Development of the ceramics industry in North Africa

tr

UNITED NATIONS

ECONOMIC

AND !

SOCIAL COUNCIL

E/CN,

28 February ENGLISH

Original: FRENCH

ECONOMIC COMMISSION FOR AFRICA

DEVELOPMENT OF THE CERAMICS INDUSTRY IN NORTH AFRICA

J

M69-1OS6

table of contents

TRODUCTION•••*»«••••••••.«••••*•••••••••••

CURRENT SITUATION <

OJECTION OF DEMAND UP TO 1980 -

UTS

i) Ceramic stoneware - •

ii) Ceramics of porcelain, china and vitreous ware V. ^2KJMMARY

ANNEX

ANNEX ANNEX

ANNEX

ANNEX

ANNEX

23-2JI

II - III -

IV -

VI -

Consumption of ceramics in North Africa

Imports of ceramics into North Africa i

Exports of ceramics into North Africa

Production of ceramics in North Africa ;

Consumption of ceramics in North Africa

Consumption of ceramics in North Africa during 1964

according to technological classification ; The prices of ceramics in various countries of the ; world; in West Africa during 1963; and in North ; Africa during the period 1960-1965*

Breakdown of expenditure involved in the manufacture of ceramic stoneware

Breakdown of expenditure involved in the manufacture

of white ceramics

Ceramics - production, demand, employment and invesft ment during the period I96O-I966.

T69-O7

I.

E/dT-14/3

Page 1

INTRODUCTION

Ceramics include a wide range of products made from natural raw

baied on clay, which endow them with their distinctive characteristics baked, ^'he surface of certain products has to be improved, by means oj'

or varnishing. Ceramic products may be divided up, according to their

when glazing

uses.

inlio the following groupss

(i) Products used in building

- Bricks, tiles, hollow ceiling tiles, girders, etc...;

. - Stpneware products: fltor tiles, stoneware pipes, stoneware tiles, etc...; .

- "Wall tiles made of china;

. . - Ceramic material for sanitary, purposes! . sinks,- wash "hasi^e, bath tubs*, lavatory..bowls, etc.... . . .

Products for everyday domestic use

- In china: tableware, ornamental ware, ceramic materials

for artistic use?

- In porcelains tableware, ornamental ware, ceramic material for artistic usej

-^ Cooking utensils, flower-pots, .ornamental vases made of- '

pottery.

Products for industrial uses - Refractory products;

- Products in porcelain and stoneware used for chemistry, in laboratories, etc...;

- Electro—technical porcelain.

usec.

the

T.6S-O7

In this report, only ceramic products will be considered, .and the. i-oducts in brickworks and refractory products will not be covered, as they (form

subject of separate reports. ' ; i!

B/CN-14/BTK/WP/3

Page 2

The ceramic products dealt with in this report are divided into three

groups: :-■.-.■ ■

(i) ! Ceramic stoneware ■

....-■■* ■ i ■ . ■

Stoneware is prepared from stoneware clay. It is a-clay whose

"basic property lies somewhere between the point of. softening and the point of melting, and is not much.*.affected "by -hefatiiigV; ": It is possible to obtain stoneware clay front a non-stoneware clay of the melting type, for instance,.by an admixtures of nephelinic syenitfe or feldspar.

Stoneware clay invariably takes, on a shade of colour- when baked.

(ii) Ceramic materials in china, vitreous wars or porcelain) prepared 'by means of^pressurization either dry or humid

The following products are obtained by this method: covering tiles, some tableware, and some products for industrial use. The raw materials are: clay burnt white, suitable for moulding, kaolin burnt white, feldspars nephelinic syenite, pure sand or broken quartz and limestone.

(iii) Ceramic materials in c^ina,.* vitreous ware or poroelain» prepared

by melting the ceramic paste in gypsum moulds •

The following products are then obtained: some types of ware,

ceramic materials for sanitary purposes, ceramic products for artistic and ornamental usg. Tho raw materials used are the same as in tho case of (ii).

