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Replacing Imported Tile Adhesive with In-House Production
Location: Surat, Gujarat | Capacity: 32,000 kg/shift (DM-1000) | Plant Type: Dry Mix Mortar Plant | Year: 2022
A Surat-based tile contractor consolidated their procurement by installing a Maruti DM-1000 dry mortar plant to produce tile adhesive in-house — replacing imported premix at 40% lower per-kg cost, with consistent IS 15477 Grade C1 performance.
The client was purchasing imported C1-grade tile adhesive at ₹22–24/kg for large commercial flooring projects across South Gujarat. Volume was predictable (minimum 30 tonnes/shift/day) but import lead times of 4–6 weeks were delaying project schedules. The brief required a DM-1000 (32,000 kg/shift) plant with gravimetric batching, recipe management for at least 5 adhesive grades, and a bagging line for 25 kg retail packs.
Maruti Hydraulics installed a DM-1000 dry mortar plant with SCADA-controlled gravimetric dosing, a 5,000-litre paddle mixer with 7-minute batch cycle, and a 25 kg automatic bagging and stitching station. Five product recipes (C1 standard, C1 flexible, C2 heavy-duty, wall putty, block-jointing mortar) were pre-configured. Raw material silos for cement, sand, and additive premix were sized for 3-day buffer stock to eliminate supply-chain interruptions.
In-house production cost settled at ₹13.5/kg for C1 tile adhesive — a 40% reduction versus imported premix. The plant runs one shift per day, producing the client's full daily requirement with capacity headroom for retail bag sales. Break-even was achieved within 14 months of commissioning.
Tags: Dry Mortar Plant · Tile Adhesive · Import Substitution · Gujarat
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