kajaria plus, Kajaria tiles Shoppe, Kajaria Tile studio, Kajaria

tile galleria in all the important cities of the country offer a

panoramic view of the widest range, choices of the tiles, mix and

match to suit individual and family needs. The company has to

9

credit a strong market presence and dealer network. The market

base was systematically expanded by appointing many dealers all

over the country.

The company entered the export market in 1989-90 and on

a global front Kajaria has made significance advances and

established its first showroom in Melbourne, Australia.

Exports are being identified as a major thrust area.

The company export markets are the Gulf countries,

SARRC countries, Canada, European countries, etc.

KAJARIA CERAMICS LTD. is the first Tile Company having

received ISO 9002 Certification, which is symbolic for

maintaining the highest standard of quality in keeping with the

stringent international specification, it also takes pleasure in

announcing environment friendly ISO 14001 accredit ion.

10

It is the first Tile manufacturer to receive OHSAS 18991 in India

to receive OHSAS 18001 in fulfilling international standards in

occupational health and safety management system specification.

Kajaria has won the CAPEXIL Export Award for the highest

exports, for six consecutive years.

It has been the recipient of the Global Growth Company Award

by the world economic forum in December 1997.

Today Kajaria is the largest selling brand in India and the

largest exported brand from the country. Despite the fact

that the Kajaria Ceramics ltd. has the largest manufacturing

facility in the country.

The company has been consistently producing above 100%

of its rated capacity.

The Management of Kajaria Ceramics Ltd, since its inception has

always remained conscious about the environmental aspects of

the business and to materialize its objective the Management has

11

incorporated the latest technology available in the world. Several

other initiatives towards improving the environmental

performance have been taken. One of this is to establish unit as a

“zero liquid effluent plant”. The unit is the first tile plant in India

and among a very few ceramic Tile plant in the world to recycle

100% water which comes out as an effluent from the various

point during the manufacturing process. Another unique

initiative is adoption of Vermiculture Bio-technology for organic

waste.

As its most bold step, Kajaria introduced Kajaria World, the

biggest and most elegant imported tile showroom in the country.

Opened in Gurgaon over an area of 14,000 Sq. Ft., Kajaria World

is the last word in premium and high quality concepts for home

design.

The entire area at Kajaria World is divided into a vitrified tile

section, a ceramic floor tile section, bathroom concepts and mock 12

up flats where consumers can browse through and view thousands

of options and their applications.

The company's in-house team of designers has done a remarkable

job of creating an elegant and exclusive ambience.

On display consumers will fine, modern bathroom concepts with

over 100 alluring creative patterns and ideas. Mock-up flats

where they can walk through and find out how Kajaria tiles and

ideas suit kitchens, living rooms, dining halls, study rooms and

bedrooms. Imported porcelain tiles in various shades and marble

finish selected from leading tile manufacturers of the world,

ranging from 60x60 cm to large format 1x1 Mtr. Tiles.

Kajaria World also offers customers advise from trained experts

in the fields of architecture and interior design to help them make

the right choice for their dream home.

13

BOARD OF DIRECTORS

1. Shri A.K.Kajaria (Chairman & M.D)

2. Shri Chetan Kajaria (J M D)

3. Shri Rishi Kajaria (J M D)

4. Shri H. Rathnakar Shetty

5. Shri R.K. Bhargava

6. Shri R.R. Bagri

7. Shri D.P. Bagchi

8. Shri B.K. Sinha (Technical Director)

9. Shri R.C. Rawat (V.P. (F) & CO.SECY.)

14

KAJARIA MILESTONES

TWO MEMORABLE DECADES

1988 Production of ceramic tiles begins with single firing

technology.

1990 Expansion of capacity from 12,000 MT to 26,000 MT.

1991 Further increase in capacity to 40,000 MT.

1992 Kajaria wins the CAPEXIL Award for the highest

exports.