II. THE CURRENT POSITION -

In North Africa, ceramic requirements are practically over-supplied by imports and by domestic production. At present, only handicraft production exists in all the North African countries from potteries using clay burnt red;

T.69-07

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Page 3

andpn Algeria, enamelled setts- for wall tiling, are produced, being m facTtfcred by the Rouffak' ceramic enterprise using clay burnt red.

■of

In 1967* a plant was completed at Biaerta in Tunisia, for the manujftotur litary articles, using imported raw materials and having a capaci-fcb

3,0d0 tons per year. In Tunisia, there is a handicraft centre at Nabeu^ whi

produces large quantities of setts for wall tiling as well as pottery

A piDp«?tion of this production Is based on clay burnt red, and. the reminder on dlay burnt white, having a greater or lesser degree of colouration, | |

■ ■ I

, .. In. the United Arab Republic, besides handicraft production, there J- .kewi exists, very.large-scale and varied ceramic production by commercial ent|; 'pris

of

The fac

l-Fasr Company, producing Sornaga refractory products and stonewar*| mac:

es stoneware pipes and accessories of all diameters for draining

stoneware guttering conduits for telephone cables, sanitary articles, s^ibs

insulators, household articles, ceramic flags, china setts for wall tiljfo g,

vitrifled anti-acidic blue bricks for flooring. This company has faotoijl at El-W^idx,rMarkaz-el-Saff and Guizeh, The second company U the general \i omps:

located at Mestorod and manufacturing ceramio and porcelain products, wijih same range of articles produced. The third is the Egyptian Company- for j^ttac

torx««j. with plants at Cairo, El-Tebein, Helwan, Alexandria and ja-HoehaL whir

produce services of tableware, sanitary articles, china setts, ornaments| and

curie*

products according

Ceramio products, except products manufactured by brickworks, refractory and electro-porcelain, and included in the foreign trade stat

■■'■■- ' i ■

to the SITC and BTK classifications, for the following categorp,

662.4(3) - Ceramic piping, conduits

and guttering '

662.4(4) Unglazed ceramic, setts,

flags and tiles

69*06 Piping, conduits and;

(

662.4 [5) Glazed ceramic setts,

flags and tiles

g, ; gt

(including angles, bends similar fittings)

69.07 Unglazed setts, flags

hearth and wall tilep

69.08 Glazed s.etts, f;-Ps hearth and t1'!

as:

Juid

T.69-67

.Page \ •■ ■..-),

663*9(2) Other articles of ceramic

materials

•666.4 Porcelain «r china house-

■ ' .-. hold ware

666.5

666.6

612.2

663.9(1) Laboratory and industrial 69.09 Laboratory, ,c^mical or:

'rS?orS>etC''^: _rerraotory >*^*TO trough^ tubs"*ni simrla*'reCeptaoles of a kind

used in agriculture, pots, jars ..,'.-,., , ;. ,. . and similar articles of a kind

commonly used for the. conveyance ' or packing of?goods

69»14 Other articles

.69*11 Tableware and other dtfticles of

a kind commonly used for.domes tic or toilet purposes' of poroelain or china (including

! biscuit porcelain and parian)

.69* 12 Tableware and other' articles of

a kind commonly used fpr domestic

*r toilet'purposes, of »ther kinds pf-;pottery ■ ?' ;;

69.13 Statuettes and other ornaments

and articles of personal adorn-

■ ment| articles of furniture 69.10 ^inks, wash bas'ins, bidets,

... water cJ-Oset pans, urdhals, ba.thf and like sanitary., fittings ,,

---,.. D4r _„ is included in the category of electrical apparatus, and

there is ^o.;Special. classification cohering this type of ceramic-product in.the

foreign trade statistics.

