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Ceramic Water Filtration

Product design and development

3/28/2013

Haile G/tsadik

Gizachew Tesfaye

Kidu Tsegay

Girmay KahsayAlemayehu


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CERAMIC WATER FILTRATIONMarch 28,

2013

Portable water filter for Ethiopia Page2

Contents

Abstract.......................................................................................................................................... 3

Acknowledgements ...................................................................................................................... 3

Objective........................................................................................................................................ 4

Current practice ............................................................................................................................ 4

Problems in Current Scenario .................................................................................................... 5

Need of the Project & Opportunities for Stakeholders............................................................ 6

Ceramic filter technology ................................................................................................................ 6

Targeted Customer...................................................................................................................... 8

Differentiating factor..................................................................................................................... 8

Working of the Entire Business Process .................................................................................. 9

Products(this from catia) ........................................................................................................... 10

Economic analysis ..................................................................................................................... 14

Marketing Strategy ....................................................................................................................... 17

How to compete ....................................................................................................................... 17

How to Deliver .......................................................................................................................... 17

Concept Selection Matrix .............................................................................................................. 18

Choice of Water Filtration Method ........................................................................................... 18

Manufacturing strategy ................................................................................................................ 19

Reason for selection of these cities: ............................................................................................. 20

SWOT Analysis ............................................................................................................................... 21

DFX Review.................................................................................................................................... 21


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Abstract

That problem is the growing number of people who die each year due to

water borne diseases. It is estimated that five million people die each year

due to water borne diseases. In Ethiopia, other expert studies show that

approximately 300,000 children under five years of age die each year

because of drinking unsafe, contaminated water. Despite the numerous

efforts made in the past years to solve this problem a large number of

Ethiopians still have no access to clean, safe drinking water. Accordingly,

the numbers of Ethiopians who die, especially children, from water borne

illness continues to plague the country. Ethiopia is one of the third world

countries; most of our population around 85% of the 80 million

populations is in rural area of the country. Household water treatment and

safe storage (HWTS) interventions are proven to both improve water

quality and reduce disease incidence in rural area of Ethiopia, in this

project a simple water treatment system for remote rural households

which overcomes the limitations of existing systems is developed based

on unique and robust water filtration system using simple ceramic

equipment.

A manufacturing line to produce the dual water filters is proposed and the

cost of manufacturing a unit is calculated to be 91 Birr, which is an

affordable price for people in third world countries. With low cost water

filter available, residents in the third world countries could enjoy having

safe drinking water and improve quality of life.

Acknowledgements

First and foremost, we would like to thank our teacher prof. Jayanta

chatterjee, our teacher, for his tremendous, excellent effort and honest

support throughout the contact of ten days not only to know and

implement the NPD course but also his valuable life experience and to

use the subject in our industries and to push our country forward within

the constraints. Finally we would like to thank prof. mishira for tirelesssupport and encouragement in the marketing the process of doing the 6

hours PG .


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Objective

The intent of this project is to lay the foundation for developing a ceramicwater filter for rural Ethiopia. The overall goal of developing a low-cost

ceramic water filter is to provide an affordable means for citizens to

improve their drinking water quality to standards suitable for human

consumption. In addition to improving drinking water quality, the

development of a sustainable ceramic water filter industry within Ethiopia

will hopefully contribute to economic development whereby local

entrepreneurs, such as Ethiopian ceramic industries, can develop a

sustainable business through manufacturing and marketing ceramic water

filters to higher quality control/quality assurance standards than those

currently being produced.

Current practice

The coverage of safe potable water in several countries is very small. This

is also true in Ethiopia. In fact in the majority of the country, only 21% to

54% of the population has access to safe drinking water. Most OfEthiopias countryside residents drink water obtained from rivers, ponds,

lakes and wells, which are not sources for safe potable water.

Implementation of water treatment technology at the household level

helps to provide safe, clean and clear drinking water. That is why CWF

water purifier was created; it essentially eliminates diarrhea and other

waterborne related diseases, which lead to deaths the majority of times.

Thus having access to clean and safe drinking water significantlyincreases the socio-economic development of the country as a whole and

CWF water purifier helps achieve this. After all, CWF water purifier cleans

and eliminating the risk of diarrhea, water born related diseases and the

deaths that result from water born diseases everywhere there is no

access to safe drinking water.

At this time chemical treatment is the most used method in Ethiopia.

Chlorine is the most widely used primary disinfectant and is also oftenused to provide residual disinfection in the distribution system. Monitoring

the level of chlorine in drinking water entering a distribution system is


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normally considered to be a high priority (if it is possible); because the

monitoring is used as an indicator that disinfection has taken place.