1994 Monoporosa Wall Tiles introduced for the first time.

1995 Capacity expanded to 80,000 MT.

1996 Rs.1 Billion turnover crossed.

1997 World Economic Forum honors Kajaria as one of the top

performing Global Growth Companies from India.

Kajaria captures 16% market share and reaches the No. 2 position

in the ceramics tiles industry.

15

1998 Capacity expanded to 150,000 MT equivalents to 33,000

Sq.m Per day, at par with the international players.

1999 Rs. 2 Billion turnover crossed.

2000-01 Fourth time winner of CAPEXIL Export Award.

2002-03 Starts advertisement in T.V.

2004- Kajaria has registered turnover of Rs.2390 million.

2005- Company has register red turnover of Rs.2698 million.

16

DEPARTMENT AT KAJARIA CERAMICS LTD.

17

KCL CERAMICS LTD.

CHAIRMAN

VICE CHAIRMAN

MANAGING DIRECTOR

OFFICEPLANT

INFOTECH MKTG P&A EXCISE &

SALES

SHARE MATERIAL DISPATCH

PURCHASE

STORE HRD

PERSONNEL

ADMINISTRATION

SECURITY

TRANSPORT

EXPORT

OEM

TRADE

PRESIDENT

PERFORMANCE OF KAJARIA CERAMICS LTD

Buoyed by the improved

business prospects and

growth in earnings, the

stock prices of companies

in the ceramic tile

industry have moved

up the past few months.

Industry heavy weight

Kajaria Ceramics is

no exception. Taking into

account the company's

strong position's in the industry, the commissioning of expanded

capacity and growth prospects, long-term investors may include

the stock in their portfolio.

Kajaria Ceramics is one of the bigger producers and exporters of

ceramic tiles.

18

After passing though a rough patch in the late-1990s, the company

and other ceramic tile producers benefited from the robust growth

in demand of recent years.

The softening interest rate regime and the pick-up in the real-estate

and construction sectors played a key role in bolstering demand for

ceramic tiles.

Apart from the retail segment, consisting primarily of residential

housing, the demand for tiles picked up from the institutional

segment as well.

Along with the factors listed above, the lowering of excise duty on

ceramic tiles also helped the company's cause. This has effectively

19

narrowed the price differential between ceramic tiles and the

traditionally popular mosaic tiles.

To cater to the growing demand, the company has expanded its

production capacity from time to time.

This has placed the company in the position to take advantage of

the growing demand for ceramic tiles Kajaria is also expanding its

geographic footprint and its retail presence by opening exclusive

outlets across the country. The trend of healthy growth in earnings

is evident in this fiscal as well.

The continued boom in the construction sector, housing industry in

particular, would spur demand for ceramic tiles. With expanded

capacity in place, the company would also have the option of

enhance its export earnings if there is surplus capacity.

Considering that the ceramic tile penetration is still low in India,

there is significant room for growth for the industry.

Kajaria and other tile majors such as Bell, Murudeshwar, SPL and

Orient may continue to see robust growth in demand.

20

GROWING GLOBAL PRESENCE

After successfully establishing its first showroom in

Melbourne, Australia through its subsidiary Kajaria (Aus)

Pty. Ltd. In February 2001, Kajaria has spread its wings

wider and has made significant advances in global retailing.

While the impressive Melbourne showroom stands

testimony to the strengths of Kajaria in global retailing, its

matter of great pride and accomplishment to Kajaria that

today its product are sold in Australia through over 50

dealers. This shows the heartening response and acceptance

the products have received in this sophisticated market,

where Kajaria is pitched against other world-class brands

and products.

Global retailing opens up new avenues for growth. Having

established a growing presence in a short span, Kajaria is

now playing more exciting showrooms in other cities of

Australia. The objective is to emerge as a strong force in

21

global retailing and a strong brand in the international

arena.

Company’s Performance In 2011-2012

Company’s crossed Rs. 10 billion in revenues during 2011-

12. The revenue grew 29% and bottomline registered a

growth of 69%.Return s on investment in the business

strengthened- ROCE grew 600 bps, ROE climbed 905 bps

and earnings per share increased form Rs.4.87 to Rs 8.24

per share during the same period.