The imports in these categories for the period I96O-I965 are shown in Annex i, together with exports, consumption and production. As regards the determination of basic consumption, figures are lacking for Algeria, except for the yeare 196I and 1963, in the case of Libya, no statistics exist until 1964, and in Sudan, statistics are available only from 1963. Nevertheless, estimate*

«st be made. In Algeria, .construction reached its highest point in I96O-196I, and this was followed by a decline up to I964. This decline was naturally

linked with a reduction in the consumption of ceramics intended for' construction

purpose^ Consumption of ceramics for sanitary purposes was .10,301 tons in 1961

and 2,880 tons in -1963, which represents only 28 per cent ;of Consumption in 1961.

T. 69-07 .— >.

Household ware of other ceramic materials "' '

Ornaments and furnishing goods of porcelain, china or other ceramic materials.

Sinks, wash basins, .bidet», baths and other sanitary furnishing fixtures

Page 5

Wh< however* we compare unit:consumption ** in.other, words,- consumption in kg;^{S. '! -} pea;!.million applied to construction - we arrive at the.: figures #»f 3,

Lllion in 196land 2,450 kgs./$ million, in 1963. It may "be estima thik unit consumption was approximately 2,790 kgs./$- million in 1963'

ooxmimption was approiimately 520 tons.

:8 kgs.

at at

On the basis of this method, we may estimate consumption of gla*e(ti setts

,950 kgs,/$ million, »r 920 tons, in 1964, and consumption of ungljfed set-

,250 kgs./$ millionT or 780-tons, in the same year.

The consumption #f ceramic tableware is more regular, and ie linki private consumption. In Algeria it amounted to 345 gr, per capita per 196' and 389 gr» per capita per year in 1963- The estimated consmoptibaji 1964 was 367 gr. per capita per year, or 4,160 tons per year.

and

Information relating to the United Arab Republic may be found in 4«nex VI

in Table 1 bel»w:

B/CU-1

Page 6

We are now able to divide up the foreign trade groups into oat-egories according to technological classifioation, 'based on the. three categories of ceramics specified in Seotion I, paragraph 2, so as to obtain the following

estimated.percentages* ..

table; 2

Percentages according to technological classification

Ceramic stone ware products

Pressed products . Molten products

■.- . ■■.•.■■

662.4(3) 662.4(4)

662.4(5) 663.9(1).

663.9<2) 666.4 666.5 666.6 812.2

1«0 80 30

75

- -

—

20 70 25 50

50

50 100 50 100 100

The figures of consumption relating to these teohnologioal classifications will be found, expressed in tons, in Annex III. The resulting figures for the North African countries in the base year 1964 were as follows:

in tons

1. Ceramic stoneware products

2. Pressed products 3. Molten products

Total

Algeria Libya Moroooo Tunisia Sudan UAR Maghrib

810 6,980 1,480 1,540 130 1,750 10,810 2,660 3,710 2,945 3,130 310 3,050 13,445 3.410 1,500 2.355 1,510 2,725 4,600 8,775 6,880 12,190 6,780 6,180 3,165 9,400 32,030

T.69-07

1. Ceramic stoneware products 2. Pressed products

3. Molten products

Tot el.

In

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Page 7

in tons "

UAS and Sudan 1,880 3,360 . 7,325

Sub-re&ion 12,690

16,100

12,565 44,595

III. PIOJECTIOH OF DEHAUD.UP TO 1980

seeking a suitable method of projection, three approaches may, i-n principle, be used. Thu first is biased on the direct calculation of require^

ments ir ceramic products for industry and new construction; the second is based oh the link between consumption of ceramic products and the growth rafcs

in construction, in industry and in private consumption; and finally, the ' tilrd

approach is based upon the evaluation of ceramic consumption as ratios - in

other words, in kgs. por $ million applied to-construction, or in ■grammes

capita of private consumption - and these ratios must be compared with tho©*!|o*

other countries. . . . ' ' !

