What is a di calcium phosphate project report?
A di calcium phosphate project report is a detailed project report (DPR) for a plant that dissolves rock phosphate in acid and precipitates feed grade DCP with lime. It sets out the process route, machinery, raw materials, effluent handling, BIS testing, project cost, means of finance, five-year projections, DSCR and break-even that a bank needs before it funds the plant.
Promoters use it to choose a route and capacity and to apply for a term loan; feed companies and lenders use it to judge whether the plant can hold its grade and repay.
Also known as: DCP plant project report, project report on di calcium phosphate, di calcium phosphate business plan, dicalcium phosphate manufacturing plant report, calcium hydrogen phosphate plant DPR.
DI calcium phosphate plant economics and project cost
Our sample report models a 27 metric tonnes per day (MT per day) feed grade DCP plant on the hydrochloric acid route, running 330 days a year. It starts at 60% of capacity and reaches 80% in Year 5, selling at ₹41,000 per MT before GST.
| Land and site development | 110.06 |
|---|---|
| Building and civil works | 361.42 |
| Plant and machinery | 690.92 |
| Other fixed assets | 79.39 |
| Contingencies | 52.62 |
| Preliminary and pre-operative | 32.36 |
| Working capital margin | 84.34 |
| Total | 1,411.11 |
| Promoter's contribution (25%) | 352.78 |
|---|---|
| Term loan from bank (75%) | 1,058.33 |
| Cash credit limit (separate) | 253.02 |
| Total project cost | 1,411.11 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. DSCR is lowest in Year 2, at 1.48, when full instalments begin. All figures are illustrative.
Dicalcium phosphate manufacturing process
Many Indian feed grade units dissolve rock phosphate in hydrochloric acid and precipitate DCP with lime. The quality of the product is decided mainly at two points: how well fluorine is removed, and how tightly pH is held during precipitation.
- Grinding
Rock phosphate is ground in a ball mill so the acid reaches every particle; coarse rock leaves phosphate undissolved in the sludge.
- Acid digestion
The powder reacts with dilute hydrochloric acid in rubber-lined reactors, giving a phosphate liquor rich in calcium chloride.
- Defluorination
The liquor is part-neutralised so fluorine and insoluble matter drop out, and the sludge is filtered off before the product stage.
- Precipitation
Lime slurry is added slowly under pH control, and dicalcium phosphate settles out as a white solid.
- Filtration and washing
Filter presses or centrifuges separate the wet cake and wash out calcium chloride, which would otherwise raise chloride in the feed.
- Drying and milling
A flash dryer removes moisture at a controlled temperature, then a pulveriser and vibro sieve bring the powder to feed fineness.
- Testing and packing
Every lot is checked for phosphorus, calcium, fluorine and moisture and packed in 50 kg HDPE bags.
Hydrochloric acid route or phosphoric acid route?
The route decides your raw material contracts, your effluent plant and much of the project cost. Settle it before you ask for machinery quotations.
| Point to compare | Rock phosphate and HCl | Phosphoric acid and lime |
|---|---|---|
| Main inputs | Rock phosphate, hydrochloric acid, lime | Purified phosphoric acid, lime or limestone |
| Process steps | Grinding, digestion, defluorination, precipitation | Neutralisation and precipitation only |
| Effluent | Large volume of calcium chloride liquor to treat or recover | Little liquid effluent |
| Plant cost | Higher: grinding, acid-proof reactors, ETP | Lower and simpler |
| Running cost | Lower if acid comes cheaply from a nearby chlor-alkali plant | Higher, because phosphoric acid is costly |
| Best fit | 25 MT per day and above, near an acid source | Smaller units and higher grades |
Acid decides the site: hydrochloric acid is bulky and corrosive to transport, so HCl-route plants are usually set up within easy reach of a chlor-alkali or other by-product acid source.