The main factors for superior performance have been strengthening in average sales realization per sq.mtr. as company sold more large-format ceramic and vitrified tiles and value added tiles, gas supply for our Gailpur unit form may 2010, replacing high-cost propane, significantly reducing energy cost and reduction in interest liability by 20 per cent even as general interest rate climbed

22

INTERNATIONAL MARKETS: -

Kajaria Ceramics is the Largest Exporter of India

Kajaria ceramics exports to more than 20 countries round

the Globe. The International Marketing operations are

organized by a specialist export division that manages a

network of international agents and distributors supported

by our exclusive office/showroom in Australia. Now in

international markets we enjoy a similar brand Recall as

that of Domestic.

Our Brand “KAJARIA TILE” has today become synonym

of quality, service and innovation not only in the domestic

market but even in the international market. With increased

capacity, increase in turnover and a growing domestic

exports market, Kajaria Ceramics is set to emerge as a

leader in the international ceramic tiles market.

23

MISSION STATEMENT

To remain forefront in the Ceramic Tile Industry.

To remain the highest brand recall in the mind of discerning

customers for quality, designs and as a provider of new

concepts and ideas.

To reach into everyone’s dream home.

To follow the principles of transparency, high business

ethics, global quality standards and in creating new

intellectual assets.

Translating vision into reality

24

Kajaria Ceramics limited, the leading manufacturer and largest

exporter of latest technology single fired ceramic tiles in the country

and is touching new heights. Within 24 years of operations, it has

moved very close to its vision of becoming a leader world wide.

Kajaria Ceramics has grown at a breathtaking pace during the last

decade in turnover, profits and foreign exchange earnings.

ISO-14001And

OHSAS-18001

25

The Company is the largest exporter of ceramic tiles in the country

and has won 7 export awards since inception. The has also been

selected as one of the  top performing  Global Growth  Company

from India by World Economic Forum in 1997. Kajaria is the first

ceramic tile Company in India and may be 5th in the world

accredited with ISO 9002 certification for its quality system and

26

recipient of ISO 14001 for Environment Management System.

The company has also been given OHSAS 18001 Certificate by M/s.

TUV Suddeutschland, Germany. The Certificate has been given for

the commitment for the Company for fulfilling International

standards in  Occupational Health and Safety Management System –

Specification.

Kajaria Ceramics is the first ceramic tile company in the world to get

this certification . We at Kajaria always believe that safe working

methods lead to better business performance, motivated workforce

and higher productivity.

With ongoing training, R&D and human resource development, the

company continuously strives to bring International quality

consistently, surpassing itself and always reaching a peak higher.

Kajaria Ceramics has consistently pioneered and brought in the latest

in international quality products in India. The company launched the

high hardness and abrasion resistant Group-5 floor tiles for heavy

traffic are as for the first time in India. It was international quality

with single fired Monoporosa technology. With an attractive range of

borders, pencils and mouldings, Kajaria Ceramics manufactures the

widest range of floor and wall ceramic tiles to provide the complete 27

wall and floor solutions.

.

Pioneering initiatives

It gives me immense pleasure to inform that company

undertook pioneering initiatives which will only raise the

bar for the India tile industrtry

Received ISO 22000 for food safety Management

System, the first in the India tile sector to received this

accreditation

Established the solitaire range, comprising

technologically advanced large formate products (80 x

120 cms), providing Indian customers an alternative

natural Italian marble for the first time

28

Introduced the lappato range of glazed vitrified tiles with

a smooth, shiny and non-slippery surface, a first for the

Indian customer

Strengthening the consumer pull

In 2010-11, company undertook a number of initiatives to

translate stray consumer interest into a distinctive

consumer pull, contributing ti higher volumes.

