What is a calcium hypochlorite project report?
A calcium hypochlorite project report is a detailed project report (DPR) for a plant that chlorinates lime and caustic soda to make granular calcium hypochlorite with 65–70% available chlorine. It sets out the process, chlorine safety systems, machinery, raw materials, project cost, means of finance, five-year projections, DSCR and break-even.
Promoters use it to size the plant and raise a term loan; lenders and chlorine suppliers use it to judge whether the unit is viable and safe.
Also known as: calcium hypochlorite business plan, cal hypo plant feasibility report, DPR for calcium hypochlorite manufacturing, HTH chlorine granules project report.
Calcium hypochlorite plant cost in India: sample economics
Our sample report models a plant making 3.7 metric tonnes per day (MT per day) of granular calcium hypochlorite, or 1,221 MT per year over 330 working days. It starts at 60% of capacity, reaches 80% in Year 5 and sells at ₹98,400 per MT, ex-GST.
Plant and machinery is just over half of the project cost. That is typical for this product: chlorine handling, cooled reactors, a centrifuge and a dryer cost far more than the simple chambers of a bleaching powder unit.
| Land and site development | 43.48 |
|---|---|
| Building and civil works | 114.55 |
| Plant and machinery | 292.21 |
| Other fixed assets | 42.87 |
| Contingencies | 20.34 |
| Preliminary and pre-operative | 12.84 |
| Working capital margin | 26.88 |
| Total | 553.17 |
| Promoter's contribution (25%) | 138.29 |
|---|---|
| Term loan from bank (75%) | 414.88 |
| Cash credit limit (separate) | 80.63 |
| Total project cost | 553.17 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments; lowest yearly DSCR 1.61. All figures are illustrative.
Calcium hypochlorite manufacturing process
The sample plant uses the sodium process, which gives the granular 65–70% grade sold for water and pool treatment. The whole line runs wet until the dryer, and temperature control decides the yield.
- Slurry make-up
High-purity hydrated lime is mixed with water and caustic soda lye, then screened so grit and unburnt lime do not reach the reactors.
- Chlorination
Chlorine from the tonner evaporator is fed into jacketed reactors cooled by chilled water; a warm batch turns hypochlorite into useless chlorate.
- Crystal growth
The reacted mass is held and thickened so the calcium hypochlorite dihydrate crystals grow large enough to filter and wash cleanly.
- Centrifuging
A basket centrifuge spins off the salt-rich mother liquor; the liquor is dechlorinated before it goes to effluent treatment.
- Drying
The wet cake is dried with controlled hot air to 65–70% available chlorine; overheating here burns off strength that cannot be recovered.
- Granulation and sieving
Dry powder is compacted, crushed and sieved to a low-dust granule size that dissolves evenly in water.
- Scrubbing and packing
All vents pass through a caustic scrubber, and granules are packed in sealed plastic drums kept cool, dry and away from organic material.
Which process route should a calcium hypochlorite plant use?
Three routes make chlorine products from lime, and they lead to very different plants. Decide the grade you will sell before you size the machinery.
| Sodium process | Lime slurry and caustic soda are chlorinated together, and the by-product salt leaves with the mother liquor. It gives the high-strength granular grade and is the route modelled in our sample report. |
|---|---|
| Calcium process | Chlorine reacts with lime alone. It saves caustic soda, but calcium chloride stays with the product, which then picks up moisture and loses strength faster in storage. |
| Bleaching powder route | Dry slaked lime is chlorinated in chambers. The plant is cheaper and simpler, but the product is bleaching powder, a weaker and different product with its own market and price. |
Grade decides the plant: the sodium process needs a steady caustic soda supply and an effluent plant for salt-rich liquor. If you cannot secure both, a granular calcium hypochlorite plant is the wrong project for that site.
Raw materials for calcium hypochlorite production
Caustic soda and chlorine together make up 76% of raw material cost in our sample, and both come from chlor-alkali plants. Raw materials take 41.3% of sales in Year 3, so a long-term supply contract matters more than the price on any single day.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Caustic soda lye | 52% | 180.55 |
| Liquid chlorine | 24% | 83.33 |
| High-purity hydrated lime | 17% | 59.03 |
| Process chemicals and stabilisers | 7% | 24.30 |
| Total | 100% | 347.21 |
Lime must be low in iron and other heavy metals, which speed up the breakdown of hypochlorite in storage.