Residual concentrations of chlorine of about 0.6 mg/l or more may cause

problems of acceptability for some consumers on the basis of taste and

odor. Monitoring free chlorine at different points in the distribution system

is sometimes used to check that there is not an excessive chlorine

demand in distribution that may indicate other problems in the system,

such as ingress of contamination. Chlorine reacts with naturally occurring

organic matter in raw water to form a range of unwanted by-products.

Guideline values have been established for a number of these

byproducts.

Problems in Current Scenario

Similar to many African countries, parts of Ethiopia face water shortages,

poor sanitation, and a lack of access to clean water sources. Ethiopia is

located in Africa's Horn where drought and politics are two leading causes

of water shortage. In a study conducted by Water.org they found that

"42% of the population has access to a clean water supply" and only

"11% of that number has access to adequate sanitation services". In rural

areas of the country, these figures drop even lower, resulting in health

problems in the villagers as well as their animals. In the past twenty years,

droughts have affected several areas of the country, leading to ponds,

wells, streams and lakes drying up or becoming extremely shallow. Many

people living outside of the cities collect water from these shallow water

sources, which are often contaminated with human and animal waste,

worms, or disease. During months and sometimes years of drought,

disease runs rampant through small villages and towns. Frequently there

is not enough water for people to bathe, leading to infections and sickness

in children. Water borne illnesses, such as cholera or diarrhea, are the

leading cause of death in children under five years old in Ethiopia. In

addition to illness, many Ethiopian children, especially girls, face problems

with school. Statistically only 45% of kids attend primary school. The


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others are put to work collecting water each morning and helping their

families earn money.

Need of the Project & Opportunities for Stakeholders

For improving water quality involves mitigating disease causing biological

agents (pathogens) as well as harmful chemical contaminants and non-

harmful compounds that impart an unpleasant taste, odor, or appearance.

Household water treatment and safe storage (HWTS) interventions are

proven to both improve water quality and reduce disease incidence in

Ethiopia. Household Water Treatment and Safe storage (HWTS) systems

are proven, lowcost interventions that have the potential to provide safewater to those who will not have access to safe water sources in the near

term, and thus significantly reduce morbidity due to waterborne diseases

and improve the quality of life.

Commerciallyproduced ceramic water filters are one pointofuse water

treatment technology that is effective in reducing bacterial contamination

in water and reducing the risk for diarrhea (Clasen, 2004) (Brown, 2007).

Frequently coated or impregnated with silver for its antibacterialproperties, ceramic water filters are considered by some to be, one of the

most promising and accessible technologies for treating water at the

household level

Ceramic filter technology

Ceramic water pots (CWPs) consist of a ceramic filter and accompanying receptacle

for the filtered water. The typical filter holds eight to ten liters of water and is

suspended inside a plastic or ceramic receptacle with a capacity of around 10 to 20

liters. The receptacle is fitted with a tap and a lid: users pour water into the filter, wait

for the water to flow through into the receptacle, and dispense filtered water from the

tap. Ceramic water filters are one of a number of products for household water

treatment and have been in use since ancient times.5 Candle-shaped ceramic filters

were first produced commercially in England in the early 1800s and are used today

in devices such as mineral pots and traditional drip pots in India. The most widely

promoted CWP filter design today in the developing world is a flowerpot-shaped


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ceramic vessel based on a filter developed in Guatemala in 1981 by Dr. Fernando

Mazariego. In the mid-1990s, Ron Rivera of the nongovernment organization Potters

for Peace redesigned the manufacturing process, and filters based on this design

now are made in over 20 countries. Locally produced ceramic pot-style filters have

the advantages of being relatively inexpensive, low-maintenance, portable, effective,

and easy to use. The filters remove microorganisms from water by gravity filtration

through porous ceramics, with typical flow rates of 23 liters per hour.6Filters for

CWPs are made by pressing a mixture of clay and a combustible material such as

finely ground sawdust or rice husks into the filter shape, allowing it to dry, and firing it

in a kiln. The tiny holes left when the flammable material burns determine the

effectiveness of filtering the water. The pore size can be made small enough toremove bacteria, protozoa, and worm eggs, down to a diameter of 0.2 microns.

Challenge tests on filters in Nicaragua achieved a 4-log reduction in protozoa

(Lantagne, 2001); other tests of filters in Nicaragua, Ghana, and Cambodia,

achieved 26 log reduction value in protozoa (van Halem, 2006)7. After firing, pots

are typically coated with colloidal silver, a liquid suspension of microscopic silver

particles with bactericidal properties.8 CWPs are very effective against bacteria as

well. Studies in Cambodia have shown a mean 1 to 1.4 log reduction value of E. coli

and total coliforms.9,10 Hydrologic produces the ceramic filter element of its Rabbit

unit at factories in Kampong Chhnang and Prey Veng using local clay mixed with

finely ground rice husks. The factory workers form the pots with a press mold and

fire them in a kiln. The plastic exterior of the unit is produced at another facility in

Cambodia, and the final product is assembled and packaged at the Hydrologic plant.

