What is a poly aluminium sulfate from aluminium sulfate project report?
A poly aluminium sulfate from aluminium sulfate project report is a detailed project report (DPR) for a plant that partly neutralises alum solution to make a pre-polymerised liquid coagulant. It covers the process, raw materials, machinery, gypsum handling, market, project cost, five-year projections, DSCR and break-even that a bank or investor reviews before funding the plant.
Promoters use it to size the plant and raise a term loan; lenders use it to judge whether the unit can sell its output and repay on time.
Also known as: PAS project report, polyaluminium sulphate plant DPR, basic aluminium sulphate project report, poly aluminium sulfate business plan, project report on poly aluminium sulfate from aluminium sulfate.
Poly aluminium sulfate manufacturing plant cost in India
Our sample report models a liquid poly aluminium sulfate plant of 40 MT per day, working 330 days a year for 13,200 MT per year at full capacity. It starts at 60% of capacity, reaches 70% in Year 3 and 80% in Year 5, and sells at ₹14,200 per MT ex-factory.
| Land and site development | 62.48 |
|---|---|
| Building and civil works | 168.89 |
| Plant and machinery | 348.66 |
| Other fixed assets | 61.92 |
| Contingencies | 25.88 |
| Preliminary and pre-operative | 16.70 |
| Working capital margin | 42.52 |
| Total | 727.05 |
| Promoter's contribution (25%) | 181.76 |
|---|---|
| Term loan from bank (75%) | 545.29 |
| Cash credit limit (separate) | 127.57 |
| Total project cost | 727.05 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments; DSCR (cash available to repay the loan, divided by the instalments due) never falls below 1.70. All figures are illustrative.
Poly aluminium sulfate from aluminium sulfate manufacturing process
The plant takes ordinary alum and removes part of its sulphate, so the aluminium ends up partly as polymeric hydroxide. The share of aluminium neutralised this way is called basicity; most liquid grades aim for about 40–60%.
- Alum dissolution
Solid non-ferric alum is dissolved in hot water in an agitated tank. A solution of about 28% aluminium sulphate carries roughly 8% alumina (Al₂O₃), close to the strength of the final product.
- Clarification
The solution is settled and filtered so insoluble grit from the alum does not end up in the product or the filter cake.
- Partial neutralisation
Fine calcium carbonate slurry is fed slowly under high-shear mixing. It reacts with the acidic solution and releases carbon dioxide, so the vessel needs headspace and a controlled feed rate to stop foam spilling over.
- Polymerisation
The batch is held warm, typically for one to two hours, while the aluminium forms polymeric hydroxy sulphate species and the liquid clears.
- Gypsum removal
The sulphate taken out of solution leaves as calcium sulphate (gypsum). A filter press separates it; the cake is washed to recover alumina-bearing liquor.
- Testing and adjustment
Each batch is checked for alumina, basicity, pH and specific gravity. Soda ash or water brings it to the grade agreed with the buyer.
- Storage and dispatch
The acidic liquid goes into FRP tanks and is filled into carboys, IBCs or rubber-lined road tankers.
Which route should a poly aluminium sulfate plant use?
Two bases are used to neutralise alum. Our sample report uses calcium carbonate because it is cheap and easy to buy in India; sodium aluminate gives a cleaner process at a higher chemical cost.
| Point | Calcium carbonate route | Sodium aluminate route |
|---|---|---|
| By-product | Gypsum filter cake that must be pressed, washed and disposed of | Sodium sulphate that stays dissolved in the product |
| Filtration | Filter press needed, the main maintenance item | No filter cake, so no press |
| Chemical cost | Low; limestone powder is a small share of raw material cost | Higher; sodium aluminate also adds alumina, which lifts product strength |
| Process control | Watch foaming from carbon dioxide and alumina lost in the cake | Needs cooling and very high-shear mixing to avoid gel lumps |
| Suits | Regional plants selling to water boards and effluent plants | Plants serving buyers who want a stronger, low-solids grade |
Choose by buyer, not by chemistry alone: if most of your volume goes to municipal tenders priced per tonne, the cheaper limestone route usually wins. A strength-based price favours the aluminate route.
Raw materials for poly aluminium sulfate
Alum decides the cost. As an indicative guide, each MT of 8% product needs about half a tonne of solid non-ferric alum, plus roughly 100–120 kg of calcium carbonate at 40–50% basicity. Buy alum made to IS 260 (non-ferric); the ferric grade covered by IS 299 brings iron and colour that drinking water buyers reject.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Non-ferric aluminium sulphate (alum) | 82% | 496.96 |
| Calcium carbonate powder | 9% | 54.55 |
| Soda ash | 5% | 30.30 |
| Stabilising additive | 4% | 24.24 |
| Total | 100% | 606.05 |
Raw materials are 46.2% of sales in the sample. Alum quantities per MT are indicative and depend on alum strength and target basicity.
