Organisational Study at Travancore Titanium Products Limited, Trivandrum.

By

•TiO2

Titanium Dioxide is

• A chemical compound consisting of Titanium and Oxygen.

• Used for a large number of industrial purposes.

• Whitest of white pigments used in industrial purposes.

• Mainly two grades-Rutile Grade and Anatase Grade.

Uses

• Used in white and pastel shades of paints.• Rubber industry.• Glazed paper • Plastics ,Printed fabrics, Soaps and face

powders• Flooring materials like white mosaics.

• Pharmaceutical and cosmetic products

• Electronic components

• Materials for interior decoration

• Foot-wear and leather goods

• Dyes and printing inks

Industry Profile

• World’s total installed capacity for Titanium Dioxide production is of the order of 4.22 to 4.38 million tones per annum.

• Titanium Dioxide enjoys a large market by any measure Historically the market has grown in volume at 3.5% annually to reach close to $8 billion in production value today. In the last decade the demand h as slowed down to 3% and it is expected in the next decade growth will be in the range of 2.5-3.5

• The top five producers of world now control 78% of the global capacity. They are

• DuPont (USA), • Millenium Inorganic chemicals (Australia), • Kert Megee (Canada), • Huntsmwn (Tioxide) & Kronos (Germany) • ISK (Japan).

• Kemera, sachtlaleen and crystal come in the second tie. Cinkara, Precheza, Zachem, Prolice, Hankook (South Korea), Sakai and Tyka (Japan). Kerala Minerals & Metals Ltd (India) and two other Ukranianian producers come next.

• KMML is the only unit producing Rutile grade Titanium Dioxide pigment in India with an installed capacity of 30,000 tonnes per annum.

Company Profile

• Travancore Titanium Products Limited (TTPL) was incorporated on 18th December, 1946, in collaboration with British Titan Products Limited, UK, for the manufacture of Anatase grade Titanium Dioxide pigment through the ‘sulfate route’

• The installed capacity of the plant was 1800 tonnes per annum

(i.e.5 tonnes per day) • Though commercial operations started in 1950, the full swing

production could be maintained from 1.1.1954 consequent on the Central Government granting tariff protection and also after availing a loan of Rs.15 lakhs from IFCI.

• The management of the company was vested with a Managing Agency, viz, Indian Titan Products Company Pvt. Limited, as per a management Agency Agreement dated 3.3.1947 on a remuneration of 10% of net profits(This arrangement continued till 15.08.1960 when the management was taken over by the state government)

• The company started its first expansion program in 1957 for doubling the annual production capacity from 1800 to 3600 tonnes (5 to 10 tonnes per day – 1800 tonnes Rutile and 1800 tonnes Anatase)

• A R&D wing was set up in the company in 1961.• Industrial license for 50 tonnes per day expansion was obtained in

July 1961. It was proposed to produce rutile grade and Anatase grade side by side.

• Next grade expansion from 18 to 8 tonnes per day was completed in October 1963. However the rutile production was temporarily discontinued in 1963.

• Government approved the expansion programme for producing 50 tonnes per day in 1967.

• The sole selling agency agreement with M/s TTK & Co. which has been in existence since 1954, was terminated on 30.6.1970 from which date TTP took over the sales directly.

• The next expansion programme to 24,500 tonnes per annum, including plant and equipment for the production of coated rutile grades, was completed in 1973

• As the capacity utilization was very low, a committee appointed subsequently by the government viz, Dr. Vazir Committee, assessed the achievable capacity of the plant as 1,25, 000 tonnes per annum of Anatase grade pigment.

• The Resource Mobilization Policy Committee set up in 1974 by the State Planning Board recommended for formation of a Sole Selling Agency for the sale of products of government companies. Accordingly, the Kerala State Industrial Products Trading Corporation (KSIPTC) was formed in the year 1976.

• KSIPTC was appointed as the sole agents with effect from 1st March 1979.

• Conversion of Sulphuric acid plant into DCDA technology by FEDO on a turnkey basis at a cost of RS. 193.69 lakhs, inaugurated on 13.9.1980.

• The DCDA project started in 1980 was commissioned in June 1984.

• Installation of 1000 KV generator in December in 1985.• During 1989 – 90 another 1000 KVA generator was installed and

a 66 KV substation commissioned.• Order for construction a new 300 tonnes per day sulphuric acid

plant with the latest emission control devices awarded to M/s DMCC on 21.10.1993 at a cost of Rs. 24, 42 crores. The plant was commission3ed in March 1996.

• A marketing department was set up in March 2003 and is presently carrying out the marketing function

• A project for carrying out Modernization and revamping is been carried out with an estimated cost of 257 crores

• Acid neutralization plant is under construction. It costs 497 crores.