Machinery for a calcium hypochlorite plant
The chlorination reactors and the dryer are the two largest items in our sample at ₹58.44 lakh each. Wetted parts that touch chlorine and hypochlorite need corrosion-resistant linings or alloys, which is why this plant costs more per tonne than most inorganic chemical units.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Chlorine tonner handling and evaporator | Turns liquid chlorine into a metered gas feed | 23.38 |
| Lime slurry and caustic tanks | Prepare and screen the reactor feed | 20.45 |
| Jacketed chlorination reactors | Cooled reaction of chlorine with the slurry | 58.44 |
| Crystalliser and thickener | Grows filterable crystals | 23.38 |
| Basket centrifuge and filter press | Separate wet cake from mother liquor | 35.07 |
| Flash dryer and granulator | Dry to strength and form granules | 58.44 |
| Chilled water and refrigeration plant | Keeps reactors cool | 23.38 |
| Caustic scrubber and effluent treatment | Captures vent chlorine, treats liquor | 32.14 |
| Drum filling and sealing machine | Packs granules in sealed drums | 17.53 |
| Total plant and machinery | 292.21 | |
Costs are the sample report's estimates for a 3.7 MT per day plant. Get current quotations before you finalise.
Utilities, effluent and manpower
Calcium hypochlorite runs on cooling first and heat second. Both loads, and the effluent they leave, belong in the project cost from the start.
| Power and fuel | ₹74.05 lakh in Year 3 in our sample, or 8.8% of sales, mainly for refrigeration, the centrifuge and dryer heating |
|---|---|
| Chilled water | Continuous supply to the reactor jackets; a refrigeration failure means stopping the chlorine feed |
| Hot air for drying | A fuel-fired or electric air heater with close temperature control at the dryer inlet |
| Effluent | Salt-rich mother liquor and scrubber bleed, dechlorinated before treatment and discharge |
| Power backup | Standby power for the scrubber fan and chlorine leak systems, so they keep running in an outage |
| Manpower | 26 people in our sample: 4 in management and supervision, 9 skilled operators and 13 semi-skilled and unskilled workers |
Licences and safety approvals for a calcium hypochlorite plant
Chlorine storage drives most of the approvals. Lenders usually ask for these approvals, or proof of application, during appraisal.
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board; state lists that follow CPCB criteria place "chlorine, fluorine, bromine, iodine and their compounds" in the red category |
| Chlorine tonner storage | A licence from PESO under the Gas Cylinders Rules, 2016 to possess filled chlorine containers |
| Hazardous chemical rules | Storing 10 tonnes or more of chlorine brings in duties under the MSIHC Rules, 1989; at 25 tonnes or more, further duties apply, including a safety report and on-site emergency plan |
| Product transport | Shipped as a Class 5.1 oxidiser under UN 1748 or UN 2880, in approved packaging with hazard labels |
| Factory and fire | Factory licence and fire NOC, with oxidiser storage kept apart from fuels and organic material |
| Customs classification | HS subheading 2828 10, calcium hypochlorites, for import and export documents |
Checked October 2026. Rules and categories differ by state; confirm with the board and PESO before you apply.
Who buys calcium hypochlorite in India?
Buyers choose calcium hypochlorite when they need chlorine in a solid that travels well. Rural piped water schemes, swimming pools and flood relief all fall in this group, because liquid sodium hypochlorite is bulky to move and loses strength within weeks.
Water board tenders bring volume, while pool and institutional buyers usually take smaller, sealed packs. Granular product also competes with imported material, so a domestic plant has to win on delivery time, freight and pack sizes.
- Municipal water boards and public health engineering departments
- Swimming pool operators and pool chemical distributors
- Water treatment chemical traders
- Dairies, food and beverage plants
- Hospitals and institutional sanitation contractors
- Disaster relief agencies and NGOs
Strength is the product: buyers pay for available chlorine, and relief agencies typically specify a minimum at packing. A plant that holds 65–70% through storage and transport keeps its customers.
Mistakes that weaken a calcium hypochlorite project report
- Pricing it like bleaching powder
Granular calcium hypochlorite and bleaching powder sell at very different prices. Mixing up grades makes revenue, DSCR and the machinery list all wrong.
- Ignoring strength loss
Heat and moisture reduce available chlorine in the dryer, the store and the truck. Sales should be based on saleable strength, not on what leaves the reactor.