Raw materials for DCP: rock phosphate, acid and lime
Raw materials take 52.4% of sales in our sample report, and rock phosphate is the biggest item. Rock comes from Indian mines and from imports, and its phosphate and fluorine content changes from lot to lot, so each lot is assayed before it is used.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Rock phosphate | 45% | 603.41 |
| Hydrochloric acid | 30% | 402.27 |
| Hydrated lime and limestone powder | 20% | 268.18 |
| Defluorinating agent and flocculant | 5% | 67.04 |
| Total | 100% | 1,340.90 |
Packing in 50 kg HDPE bags is a further 4.3% of sales in the sample.
Machinery for a di calcium phosphate plant
Everything that touches acid liquor is rubber-lined, FRP or polypropylene. The digestion reactors are the largest single machinery cost in our sample.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Ball mill with classifier | Grinds rock phosphate | 82.91 |
| Rubber-lined digestion reactors | Dissolve rock in acid | 124.37 |
| Defluorination and precipitation reactors | Remove fluorine, form DCP | 110.55 |
| Filter presses and centrifuges | Separate and wash the cake | 96.73 |
| Flash dryer with hot air generator | Dries the wet cake | 96.73 |
| Pulveriser and vibro sieve | Brings powder to fineness | 41.45 |
| Acid storage tanks and scrubber | Store acid, capture fumes | 62.18 |
| ETP and calcium chloride recovery | Treats the chloride liquor | 48.36 |
| Bag filling and stitching | Packs 50 kg bags | 27.64 |
| Total plant and machinery | 690.92 | |
Sample estimates for a 27 MT per day line. Get current quotations before you finalise.
Utilities, staff and the testing lab a DCP plant needs
A DCP plant tests every lot, so the quality lab is part of the plant, not an extra. The BIS product manual for IS 5470 lists the tests a licensed maker must run in-house.
| Power and fuel | Ball mill, agitators, centrifuges and the dryer's hot air generator; 5.7% of sales in our sample, ₹146.27 lakh in Year 3 |
|---|---|
| Water | Process water for acid dilution, lime slurry and cake washing, plus cooling and domestic use |
| Manpower | 66 people in our sample, including operators for reactors, filters and dryer; ₹149.04 lakh in Year 1 |
| Lab tests per lot | Moisture, calcium, phosphorus, fluorine, acid insoluble ash, total ash, lead, arsenic and fineness |
| Lab equipment | UV spectrophotometer for phosphorus, fluoride ion-selective electrode, muffle furnace, vacuum oven, 200-micron test sieve |
| Outsourced tests | Checks for adulterants and harmful bacterial spores, once a month, may be sent to an outside lab |
Licences, BIS certification and GST for a DCP plant
| BIS certification | Dicalcium phosphate, animal feed grade, must meet IS 5470 and carry the BIS mark; BIS lists the enforcement date as 1 April 2027 |
|---|---|
| Pollution category | Phosphorus compounds and phosphate rock processing are Red category under CPCB criteria, so consent to establish and operate comes with strict effluent and emission conditions |
| GST | Feed grade DCP conforming to IS 5470:2002 is exempt under heading 2835, as of October 2026; other grades are taxed |
| Factory and safety | Factory licence, fire NOC and safe storage of hydrochloric acid, as required by your state |
| Business registration | Udyam (MSME) and GST registration |
Rules change and vary by state. Confirm current requirements with BIS, your State Pollution Control Board and your tax adviser.
Who buys feed grade DCP in India?
DCP supplies phosphorus and calcium for bone growth, milk yield and egg shell quality, so it goes into most compound feeds and mineral mixtures. Buyers order in truckloads, test each lot, and switch suppliers quickly when phosphorus or fluorine drifts.
- Compound cattle feed plants and dairy cooperative feed units
- Poultry feed mills and integrators
- Mineral mixture manufacturers
- Aqua feed producers
- Feed ingredient traders and distributors
What the BIS order changes: mineral mixtures (IS 1664) come under compulsory certification along with DCP. Mixture makers will need certified, consistent DCP, which favours plants with a working lab and documented quality control.
Mistakes that weaken a di calcium phosphate project report
- No plan for the calcium chloride liquor
The HCl route makes far more chloride liquor than product. A report without its treatment or recovery cost will not clear the pollution board or the bank.
- Assuming input GST comes back
Feed grade DCP is exempt, so GST on rock, acid and machinery is usually a cost, not a credit. Leaving it out understates the project cost.