Production Process

• Milling Illmenite an ore of Titanium is ground into ball mills of 40

microns• DigestionGround illuminate is reacted with concentrated sulfuric acid

in specially designed digestersFeO+H2SO4 FeSO4+H2O

Fe2O+3H2SO4 Fe2S(O4)3+3H2O

TiO2+3H2SO4 TiSO4+H2O

• DissolutionThe poruscake obtained as reaction product is dissolved in

water• ReductionThe Ferric iron present in the solution is reduced to ferrous

iron using scrap iron.Fe+H2SO4 FeSO4+2(H)

Fe2 (SO4)3+2H 2FeSO4+SO2

Fe+Fe2 (SO4) 3FeSO4

• Clarification The reduced liquor is clarified in settling tanks using

coolants• Concentration The clarification liquor free from suspended impurities is

evaporated in concentrator’s make of copper.• Precipitation The concentrated liquor is hydrolyzed by injection of steam

on boiling Titanium get precipitated as hydrated TitaniaTiOSO4+2H2O TiO (OH)2+H2SO4

• 8 FiltrationPrecipitated liquor filtered over rotary vacuum filters.

At this stage solid liquid separation takes place.• Calcinations The treated pulp is dewatered and fed to oil fixed

rotory kilns. The moisture gets removed first and then the occluded Sulphuric acid is decomposed .the crystalline properties gets developed at 8000c

TiO2+NH2O TiO2+NH2O

• MillingThe caluner discharge is cooled and pulverized in

pendulum mills to fine particles of average size .30 microns.

Product Profile• Anatase – ISI Grade• Anatase – GP Grade • Anatase – GR Grade• Anatase – RG Grade• Rutile – RD – 01 Grade

• Potassium Titanate• Sodium Titanate• Special grade• Butyl Titanate• Rayon Titanate• Granular Grade

Organisational Structure

• Board of Directors• Shri S.Sreenivaas (Chairman& Managing

Director)• Aswini Kumar Rai IAS ( Director)• Shri N.R Subramanian (Director)• Shri K. Gopakumar (Director)

• Managers 40• DY. Managers 85• Other Executives 255• Supporting staffs and Workers 570• Total 950

Departmentalisation

• Production Department • Finance Department• Personnel Department• Engineering Department• Project department• Research & Development Department• Security And Vigilance Department• Safety Department

• Medical Department• Material Department• Legal Department• Commercial Department• Training Department• Marketing Department• Data processing Department

• Functions

• To prepare detailed production plan• To prepare detailed raw materials plan and ensure the incoming quality

standards their project usage etc.• Constantly evaluating alternative sources of raw materials, direct trials of the

same and to help the management to firm up the sources.• Integrate , direct , and control efforts of production of Sulfuric Acid pigments

dispatch raw materials etc resulting in fulfillment of planned targets for production and provide overall supervision of Titanium Dioxide production

• Receiving of raw materials and packaging of final products.• Integrating the department itself with Research and Development

Department for identifying solutions to long term problems• Carry out investigations and guide management on long term measures

towards achievements of the goals of expansion in the areas of production and quality

• Integrate production efforts with maintenance to ensure implementation of production and maintenance schedules and to avoid break downs by helping maintenance under take jobs on time basis etc

• Functions• objectives of engineering department include:• Planning, arranging and initiating preventive maintenance programmers

and repair of equipments and installations in the factory including vehicles.

• Ensuring proper upkeep of estate maintenance• To advice the management to take decision on all engineering matters.• To arrange planning engineering equipments and stores materials

required for the factory• Preparation of plants• Preserve the working life of plant• To safeguard the investments• Maintaining safety and efficient working condition• To achieve minimum break downs• Inspection of jobs at successive stages of production.• Ensure normal productivity.• Ensure availability of machine building etc

Functions• Prevention and settlement of industrial dispute • Represent the company in the court of law• File cases against internal parties• To provide leadership for management of industrial relations

and employees welfare function of the company.• To provide basics for corporate strategies and polices for

maintenance of industrial peace and for work• For evolving system of prompt attention and redressal of

employees grievance and the prevention of the same.• Administration the different committees for employees

participation• Evolve and update practices for checking incoming and outgoing

of materials and persons.• Implementing the standing orders pertaining in the company

Functions• To collect all sums due to the company in time as per sales, orders

etc• To make timely payments to creditors, suppliers, contractors,

employees, Government statutory bodies, service providers etc• Timely dispersant of salary/wages/perks to employees as per

agreement, MOU etc• To assist all types of audit work.• To prepare MIS as required by the management

– To complete all Budget works.– To manage cash proper to maintain liquidity– To assist all departments in providing financial administration of all

transactions. – To make proper entries in books of accounts and extracts reports like Trial

balance, P&L A/c , Balance Sheet on a time bound basis– As TTPL is a PSU, the government of Kerala holds 80.94% of shares.