- Leaving out the effluent cost
The sodium process produces salt-rich liquor that must be dechlorinated and treated. Without a costed treatment plan, pollution consent is hard to obtain.
- Assuming a fixed chlorine price
Chlorine and caustic soda prices move in opposite directions with chlor-alkali demand. The report should test both, and show the supply contract.
- Under-budgeting chlorine safety
Leak detectors, an emergency scrubber, tonner handling and standby power are core project costs, not extras. Missing them delays approvals and the loan.
How NPCS helps you plan a calcium hypochlorite plant
- Route and grade selectionMatch the process route and product grade to your market and to the chlorine and caustic soda you can secure.
- Plant and safety designSize the reactors, cooling, dryer and scrubber, and list chlorine safety equipment for your approvals.
- Bank-ready project reportProjections, DSCR, sensitivity to chlorine and caustic prices, and working capital in your lender's format.
- Approvals roadmapPollution consent, PESO storage licence and hazardous chemical rule duties for your state and storage size.
NPCS's client list shows 269 assignments in the specialty chemicals sector, prepared for entrepreneurs, banks and companies since 1994.
What's inside the calcium hypochlorite sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
19 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Calcium Hypochlorite project report: frequently asked questions
What is the cost of a calcium hypochlorite manufacturing plant in India?
Our illustrative sample report models a 3.7 MT per day plant at a total project cost of ₹553 lakh. That includes ₹292 lakh of plant and machinery, ₹158 lakh of land and buildings and a working capital margin. Cost rises with capacity, the drying and granulation system chosen and the chlorine safety equipment, so your report should price these for your own site.
How is calcium hypochlorite manufactured?
Granular product is usually made by the sodium process. A slurry of hydrated lime and caustic soda is chlorinated in cooled reactors. Calcium hypochlorite crystals are grown and separated in a centrifuge, and the wet cake is dried and granulated to 65–70% available chlorine. Vent gases pass through a caustic scrubber, and the salt-rich liquor is treated before discharge.
What raw materials are needed to make calcium hypochlorite?
The main inputs are liquid chlorine, caustic soda and high-purity hydrated lime, plus small amounts of process chemicals. In our sample report caustic soda lye is the largest item at 52% of raw material cost, followed by chlorine at 24% and lime at 17%. Buying chlorine and caustic soda from a nearby chlor-alkali plant cuts freight and risk.
Is calcium hypochlorite the same as bleaching powder?
No. Both are chlorine compounds made from lime, but bleaching powder is made by chlorinating dry slaked lime and has far less available chlorine. Granular calcium hypochlorite is a purer, stronger product, often sold as HTH or pool chlorine at 65–70% available chlorine. The plants, costs and selling prices are different, so each needs its own project report.
Is calcium hypochlorite manufacturing profitable?
In our illustrative sample, a 3.7 MT per day plant earns a 22% return on investment in Year 3. It breaks even at about 37% of capacity and pays back in about 3.5 years. Real profit depends on your chlorine and caustic soda prices, drying losses, power cost and how much of the product holds its strength through storage and transport.
Which licences does a calcium hypochlorite plant need?
Beyond Udyam, GST, a factory licence and fire clearance, the plant needs consent from the State Pollution Control Board, usually under the red category for chlorine compounds. Storing chlorine tonners needs a PESO licence under the Gas Cylinders Rules, 2016, and larger chlorine stocks bring in the hazardous chemical rules. The product ships as a Class 5.1 oxidiser.
Is the sample project report PDF free, and can I use it for a bank loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, location and chlorine supply.
Sources and references
- Calcium hypochlorite supply chain profile (EPA 817-F-22-017)United States Environmental Protection Agency, checked Oct 2026
- Calcium hypochlorite 68% product specification (S0000588)UNICEF Supply Division, checked Oct 2026
- Frequently asked questions on the Gas Cylinders Rules, 2016Petroleum and Explosives Safety Organisation, checked Oct 2026
- Manufacture, Storage and Import of Hazardous Chemical Rules, 1989: Schedule 2Wildlife Institute of India (Ministry of Environment, Forest and Climate Change), checked Oct 2026
- Categorisation of industrial sectors under Red as per CPCB criteriaState Pollution Control Board, Odisha, checked Oct 2026
- Commodity code 282810: calcium hypochloritesHM Revenue and Customs (uktradeinfo), checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.