Machinery for a poly aluminium sulfate plant
Everything that touches the liquid must resist a hot, acidic sulphate solution, so vessels are rubber-lined mild steel or FRP and pumps are acid-resistant. The reaction vessels are the largest single cost in the sample.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Alum dissolving tank with agitator | Makes the alum solution | 41.84 |
| Rubber-lined reaction vessels, high-shear agitators | Neutralisation and polymerisation | 90.65 |
| Calcium carbonate slurry and dosing system | Feeds the base at a steady rate | 27.89 |
| Filter press for gypsum separation | Removes and washes gypsum cake | 55.79 |
| FRP product storage tanks | Hold finished liquid | 48.81 |
| Steam boiler and heating coils | Heat for dissolving and ageing | 27.89 |
| Acid-resistant pumps and piping | Move liquor between stages | 34.87 |
| QC laboratory with jar test apparatus | Batch tests and buyer trials | 10.46 |
| Carboy, IBC and tanker filling station | Dispatch | 10.46 |
| Total plant and machinery | 348.66 | |
Costs are the sample report's estimates for a 40 MT per day plant. Get current quotations before you finalise.
Manpower and utilities for a 40 MT per day plant
Steam heats the alum and the batches, and power runs agitators, pumps and the filter press. Together they cost ₹117.48 lakh in Year 3 of the sample, or 9% of sales. The plant runs in shifts with 37 people.
| Category | Number | Monthly wage (₹) | Annual cost (₹ lakh) |
|---|---|---|---|
| Management, supervision and administration | 6 | 32,500 | 23.40 |
| Skilled workers and operators | 13 | 20,500 | 31.98 |
| Semi-skilled and unskilled workers | 18 | 13,500 | 29.16 |
| Total (Year 1) | 37 | 84.54 |
Licences and standards for a poly aluminium sulfate plant
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. The Odisha board's red list (checked October 2026) does not name alum or poly aluminium sulfate but includes basic chemicals and their derivatives, so confirm the category with your state board |
| Gypsum cake | Storage, sale or disposal of the filter cake as set in the consent conditions |
| Raw material standard | IS 260 for non-ferric aluminium sulphate (2024 edition); IS 299 covers the alumino-ferric grade |
| Buyer approval | Water boards and municipal bodies usually ask for supplier registration and batch test certificates before accepting a coagulant for drinking water |
| Factory and fire | Factory licence where worker and power thresholds apply, and fire NOC where required by the state |
Who buys poly aluminium sulfate in India?
Demand comes from plants that already use alum and want better settling at a lower dose. Pre-polymerised coagulants of this kind work better than alum in cold water and lose less alkalinity, which means less lime or soda for pH correction downstream. Poly aluminium chloride is the main rival, and sulphate-based PAS wins where chloride in treated water is a concern.
- Municipal corporations and water supply boards
- Industrial effluent treatment plant operators
- Paper and board mills, for sizing and retention
- Textile processing and dyeing units
- Sewage treatment plant operators and contractors
- Water treatment chemical distributors
Freight sets your market radius: liquid PAS is mostly water, so each tanker carries little alumina. Plants usually sell within a few hundred kilometres, which favours a site between the alum supplier and the water boards it serves.
Mistakes that weaken a poly aluminium sulfate project report
- Pricing per tonne without stating strength
Buyers compare cost per kg of alumina. A report that prices an 8% product against a 10% grade overstates revenue.
- No plan for gypsum cake
The limestone route makes a heavy wet cake every day. Leaving out filter press capacity, cake storage and disposal cost hides a real running expense.
- Chasing high basicity
Very high basicity can make the liquid turn cloudy in storage. Rejected tankers cost more than the small gain in performance.
- Ignoring alumina lost in the cake
Some alumina stays in the filter cake. Yields should allow for it, or raw material cost per MT comes out too low.
- Assuming quick payment from public buyers
Tender-based water boards can pay late. Working capital should be tested with longer debtor days than the 45 used in our sample.
How NPCS helps you set up a poly aluminium sulfate plant
- Route and grade selectionCompare the limestone and aluminate routes and fix strength and basicity for your buyers.
- Raw material and buyer studyMap alum suppliers, freight and water board demand around your site.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender wants.
- Plant layout and approvalsTank farm, filter press and gypsum yard layout, plus the consent list for your state.
NPCS has prepared project reports and feasibility studies for chemical plants since 1994, for entrepreneurs, banks and companies in India and abroad. It has also published project profiles on both poly aluminium sulfate and poly aluminium chloride.