Product development

Company launched digital wall tiles in two sizes i.e. 30

x 60 CM and15 x 45 CM in more than 45 designs

Company installed a unique designs software which

demonstrated to the costumer the concept and designs

as it would appear after the layout

Outreach initiatives

Company widened the dealer network and opened 50

new Kajaria Eternity studio’s with Shope in Shope

concept for select dealers in key cities, enhancing the

company’s brand visibility in glazed vitrified tiles

29

Company opened four new Kajaria World showrooms,

extending the company’s reach to Hyderabad, Chennai,

Coimbatore and Cochin

Business strengthening initiatives

New capacity: company commissioned the 6-MSM

brownfield

Exports Market:-

EXPORT PERFORMANCE

67.6113

163 167

429

620

458423

0

100

200

300

400

500

600

700

Series1

30

The export were lower this year due to increase in domestic

demand for company’s demand .

Kajaria Tile Brand is established not only in the domestic

market but also even in the international market, with

exports to quality conscious markets in Europe, Canada,

Arabian Gulf and SAARC countries. With increased

capacity, increase in turnover and an overgrowing domestic

and exports market, Kajaria Ceramics is to set to emerge as

a leader in international Ceramics Tiles Market.

31

“People don’t buy products, they buy what

products do for them.”

~John Wilhmurust

Kajaria Ceramics Ltd.’S Main Products:

KAJARIA CERAMICS LTD. manufacturers two types off tiles

i.e. CERAMIC GLAZED TILES and POLISHED VITRIFIED

TILES OR GLAZED VITRIFIED TILES.

DIFFERENCE BETWEEN “CERAMIC GLAZED TILES” &

“POLISHED VITRIFIED TILES”

A. CERAMIC GLAZED TILES

32

Ceramic glazed tiles are glazed and burned clay products

principally used for decorative and sanitary effects on the wall

and floor. It has 3-6% water absorption. These tiles have

decorative coat on the top of the tile body, hence their

composition is non consistent.

MANUFACTURING PROCESS OF CERAMIC GLAZED TAILS:

Weight of raw material batch

First of all the raw material are weighed according to the batch composition which depends on the type of body is intended to be product e.g. monoporosa, monocottura, bicottura or vitrified. The size of the batch generally corresponds to the capacity of the mill in which this body is going to be charged. Once the batch has been weight in the weighing hooper, the batch is conveyed through a set of belt conveyed to the ball mills where it will be to produce body slip.

33

Ball Milling

In this section, individual batch of about 12.5MT. consisting of Crude Clay [Local Field Clay], Bikaner Ball Clay , Feldspar Powder in the ratio of 70 : 15 : 15 parts by weight is weighed into a weighing cassiona and transported through conveyor belt to be loaded into individual ball mill. Here the mill additives like S.T.P.P. and Pilsperse are also added along with the required quantity of water. The individual ball mill is run for about 6.00hrs. where due to the attrition action between the Haridwar Pebbles the big particles of all the raw materials are ground to a very fine size and thus the body slip is discharged and stored in the respective stock tanks for ageing.

Now the body slip after sieving and demagnetisation is stored in the under ground tank which is known as final body slip ready for spray drying. The slip is pumped through a piston pump at a pressure of 25 + 5 bar into the spray drier chamber where the hot air is supplied from the top for drying of the slip. Thus the body dust containing around 6.0% moisture is transported through conveyor belts and bucket elevators and stored in the respective silos for ageing to make the moisture homogeneous.

SIEVING STRONGE AND ELECTRON-MAGNETTING The tile body is in slurry form when discharged form the mill. This slurry is first of all sieved through fine mesh (100 #/120 #) to separate coarse unground particles. The residue on this mesh is discarded and the sived slurry is passed through electro- magnet or high intensity rare earth permanent magnets to remove any free iron particles which manyhave been picked up during any

34

operation upstream. In this section, the powder prepared in the Body Preparation Section is pressed at around 6.0% moisture into tile shapes by the desired size of Dies with fully hydraulic multi-strokes and high capacity presses, Sacmi PH-980. After this the tiles are passed to the vertical drier where the hot air is supplied to remove the excess moisture and to make the tiles bone dry.

