What is a sodium percarbonate project report?
A sodium percarbonate project report is a detailed project report (DPR) for a plant that reacts soda ash with hydrogen peroxide to make a dry oxygen bleach. It sets out the process, machinery, raw materials, market, project cost, means of finance, five-year projections, DSCR and break-even that a lender needs.
Promoters use it to size the plant and raise a term loan; detergent makers adding captive bleach capacity use it to test the economics.
Also known as: sodium percarbonate business plan, project report on sodium percarbonate, sodium carbonate peroxide plant report, DPR for sodium percarbonate manufacturing.
Sodium percarbonate manufacturing plant cost in India
Our sample report models a 5.9 MT per day plant, or 1,947 MT per year over 330 working days. It starts at 60% of capacity and reaches 80% in Year 5, selling at ₹64,300 per MT ex-factory before GST.
| Land and site development | 50.16 |
|---|---|
| Building and civil works | 143.85 |
| Plant and machinery | 298.94 |
| Other fixed assets | 46.55 |
| Contingencies | 22.14 |
| Preliminary and pre-operative | 14.04 |
| Working capital margin | 28.61 |
| Total | 604.29 |
| Promoter's contribution (25%) | 151.07 |
|---|---|
| Term loan from bank (75%) | 453.22 |
| Cash credit limit (separate) | 85.84 |
| Total project cost | 604.29 |
Why the margin is thin: raw materials take 53.4% of sales in the sample, and the average debt service coverage ratio (DSCR, cash available to repay the loan divided by the instalment) is 1.41, with a low of 1.24. A small rise in peroxide price or a few points of yield loss moves these numbers quickly, so lenders read this plant's sensitivity tables closely.
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. All figures are illustrative.
Sodium percarbonate manufacturing process
Sodium percarbonate (2Na₂CO₃·3H₂O₂) is a crystal of soda ash holding hydrogen peroxide, about 32.5% by weight. Our sample report follows the wet crystallisation route shown here, which suits smaller plants.
- Soda ash dissolution
Light soda ash is dissolved in recycled mother liquor and filtered, because iron and other insolubles would break down the peroxide later.
- Stabiliser dosing
Sodium silicate and magnesium sulphate are added to lock up trace metals such as iron, copper and manganese.
- Crystallisation
Hydrogen peroxide is fed slowly into the cold carbonate solution in jacketed crystallisers, with chilled brine removing the heat the reaction gives off.
- Centrifuging
The crystal slurry is spun in basket centrifuges, and the mother liquor goes back to the dissolver to recover peroxide and carbonate.
- Drying
Wet crystals are dried in a fluid bed dryer, with the product kept well below the temperature at which it starts to decompose.
- Coating
Dry granules are sprayed with sodium sulphate solution in a fluid bed coater so they keep their oxygen inside humid detergent powders.
- Testing and packing
Each lot is tested for active oxygen, moisture and particle size, then packed in lined 25 kg polypropylene bags.
Wet crystallisation or spray granulation: which route fits your plant?
There are two main ways to make sodium percarbonate. The choice sets your machinery list, power load and the grades you can sell.
| Factor | Wet crystallisation | Fluid bed spray granulation |
|---|---|---|
| How it works | Product crystallises from a cold solution, then is centrifuged and dried | Soda ash and peroxide solutions are sprayed onto seed granules in a hot fluid bed |
| Typical scale | Suits small and mid-size plants, often 3–10 MT per day | Suits large continuous plants |
| Main equipment | Crystallisers, chilling plant, centrifuges, dryer | Spray granulator, hot air system, dust recovery |
| Waste stream | Mother liquor, recycled with a bleed for impurities | Little liquid waste; dust and off-gas handling |
| Product | Crystals that need coating for detergent use | Round, dense granules that suit compact detergents |
Our sample report uses the wet crystallisation route. The comparison is indicative; the right route depends on capacity and buyer grade.