Functions

• That financial and legal interest of the organization related to purchase activities are safeguarded and timely supply is guaranteed.

• The quality of materials purchased should be tested and certified by a competent officer from the department/stores

• To develop good supplier relationship this will ensure the best terms of supply of materials.

• To serve as an information centre on the materials knowledge relating to price ,source of supply, mode of delivery etc

• To make continuous available of materials so that there may be uninterrupted flow of materials for production.

Functions

• To achieve maximum sales by maintaining maximum customer satisfaction.

• Price fixation, fixation of sales commission and over all sales policy including marketing budgets.

• Delivery and logistic management.• Maintaining customer relations.• Export management.• Monitoring and improving the working of

stockiest appointed all over India.

• Plant safety inspection - Detailed inspection of a particular part of a plant.

• Issues work permit for hazardous operations like digester reactions

• Periodic training programmers’ in accident prevention.• Inspections are conducted to identify the hazards.• On going inspection by the assistant safety manager.• Safety audit conducted once in two years.• Conducting investigations to identify route cause of

accidents.•

Functions

• Ensure the Safety & Security of all property• Safeguard the companies functions.• Assist the police department during disputes

and emergency situations.

• Plant Modification• Plant Expansion

Functions

• Full up or modify ordering level and the ordering quantity based on consumption pattern, sources, lead time and unit time.

• Originate purchase indent for items whose level is less than the ordering level.

• Forward the indent to commercial manager.• On receipt of the quotations make recommendations for

placing order. • In case of material that have stock nil but are of immediate

requirement arrange local purchase for the quantity required immediately, based on specific request from the head of department

Functions• Analyses the size of illmenite (3-5µ ) after the grinding• Testing new samples of raw materials by actual experimentation with

them in bunch scale preparations.• Render in process, stage wise testing and trouble shoot service acting

as a necessary adjunct to production.• Trying various surface coatings on rutile pigment including organic

coatings with a view to evolve suitable rutile treated grades comparable in performance to international grades.

• Developing titanium based products such as metallic titanates, special purpose titanium dioxide grades, organo titanium compounds etc.

• Maintaining pilot plant units to try and perfect large scale production of the above materials which have been developed in the laboratory on a bench scale and has found some acceptance in the market.

Types of Trainings Conducted

• Apprenticeship Training• Outside Programs• Inhouse Training• Induction Training• On the job and Off the job Training

SWOT ANALYSIS

• STRENGTHS• TTP Ltd is a public sector undertaking (PSU) under Government of Kerala• Brand name and reputation are excellent due to the quality products of

TiO2

• Large adaptive labour force.• Demand for the products exceeds supply• Demand based production. Different grades of Anatase pigments are

made for different customers• Products are delivered, as quickly as they are produced.• Storage time of final product is zero• ISO 9002 certification of TTPL• Low accident rates• Up to date training is offered to employees.

• WEAKNESS• Due to the liberalization policy made by the central

government, the sale has been decreasing.• The machines were commissioned in1973 and it is

quite old .so the cost of production is bit high.• There are more employees than need..• Storage capacity of the product is less.• Decision making is slower as it is a PSU• Office procedures are not fully computerized.

• OPPORTUNITIES• R& D department is engaged in producing products of

higher quality, so that the higher price can be charged.• By crating neutralization plant , by products like Ferrous

Sulphate is produced which have price• If modernization can be done, the products can be

produced in large quantities and the delegation of work can be done.

• Maximum exploitation of export.• Increasing demand for TiO2 globally

THREATS

• High production cost• Increase in sales tax by state government• Import of cheap TiO2from China and Malaysia

at lower price• Threat from local competitors like Kilburn,

Colmac and KMML.

• FINDINGS OF THE STUDY• The Travancore Titanium Products Limited is one

of the pioneering units engaged in the manufacturing of anatase grade titanium Dioxide.

• Only male workers are employed in the plant of Travancore Titanium Product Limited.

• The educational qualification of the employees in TTP Ltd is very high. About 40% of the workers employed in the company are graduates.

• The company is providing a well conceived transport system and most of the workers rate the conveyance facilities as good.

• There is a good follow up of the well defined rules and regulations.

• The employees express satisfaction over the functioning of the various departments.

• SUGGESTIONS• Installation of new plants and machineries• Introduction of Direct Marketing System.• Pollution Control.