As part of its safe water work, PATH also provided funding for members of the

Ceramics Manufacturing Working Group (CMWG) to complete a set of best practices

and recommendations for the manufacturing of ceramic water filters. The product of

this collaboration, Best Practice Recommendations for Local Manufacturing of

Ceramic Pot Filters for Household Water Treatment.


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Tab le 1

Stakeholders Opportunity

Manufacturers

(entrepreneurs)

they have a large market

in the rural areas of

Ethiopia

Suppliers they have a large market

in the rural areas of

Ethiopia

Government and Ministry

of health

To reach millennium

development goals set by

UN

Reduce the cost incurs

to buy drugs for water

born disease

Rural areas of Ethiopia Portable, easy to use

and low cost and also

reduce loss of life

childrens

NGO(Non Governmental

Organizations)

To supply and train the

easily the water filtration

system

Targeted Customer

Ministry of health and Non Governmental Organizations (who are currently working

in rural area to improve the public Health).

Differentiating factor


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Opportunity for rural households to drink pure water with a least cost and

ease of maintenance ,

Since filters can be made locally by the private sector, they can also

provide a source of income in poor communities

The filters demonstrated effectiveness in improving water quality and

health, over a wide range of conditions, makes it an attractive option for

household water treatment

Working of the Entire Business Process

S/n Entity

1 Manufacturing of the product in medium and small

enterprises by collecting the row material

2 Selling the product to Government, NGO and suppliers, by

adding 20% of profit

3 Simple training to maintain the product to the distributers

4 suppliers will employ people to distribute to the rural area


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Products(this from catia)


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This is from catia professor


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Economic analysis

The gross national income per capita in Ethiopia is only $540 USD. As

proposed by the industrial partner, the target sale price for the dual filter is

40 BIRR. An economic analysis was conducted to estimate the production

cost of the filter.

The manufacturing line for making the ceramic filters consist of a

hydraulic press, ceramic kiln, clay mixer, and other tools. Further, a total

of four workers are to be hired to work at each station. The following

assumptions apply for calculating an estimated cost of making theceramic filter level. Manufacturing line operates at 8 hours a day, 5 days a

week, 50 weeks a year - A total of 100 ceramic filter elements will be

produced each day

- A total of 125,000 filters will be produced in 5 years of operation

- Tables 1, 2, and 3 illustrate the material, equipment, and operating costs

required to

- Operate a production line to manufacture the ceramic filters over five

years.

Table 1 Material Costs for Running the Ceramic Production Line for Five

Years

Materials Cost(birr) Remark

Clay 150000 Purchased

locally

Water 0.00 Surface water

Sawdust/ flour 10000 Purchased

from

Total Material

Cost

160000

Silver nitrate

(AgNO3)


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Table 2 Start-up Equipment Costs for Running the Ceramic Production

Line (fixed cost)

Power required for the hammer mill, clay mixer, and the oven are 10 kW,4.584kW and 19.935kW respectively. Referring to the assumptions made earlier,

the manufacturing line would run for 2,000 hours a year. The cost of electricity in

Ethiopia is around 3.8 Br/kWh. Therefore, the total energy cost is

260000Birr/year. The Ceramic Production Line for Five Years

Equipment Qty Cost

(ETB)

Clay Crusher 1 600

Hammer Mill 1 32000

Clay Mixer 1 10000

Misc. Tools

(Shelves, Buckets,

Brushes)

1set 4000

Hydraulic Press

with Mold

1 10000

Oven 1 100000

Total Equipment Cost 156600


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Unit Cost Summary for Production of Ceramic Filters

Number of

Operating Years

5

Number of

Production Lines

1

Number of Filters

to be Produced

25000

Total Production

Cost

488600

Unit Cost ETB 19.544

The total production cost of making 25,000 filters in year is 488600. This

yields a cost of 19.544 Birr Per ceramic filter. The plastic container we

can buy from market by the price of 40 Birr and the valve in 20 birr so the

total price of the set of portable water filtration system is 79.54 plus

the15% profit margin that is 91Birr.

QTY COST

BIRR

Workers 4 72000

Power

Consumption

-

260000

Total

Operating

Cost

332000


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Marketing Strategy

The above business proposal instead of getting into the competition

Creates a new market space for the products

Creating new brand of water filtration by promoting to the government and NGO

Encourages the existing SMEs to try and explore new avenues of creative product

development form of new filtration system.