Raw materials for sodium percarbonate
By formula, one tonne of product holds about 0.68 MT of soda ash and 0.33 MT of pure hydrogen peroxide. That is about 0.65 MT of the 50% grade most plants buy. Real use is higher because some peroxide is lost to decomposition. Soda ash is the largest raw material in the sample, with hydrogen peroxide close behind.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Soda ash (light) | 47% | 219.85 |
| Hydrogen peroxide (50%) | 45% | 210.50 |
| Stabilisers (sodium silicate and magnesium sulphate) | 4% | 18.71 |
| Coating agents (sodium sulphate) | 4% | 18.71 |
| Total | 100% | 467.77 |
Hydrogen peroxide arrives by road tanker and needs passivated stainless steel or aluminium storage, since iron and dirt start its breakdown.
Machinery for a sodium percarbonate plant
Jacketed crystallisers are the largest machinery item in the sample, followed by the fluid bed dryer. Wetted parts are stainless steel, since mild steel speeds up peroxide decomposition.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Peroxide storage tanks and dosing system | Stores 50% peroxide and meters it into the crystallisers | 29.89 |
| Soda ash dissolver and filtration system | Makes a clean carbonate solution | 23.92 |
| Jacketed stainless steel crystallisers | Hold the cold reaction where crystals form | 65.77 |
| Brine chilling plant | Removes reaction heat to keep the batch cold | 29.89 |
| Basket centrifuges | Separate crystals from mother liquor | 29.89 |
| Fluid bed dryer with air heater | Dries crystals at a controlled temperature | 53.81 |
| Fluid bed coater | Applies the protective sulphate coat | 23.92 |
| Vibrating sieve, blender and bagging unit | Grades, blends and packs the product | 23.91 |
| Mother liquor recycle and scrubber system | Returns liquor and cleans dryer exhaust | 17.94 |
| Total plant and machinery | 298.94 | |
Costs are the sample report's estimates for a 5.9 MT per day line. Get current quotations before you finalise.
Licences and safety rules for a sodium percarbonate plant
Because both the product and its peroxide feed are oxidisers, approvals focus on safe storage as much as on emissions.
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. The 2016 classification adopted by state boards lists chlorates, perchlorates and peroxides in the Red category; confirm your category with your board |
| Hazardous chemical rules | Hydrogen peroxide is listed in Schedule 1 of the Manufacture, Storage and Import of Hazardous Chemical Rules, 1989, so its storage and handling fall under those rules, including safety data sheets and labelling |
| Transport classification | Sodium percarbonate is UN 3378, Class 5.1 oxidiser, packing group III; bags and vehicles must be labelled to match |
| Factory and fire approvals | Factory licence or registration under the applicable labour law, and a fire NOC for the oxidiser store, as your state requires |
| Buyer specification | Detergent makers buy to their own limits for active oxygen, moisture, bulk density, particle size and iron content, and test each lot |
Rules checked in October 2026 against the sources listed below. State requirements differ; confirm with the departments concerned.
Who buys sodium percarbonate in India?
Demand comes from the oxygen bleach in detergent powders, colour-safe stain removers and dishwasher tablets. Detergent makers buy on a fixed specification and test each lot, so a new plant usually supplies trial lots for some months before it gets regular orders.
Domestic material competes with imports, so buyers compare your price with the landed price of imported coated grades. A plant close to soda ash and peroxide producers in Gujarat or Maharashtra saves freight on both inputs.
- Detergent and laundry powder manufacturers
- Stain remover and dishwasher tablet makers
- Textile processing and bleaching units
- Aquaculture input dealers, for pond oxygen release
- Chemical traders and exporters
Where a new plant wins: coated grades that hold their active oxygen through a humid Indian monsoon. Uncoated product loses oxygen when mixed with moist detergent bases, and buyers reject lots that fail their storage test.
Mistakes that weaken a sodium percarbonate project report
- Using trader prices as the selling price
Prices quoted for small packs are well above what detergent makers pay in bulk. The sample uses ₹64,300 per MT ex-factory; check your figure against buyer quotes.