SPARY DRYINGThe tile body, in slip form and stored in agitators is in liquid state and needs to be converted into powder state which could by supplied to pressing into tiles. spray dryers are in the shape of vertical cylinders where hot air in injected form the top, and the liquid to be dried isinjected form the bottem with the help of high pressure pump. The bone dried tiles from the vertical drier are unloaded through transversal conveyor on the glazing lines for glaze application. The glaze solution prepared in the Laboratory (Glaze Preparation Section) by grinding the raw materials with water and other additives in glaze ball mills to a very fine mesh is brought in containers to the Glazing Lines Department for further application. The glazing lines are equipped with all the facilities of application like Engobe Application, Base Glaze Application, Printing Machines etc.

As per the production programme the tiles are glazed and / or decorated on the Glazing Lines and loaded into the individual car through B&T loading machines.

PRESS SECTIONIn this section, the powder prepared in the Body Preparation Section is pressed at around 6.0% moisture into tile shapes by the

35

desired size of Dies with fully hydraulic multi-strokes and high capacity presses, Sacmi PH-980. The presses are operated at a pressure of 190-220 bar and a cycle of 12-16 per minute. After this the tiles are passed to the vertical drier where the hot air is supplied to remove the excess moisture and to make the tiles bone dry.

GLAZING LINESThe bone dried tiles from the vertical drier are unloaded through transversal conveyor on the glazing lines for glaze application. The glaze solution prepared in the Laboratory (Glaze Preparation Section) by grinding the raw materials with water and other additives in glaze ball mills to a very fine mesh is brought in containers to the Glazing Lines Department for further application. The glazing lines are equipped with all the facilities of application like Engobe Application, Base Glaze Application, Printing Machines etc.

As per the production programme the tiles are glazed and / or decorated on the Glazing Lines and loaded into the individual car through B&T loading machines.

KILN SECTION [FIRING]

36

The green glazed loaded cars are automatically transported through

hydraulic pushers near the kiln feeding end. Here the tiles are

unloaded through B&T unloading machine and allowed to enter

into the kiln in a pre programmed manner. The tiles travel on the

ceramic rollers, which are driven by a drive system. The firing of

the tiles takes place by burning Natural Gas / LPG through Burners

into three stages like pre-heating, firing at peak and cooling as per

the pre-programmed cycle and the firing curve. The peak

temperature is about 11300C – 11500C depending on the cycle and

application of the tile. All the Sacmi Kilns have their own

individual very sophisticated system of precise temperature control

and the entire operation from feeding the kiln to the exit of the tile

takes place in less than an hour.

INSPECTION & SORTING QUALITY CONTROL

Strict quality control is exercised on all incoming raw

another matrials entering into the factory.

37

B. POLISHED VITRIFIED TILES

These tiles are a specialized kind, hard backed with low porosity

and water absorption (less than 0.5%) making it stain-resistant and

strong. These tiles have a homogeneous body and consistent in

composition.

MANUFACTURING PROCESS OF POLISHED

VITRIFIED TILES:

BODY PREPARATION

In this section, individual batch of about 12.5MT. consisting of Crude Clay [Local Field Clay], Bikaner Ball Clay , Feldspar Powder in the ratio of 70 : 15 : 15 parts by weight is weighed into a weighing cassiona and transported through conveyor belt to be loaded into individual ball mill. Here the mill additives like S.T.P.P. and Pilsperse are also added alongwith the required quantity of water. The individual ball mill is run for about 6.00hrs. where due to the attrition action between the Haridwar Pebbles the big particles of all the raw materials are ground to a very fine size and thus the body slip is discharged and stored in the respective stock tanks for ageing.

38

Now the body slip after sieving and demagnetisation is stored in the under ground tank which is known as final body slip ready for spray drying. The slip is pumped through a piston pump at a pressure of 25 + 5 bar into the spray drier chamber where the hot air is supplied from the top for drying of the slip. Thus the body dust containing around 6.0% moisture is transported through conveyor belts and bucket elevators and stored in the respective silos for ageing to make the moisture homogeneous.