- One rock grade for every lot
Rock with lower phosphate or higher fluorine raises acid use and defluorination cost. Yields should be based on the rock you will actually buy.
- Ignoring acid freight and storage
A plant far from its acid source pays heavily for transport and tankage. Price acid delivered to the gate, with a second supplier.
- Leaving out BIS and lab costs
From 2027 the BIS licence, lab staff and equipment are part of running the plant. Budget them in the project cost and overheads.
How NPCS helps you plan a DCP plant
- Route and capacityCompare the HCl and phosphoric acid routes for your acid source, rock supply and budget.
- Effluent and approvalsPlan calcium chloride handling, Red category consent and the BIS licence for IS 5470.
- Machinery and labList acid-proof equipment, dryer and the testing lab, with supplier quotations.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender asks for.
NPCS's published client list records 269 specialty chemicals assignments, and the NPCS project team has prepared reports for chemical plants since 1994.
What's inside the di calcium phosphate 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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DI Calcium Phosphate project report: frequently asked questions
What is the di calcium phosphate manufacturing plant cost in India?
A feed grade DCP plant of 25–30 MT per day on the hydrochloric acid route needs roughly ₹12–18 crore including land, building, effluent treatment and working capital margin. A smaller unit that neutralises bought phosphoric acid can start lower. These are indicative ranges. Our sample report models a 27 MT per day plant at ₹1,411 lakh, with plant and machinery at ₹691 lakh.
How is dicalcium phosphate made?
Ground rock phosphate is digested in dilute hydrochloric acid to dissolve the phosphate. The liquor is defluorinated and filtered, then lime slurry is added under pH control so that dicalcium phosphate precipitates. The wet cake is filtered, washed, flash dried, pulverised, sieved and packed in 50 kg bags after testing for phosphorus, calcium and fluorine.
Is BIS certification mandatory for feed grade DCP?
Yes, with enforcement from 1 April 2027. The Bureau of Indian Standards lists dicalcium phosphate, animal feed grade (IS 5470) among quality control orders of the Department of Animal Husbandry and Dairying, with that enforcement date. After it, feed grade DCP sold in India must carry the BIS mark, so a new plant should budget for the licence and an in-house lab.
What is the GST rate on dicalcium phosphate?
Dicalcium phosphate of animal feed grade that conforms to IS 5470:2002 is listed as exempt from GST under heading 2835, as of October 2026. Other grades are taxed. Because the feed grade product is exempt, GST paid on raw materials and machinery is usually not recoverable, so the project report should treat it as a cost. Confirm the treatment with your tax adviser.
Is a DCP plant profitable?
It can be, if acid and rock phosphate are bought well. In our illustrative sample, a 27 MT per day plant earns a 19% return on investment in Year 3, breaks even at about 40% of capacity and pays back in about 3.8 years. Real results depend on acid price and distance, rock grade, fluorine control and how fast feed mills pay.
What is the difference between feed grade and dentifrice grade DCP?
Feed grade DCP is a phosphorus and calcium supplement for livestock and is tested under IS 5470. Dentifrice grade DCP is a much purer, finer powder used as a polishing agent in toothpaste and is covered by a separate standard, IS 1767. The process, purification steps, buyers and price are different, so each needs its own project report.
Is the di calcium phosphate project report PDF free, and can I use it for a 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 term loan, NPCS prepares a report for your own route, capacity, location and lender.
Sources and references
- Upcoming QCOs notified and due for implementationBureau of Indian Standards, checked Oct 2026
- Product manual for dicalcium phosphate, animal feed grade (IS 5470)Bureau of Indian Standards, checked Oct 2026
- Indian Standards pertaining to animal husbandry, fisheries and dairyingBureau of Indian Standards, checked Oct 2026
- IS 1767: Dicalcium phosphate for dentifriceBureau of Indian Standards, checked Oct 2026
- Notification No. 2/2017-Central Tax (Rate), exempted goodsCentral Board of Indirect Taxes and Customs, checked Oct 2026
- Categorisation of industrial sectors under Red category as per CPCB criteriaState Pollution Control Board, Odisha, 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.