- Taking yield straight from the formula
Peroxide breaks down in the crystalliser, dryer and mother liquor. A report that assumes theoretical yield overstates output and understates peroxide use.
- Undersizing the chilling plant
Crystallisation gives off heat, and a warm batch loses peroxide and forms fine crystals. Chiller load and power cost must be costed for summer conditions.
- Treating the warehouse as an ordinary store
The product can decompose on its own above about 50°C. Plan a cool, dry, separate store with limited stacking and fire protection.
- Ignoring buyer approval time in working capital
Trial lots and 45 days of customer credit stretch the first year's cash. In the sample, trade receivables are the largest part of current assets.
How NPCS helps you set up a sodium percarbonate plant
- Route and capacityCompare wet crystallisation and spray granulation for your budget, capacity and target buyers.
- Raw material planWork out soda ash and peroxide use, yield and supply options for your location.
- Bank-ready project reportProjections, DSCR, sensitivity to peroxide price and working capital in your lender's format.
- Layout and approvalsPlant and oxidiser store layout, chilling and power load, and the approvals list for your state.
NPCS's client list includes 1 sodium percarbonate assignment and 269 in specialty chemicals, prepared since 1994 for entrepreneurs, banks and companies in India and abroad.
What's inside the sodium percarbonate 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
18 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 |
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
Sodium Percarbonate project report: frequently asked questions
What is the cost of a sodium percarbonate manufacturing plant in India?
A plant of 3–5 MT per day needs roughly ₹3.5–5.5 crore, and a 6–10 MT per day plant about ₹6–10 crore, including land, building and working capital margin. Our sample report models a 5.9 MT per day plant at ₹604 lakh. These are indicative figures; your own report works out the cost for your capacity, route and location.
What raw materials are needed to make sodium percarbonate?
Soda ash and hydrogen peroxide, plus small amounts of stabilisers and coating salts. In theory one tonne of product needs about 0.68 MT of soda ash and 0.65 MT of 50% hydrogen peroxide. In our sample report soda ash is 47% of raw material cost and hydrogen peroxide 45%.
Which machines are needed for a sodium percarbonate plant?
A wet-route plant needs peroxide storage and dosing, a soda ash dissolver with filters, jacketed stainless steel crystallisers and a brine chilling plant. After them come centrifuges, a fluid bed dryer, a fluid bed coater, and sieving and bagging equipment. Crystallisers are the largest machinery item in our sample report, at ₹65.77 lakh out of ₹298.94 lakh.
Is sodium percarbonate manufacturing profitable?
In our illustrative sample, a 5.9 MT per day plant earns a 14% return on investment in Year 3. It breaks even at 43% of capacity and pays back in about 4.6 years. Margins are thinner than many specialty chemicals because raw materials take 53.4% of sales, so peroxide buying and yield control decide profit.
Is sodium percarbonate dangerous to store?
It is classed as a UN 3378 Class 5.1 oxidiser. It does not burn, but it feeds a fire and can start to decompose on its own above about 50°C, releasing heat and oxygen. Store it cool and dry in closed bags, away from water, acids, metal salts and combustible material.
What is the difference between sodium percarbonate and sodium perborate?
Both are solid oxygen bleaches that release hydrogen peroxide in water. Sodium percarbonate is made from soda ash and contains no boron, and it releases its peroxide readily in warm and cool washes. Sodium perborate is a boron compound that works best in hot washes. Detergent makers choose between them on wash temperature, formulation and price.
Is the sample report 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 loan, NPCS prepares a report for your own capacity, location and lender.
Sources and references
- International Chemical Safety Card: Sodium percarbonate (ICSC 1744)International Programme on Chemical Safety (WHO and ILO), checked Oct 2026
- The Manufacture, Storage and Import of Hazardous Chemical Rules, 1989Punjab Pollution Control Board, checked Oct 2026
- Categorisation of industries into Red, Orange, Green and White (circular dated 31 August 2016)Kerala State Pollution Control Board, 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.