The main business of the Facilitators is earning the income from the ceramic mold of the

products provided. The low Profit margin value as compared to the manufacturing cost and

the mutual contractual agreement done at the time of partnership with SME will help them

to sustain in business.

How to compete

Arrange Local conference in Addis abeba, Awasa, Bahiridar, Mekele about ceramic

water filtration

Contact Government bodies for Subsidy and encouragement of SME.

Encourage and fund education institutes for developing different types of water

filtration systems.

Create an awareness platform for the products made from simple home made

products.

How to Deliver

Direct Interaction with the Government ,NGO and SMES

Presentation of the Business proposals to institutions and factories to get their

involvement.

Yearly contract with the stakeholders.


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Concept Selection Matrix

Bacteria

and

Viruses

Bad

Tastes

&

Odors

Chemical

removal

Heavy

Metals

Price

(cost)

VOC's Total

+ve

-VE

Ultraviolet + - - - - - 1

5

Reverse

Osmosis

+ + + + + + 6

0

Slow Sand + + - - - + 3

3

Activated

Carbon

- + + - + - 3

3

Ceramic + + - + + + 5

1

Choice of Water Filtration Method

The main source of water in third world countries is surface water from rivers and ponds.

Surface water contaminants typically consist of sediments, bacteria, viruses, VOCs and

heavy metals. Bacteria and viruses are the main causes of waterborne diseases. Therefore,

eliminating bacteria and viruses would be the main task for the filter. Sediment and other

solid particles also need to be removed to make the water drinkable.

Of the five filters studied, it is clear that all filters, except activated carbon, would eliminate

bacteria and viruses. Ultraviolet treatment is perhaps the best method to inactivate bacteria

and viruses, but not very effective on other contaminates. Ultraviolet treatment is also

expensive. Reverse osmosis filters eliminate most contaminates, but since the target

consumers are in third world countries, having low-cost manufacturing methods and readily


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available is critical. Reverse osmosis filters require technology not yet available in third

world countries, and manufacturing cost is relatively high. Thus it is not suitable for this

application. Slow sand filters are economical and material is also easily obtained. However,

it only operates properly in large size. This is not viable for a typical home use water filter.

As shown in Table 1, the combination shows as ceramic filters would filter out most

bacteria, viruses, sediments, VOCs, most heavy metals, chlorine, radon, and reduce odor

and bad tastes in water. The ceramic filter compensates each other to provide the most

effective filtering media. Thus, they were chosen to be the focus of the project.

BOM (Bill of Material)

Bill of material for CWF

Part name Part code Qty BUY or MAKE

Ceramic filter CWF 1/05 1 ManufactureCeramic potholderand clean waterreceptacle

CWF 2/051 Buy

Cover for the

pot

CWF 3/051 Buy

Tap (valve ) CWF 4/05 1 Buy

StandCWF 5/05

1 Buy

Specification

Flow Rate: 60 liter/day

Average Capacity: (25 liters)

Working Pressure: atmospheric pressure

Working Temperature: up to 40

Weight: 7Kg.

Manufacturing strategy

We will manufacture only the ceramic part and assemble in our work shop the other part will be

outsourcing and manufacturing in local factories based on our design offer because

1. Initial investment cost is very expensive

2. We can also find simply in the market with cheapest price

3. To multiply force and maintain business relation


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4. To minimize risk of market failure

Addis abeba

Awasa

Bahiridar

Mekele

Adama

Reason for selection of these cities:

They have good facility for production

They are best to reach the rural area

They have a lot of institutions and NGO to support the project


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Portable water filter for Ethiopia Page 21

SWOT Analysis

Strength

A market-based approach can work inproviding household water treatment

and storage products to low-income

users.

Cheap and easy to make

No advanced technology required

Simplicity and robustness in design

Can be customized to the need of

scale of Business

Weakness

High maintenance, need to be

cleaned periodically

No Brand recognition Low market

Start up venture

Lack of Business experience

Opportunity

Good Government support for SMEs

Good market opportunity in our

country because 85% of the

population live in rural area

The current economical progress of

Ethiopia

Threat

Market not mature enough to accept

new concept-initial stage of learning

curve

The developed country Enterprises

can control the market

DFX Review

Design for manufacturing: we design to manufacture only pot the ceramic and assemble of

the components by buying from local market to minimize the cost and our design is suitable

to ergonomics by adding the base and need a small area during the use. Our components

are around five to increase modularity and the container is also multipurpose. Finally the

manufacturing of the pot is also low initial investment cost.

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