The| first method is possible in cases where the detailed statistics art}

availably. Ceramics are required not only for new building and new factorial,

but also for maintenance purposes. ?he life-span of sanitary ceramic wares !|e

approximately 10-12 yaars. The life-span of ceramic flags and .paving is approx

imately 15-20 years; maintenance is consequently considerable and', according; ■ to to the circumstances prevailing, consumption of this type of ceramic product [imay

account for 40;per cent or more of total consumption.

Stat ducts

calculation

T.69-07

istics relating to the number of dwellings equipped with ceramic' prld*

virtually non-existent in North Africa^ and, for that reason, direct cannot provide more accurate results than the second method.

Page 8

Direct calculation is relatively complicated and, deepite this circumstance, and despite conditions-that are not calculated to promote effectiveness, we

Bhall fcase •ur computations coexisting consumption and on adopting the same growth rates for ceramics as those proposed for the development of construction, industry.and private consumption, comparing these results with the ratios.

' -, Before Marking on th.se calculations, it is necessary to divide up the '

customs categories of products into those required for the building industry, industry in general and private consumption respectively,

1- The building industry includes the following categoties:

662,4(3) Ceremic piping, conduits and guttering? ' , 662.4(4) Unglazed ceramic setts, flags and tiles?

662.4(5) Glazed ceramic setts, flags and, tiles 3 812.2 Sinks, wash basins, bidets, baths and other

sanitary and furnishing fixtures.

2. Industry ..includes the following oategotiess

663.9(1) Laboratory "and industrial ceramic wares, etc.,

not refractory^ '

••■ 663'. 9(2) Other articles of ceramic materials.

3- Private consumption includes the following categories 666.4 Porcelain or china household ware^

666.5 Household ware of other ceramic materials;

666.6 Statuettes, ornaments and furnishing goods of

porcelain, china or other ceramic materials,

, The growth rates for the period I964-I98O proposed in the EGA "Study on Industrialization and Economic Co-operation for North Africa" (tfo.2), "Provis ional macro-economic data on Economic Development during the Period 1964-1960"

are as followss '

\] This document bears no symbol.

T.69-07

Page 9

TABLE. 3'-■-■--'

: Proposed growth rate far, the period 1964-^1968 in North Africa

1964-4970 - -1-970-1575 'i96f-VSf80

1

^{Algfri-atruetion}

Libj'a

Tunisia

Algeria Libj UAR

Indiistry

6.0%

20,5%

6-P%

5.0%

1.5%

6.8f0

a

Morqeco Tunisia Sudan

UAR S!

Private consumption.

H.9%- 4.0%

5.7%

4.0%

9.0%

4.8%

4.0^

7.0^

5.0%

6.8%

9-0%

6.0^)

5.0%

7.8*

10,8^6

8..05,

5.9%

3.5f*

7.2%

5. Ofo 6..0*

Algeria Libyi Morosco Tuniiiia Sudan UAR

4.8%

5.1%

4.

6.0%

5.3%

6.2%'

■4.9%

9.8%

6.2%

4*9%

6. f%

4-2%

5.9%

4.1%

5.4%

4*6%

■ +i ■ v .;

Detailed calculations relating to ceramics consumption in 1964, the year, iill be found in Annex III, and calculations relating to ceramics ccJ4-

sumptiin during the periods 1964-197O-1975-198O are shown in Annex IV.

resulting figures for requirements in North Africa up to 1980 are as folloi*

T.69-01

-*'■ ■••■■. ■'■ ''v' "■'-'"■ -. . - " :■'■•■ ^ ■."./y- ■- ,■*':.."V'1-,1 -.'.1* • ■■ y v ;*

Page 10

.. J,. ,... . ,,. .._ _ ....

662*4(3) 662.4(4)

662.4(5) 812.2

TABLE 4 ceramics in

..,. 4964-■--

1,340 8,850 13,540 7,200

\

North ;Afrioa

19?© -

3,865 22,475 24,290 12,060

up

- ■ ■

4 29 33 16

to i9&0

1975

,920 ,240 ,420 ,820

... ,

39 47 24

■_. >

■- -■--■

1980 -"-■

,970 ,290 . s.