PRESS SECTIONIn this section, the powder prepared in the Body Preparation Section is pressed at around 6.0% moisture into tile shapes by the desired size of Dies with fully hydraulic multi-strokes and high capacity presses, Sacmi PH-980. The presses are operated at a pressure of 190-220 bar and a cycle of 12-16 per minute. After this the tiles are passed to the vertical drier where the hot air is supplied to remove the excess moisture and to make the tiles bone dry.

GLAZING LINESThe bone dried tiles from the vertical drier are unloaded through transversal conveyor on the glazing lines for glaze application. The glaze solution prepared in the Laboratory (Glaze Preparation Section) by grinding the raw materials with water and other additives in glaze ball mills to a very fine mesh is brought in containers to the Glazing Lines Department for further application. The glazing lines are equipped with all the facilities of application like Engobe Application, Base Glaze Application, Printing Machines etc.

39

As per the production programme the tiles are glazed and / or decorated on the Glazing Lines and loaded into the individual car through B&T loading machines.

KILN SECTION [FIRING]The green glazed loaded cars are automatically transported through hydraulic pushers near the kiln feeding end. Here the tiles are unloaded through B&T unloading machine and allowed to enter into the kiln in a pre programmed manner. The tiles travel on the ceramic rollers, which are driven by a drive system. The firing of the tiles takes place by burning Natural Gas / LPG through Burners into three stages like pre-heating, firing at peak and cooling as per the pre-programmed cycle and the firing curve. The peak temperature is about 11300C – 11500C depending on the cycle and application of the tile. All the Sacmi Kilns have their own individual very sophisticated system of precise temperature control and the entire operation from feeding the kiln to the exit of the tile takes place in less than an hour.

SORTING & PACKING SECTIONHere the finished products are selected and packed into the respective Qualities / Grades on the Sorting Lines, where the non conforming products with respect to surface fault, size variation, planarity etc. are removed automatically through Deco liners. The packed boxes are stacked on wooden pallets and handed over to Bonded Store Room for storage and dispatch.

40

PROCESS FLOW CHART PROCESS FLOW CHART –– WET PROCESSWET PROCESS

HO T A IR F R O MHO T A IRG E NE R A T O R

W A T E RV A P O UR

A ND W A S T EG A S E S

W E IG E DG LA Z EW A T E R

G LA Z E P R E -P A R A T IO ND E P T T

P R E P A R E DG LA Z ES O LUT IO N

P A C K IN G

S O R TIN G A N D C L A S S IF IC A TIO N O F TH E TIL E S

R O L L E R K IL N

K IL N F E E D IN G M A C H IN E

S TO R A G E C A R S

G L A Z IN G D E C O R A TIN G L IN E S

R A P ID D R Y IN G , V E R TIC A L D R IE R S TOR E M O V E TH E M O IS TU R E A N D M A K E TH E TIL E S B O N E D R Y

P R E S S IN G

P R E S S H O P P E R S V IA V IB R A TIN G S C R E E N S

P O W D E R S TO R A G E S IL O S

S P R A Y D R Y IN G O F TH E S L IPTO G E T TH E P O W D E R

S IE V IN G A N D D E M A G N E TIS IN G TH E S L IP & S TO R IN G IN S E P A R A TE TA N K S

R A W M A TE R IA L C H A R G IN G IN TO B A L L M IL L W ITH W A TE R A N D ITS W E T G R IN D IN G

R A W M A TE R IA L W E IG H IN G

41

MAIN RAW-MATERIALS USED FOR MANUFACTURING OF TILES:

1. Body Matrial2. Frits (Indigenous)3. Frits(Imported)4. Other Glaze (Imported)5. Packing Material

THREE – MAIN KIND OF TILES:-

1. Standard Tiles – Elite Class

2. Commercial Tiles – Upper Middle Class

3. Utility Tiles – Middle and Lower Middle Class

These tiles come under ranges of:-

1. Plain Colour Range –

E.g. Blanco Nieve, Crema, etc.