What's inside the poly aluminium sulfate from aluminium sulfate 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 |
Real NPCS poly aluminium sulfate from aluminium sulfate project reports
These are poly aluminium sulfate from aluminium sulfate project reports NPCS has prepared, with the plant capacity, total capital investment, rate of return and break-even worked out in each. Costs have moved since some were written, so we bring any of them up to date for your capacity and location.
| Project report | Plant capacity | Total investment | Rate of return | Break-even | Action |
|---|---|---|---|---|---|
| Poly Aluminium Sulfate From Aluminium Sulfate | 1.00 MT/Day | ₹88 lakh | 42% | 48% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
What clients say about NPCS
4.7
264 Google reviews, as of 20 Oct 2026
Clients most often mention
- feasibility reports 18
- project report 16
- helpful for startups 15
- detailed reports 8
-
Excellent experience with Niir Project Consultancy Services. Their Techno-Economic Feasibility Reports are incredibly detailed and backed by solid market data.
Piyush Singh, Google review, 2026
-
Niir Project Consultancy Services offers excellent guidance for business setup. Their market survey and feasibility reports saved us a lot of time and helped us make informed decisions. Highly recommended
Saroj Yadav, Google review, 2026 View on Google
-
In an era of information overload, NIIR stands out for its precision. Their technical consultancy and market feasibility studies are world-class.
Shrishti Gautam, Google review, 2026
-
NIIR Project Consultancy Services provides useful books and reports for students, entrepreneurs, and small businesses. Their content is easy to understand and focuses on practical ideas for starting and managing industries. Overall, NIIR is helpful for learning about business and project planning.
Raj Yadav, Google review, 2026
Poly Aluminium Sulfate from Aluminium Sulfate project report: frequently asked questions
How much does it cost to set up a poly aluminium sulfate plant?
Our illustrative sample models a 40 MT per day liquid plant at ₹727 lakh, including ₹349 lakh of plant and machinery and ₹62.48 lakh for land. As an indicative guide, a 10–15 MT per day unit needs roughly ₹2.5–4 crore and a 60–80 MT per day plant about ₹9–12 crore. Land, building size and tank capacity move the figure most.
What is the difference between poly aluminium sulfate and alum?
Alum is plain aluminium sulphate. Poly aluminium sulfate is alum that has been partly neutralised, so part of the aluminium is already in polymeric hydroxide form. In water treatment this usually means a lower dose, faster floc, better results in cold water and less loss of alkalinity. It costs more per tonne, so buyers compare the two in jar tests.
Poly aluminium sulfate vs poly aluminium chloride: which is better?
Both are pre-polymerised aluminium coagulants. Poly aluminium chloride is more widely sold in India and usually carries more alumina per tonne. Poly aluminium sulfate adds sulphate instead of chloride to treated water, which suits users who must limit chloride, and it is made from alum without hydrochloric acid. The better choice depends on the raw water and is settled by jar tests.
What raw materials are needed to make poly aluminium sulfate from aluminium sulfate?
The main raw material is non-ferric aluminium sulphate, the grade covered by IS 260. In our sample report it is 82% of raw material cost. Calcium carbonate powder raises the basicity, soda ash makes fine corrections and a stabilising additive helps the liquid stay clear in storage. The plant also needs clean process water and steam for heating.
Is poly aluminium sulfate manufacturing profitable?
In our illustrative sample, a 40 MT per day plant earns a 24% return on investment in Year 3. It breaks even at 36% of capacity and pays back in about 3.3 years. Real results depend on the alum price, the strength and basicity buyers ask for, freight to customers and how quickly water boards and municipal buyers pay.
Which licences are needed for a poly aluminium sulfate plant?
You need Udyam and GST registration, consent to establish and operate from the State Pollution Control Board, a factory licence where thresholds apply and a fire NOC where required. Water boards usually ask for supplier approval and batch test certificates. The consent conditions will also cover how gypsum filter cake is stored and disposed of. Rules vary by state.
Is the sample report free, and can I use it for a bank loan?
Yes, the sample PDF is free to open and download, but it is not meant for a loan file. Its figures are illustrative and do not come from a real project. For a bank or investor, NPCS prepares a project report for your own capacity, site, alum supplier and buyers, with current quotations and five-year projections.
Sources and references
- Aluminium Sulphate, Non-Ferric (IS 260:2024): circular on first licence grantedBureau of Indian Standards, checked Oct 2026
- IS 299:2012 Alumino-ferric, specification (fifth revision)Bureau of Indian Standards, checked Oct 2026
- Categorization of industrial sectors under Red 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.