2. Classic –

42

E.g. Naveda Blanco, Kajaria Green etc.

3. Special Plain -

E.g. Burgundy, Oxford Blue, Terracotta etc.

4. Contractor -

E.g. Leonardo Beige, Limoni Grey, Luxor and Luna etc.

5. Printed –

E.g. Alicante Beige, Arena Grey, Antique Blanco, etc.

6. Special Printed –

E.g. Chimera Beige, Corona Grey, Galleria Brown, etc.

7. Premium Range –

E.g. Auto Grey, Alfar Blue, Archiva, Argilla, Atrium, etc.

These tiles come in various dimensions such as – 200mmx200mm, 300mmx300mm, 400mmx400mm. Thickness – 7mm, 7.80mm, 9mm, etc.

Through trend setting product innovation and design,

Kajaria keeps ahead of the times, fulfilling the

changing lifestyle needs of the consumer. Kajaria has

introduced captivating range of tiles in terms of design,

sizes and shades. Today consumers and the trade have

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come to except ultra modern and futuristic concepts in

design among the Kajaria collection.

FLOOR TILES

EMBED Word.Picture.8

Alicante Blue[300x300 mm]

EMBED Word.Picture.8

Alicante Beige[300x300 mm]

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Alicante Grey[300x300 mm]

Alicante Blanco[300x300 mm]

Alicante Verde[300x300 mm]

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Alicante Pink[300x300 mm]

AmphoraBeige[300x300 mm]

Amphora Brown[300x300 mm]

WALL TILES

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AngolaBeige

[300x200 mm]

Angola Grey[300x200 mm]

Ankara Beige[300x200 mm]

Ankara Blanco[300x200 mm]

Ankara Crema[300x200 mm]

Ankara Grey[300x200 mm]

Arabia Beige[300x200 mm]

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COMPANY POLICY OF KAJARIA CERAMICS

LTD.

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“Total customer satisfaction through quality management and continuous improvement”

We at KAJARIA CERAMICS LTD. are committed to

produce Tiles of World class quality.

Our Aim is to maximize the customer’s Satisfaction and this

is achieved through Quality product, continuous

improvement and motivated employees.

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BUSINESS PRINCIPLES

1.Organization, which is sensitive to the needs of the

Customers.

2.Continuous up gradation of Quality and Process to meet

changing needs of Customers.

3.Optimization of returns on Investment by.

Continuous Improvement.

Leadership Through Technology.

Organization and Personal Development.

Cost Reduction efforts.

Effective use of all resources.

Harmonious and Safe working conditions.

Following JIT theory in Practice.

4.Working to meet International Norms of Quality through

the best of available Equipment & to sustain the

Standard.

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COMPETITORS

These continuously threaten rather than contribute to the

survival of the business. They watch each other very

closely and follow one another prices up and down, they try

to capture either others market share and customer base to

increase their own profit margins.

The more competitors there are and the close their product

offering, the more sensitively sales respond to a relative

change in price.Non-price competition using branding and other

product

COMPETITORS OF KAJARIA CERAMICS LTD.

1.Johnson ( Oldest and biggest competitor )

2.Nitco Tiles in Mumbai

3.Somany

4.Orient

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5. Chinese Tiles Manufacturers (Due to cheap prices)

To face the challenge posed by the competitors we have to take

many measures such as regularly improve the product quality,

develop and use new technology to produce tiles according to the

new trends, appreciated by the people and to take our prices

comparable to our competitor’s prices.

CONCLUSION

“Work well begun is the work half done”

I am able to meet out my set objective laid down prior to the

study that is conducted at KAJARIA CERAMICS LTD..

In first phase: I had studied their prevailing system. In order

to assess its effectiveness I adopted three different

techniques viz: Observation, Interview, and Questionnaire.

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