,170

Total-- 30,930 62,690 84,400 118,050

*^""TT?~^~'~*~—1~~~***"" — — — — — — ————,-——,—1 a—1——t— 1 n r~ irfiir— s _ m ...i

2.

3.

4.

Industry

663.9(1)

663.9(2)

Total

Private consumption 666."4

666.5 666.6

Total _

Total oeramics

.... ..„-.. ...

566 541

1,107

2,880 8,650 990.

12,520.

44,557'

775

720

1,495

3,670 11,295 1,250

16,215

80,400

1,085

932

2,017

4,570 14,320 1,540

20,430

106,847

1,433- ■■■-

1,250

2,683

= * «M == = ^= = = ■==.= «

5,880 .18,550 ...

1,990

26,420

147,153

6^-07

Page 11 I

_ According to Table 4, the growth rates of ceramics consumption

.lows:

1964-1970 10.3 per cent 1970-1975 5*8 Per cent

: 1975-1980 ■ 6*6 P^ cent

1964-1980 7.8 per cent .

, In order to formulate proposals for development of the ceramics.

is necessary for the SITC groups to be divided up into technologic

as

ideations in accordance with Section I, paragraph 2. Tbi«

performed in Annex IV, and the figures- resulting therefrpm may be fo Table 5 below:

TABLE 5 : -

Projection of ceramics consumption according to technological classification up to I98O .>

Pressed ceramics

Molten ceramics

Ceramic stoneware

To k ftl

ce

Lan

:eria 1964 1980

19641980

ooco 1964 1980

Asia "1?64

1980 19641980

19641980

jhrib. 1964 1980 and 1964 Sfcdan 1980 19641980

1,660 6,275 3,711

18,635

3,410 7,740 1,500

6,7,40 2,935

9,280 3,130 7,790 320

565 3,050 8,460 12,436 41,980 3,370 9,025 15,806 51,005

2,360 6-670

1,51P 3,6$fo 2,725

5,300 4j6OO 12r75O 8,780 24,840 7,325 18,050 16,105 42,890

810 2,620 6,931 36,125

1,485 5,085

1,540 3,870 120 268 1,750 5,290 10,816 47,700

1,870 5,558 12,686 53,258

amics

,350

,400

597

B/C1M4/M^^^^

\ *

In order to meet these requirements, only the following factories at present existi

Algeria '■ ;' ■ f *,-* ■:>''"-.i1;1 "

In Algeria, the Rouffak oer'amics enterprise, which produces enamelled setts for wall tiling, using clay burnt red.. Its capacity is. 350,000 sq.m.,

&r approximately 3,500 to 4»000 tons.

In Morocco, there is handicraft production of setts estimated at 500 to W 550 tons' per year. One factory is under construction, with a final capacity of 5,000 tons per year approximately. It will produce pressed,and molten ceramics (setts, tableware and sanitary ceramic ware).

Tunisia

In Tunisia, there is a factory producing ceramic sanitary equipment, such as sinks, wash basins, bidets, etc., but excluding bath-tubs. Its capacity • is 3j000 tons per year. The Bernardo enterprise at Nabeul produoes fine china- ware by handicraft methods, and employs 70 workers. Production may be estim ated at about 500 tons per year. At Tabarka, a factory is under construction with a oapactiy to produce 1,000 tons of hard china tableware per year.

United Arab Republic

In the United Arab Republic, 'there is large-scale production of stoneware, including sanitary appliances, household articles, flags for paving and setts, by three factories,. Production in . 1964 amounted to 9,400 tons. It may be notec1.

that* in producing these Banitary articles in the .United Arab Republic, the melting process id not used, and tor that reason, the products are of a quality that falls short of excellence.

Present capacity in the Sub^-region is as follows:

T.69-07

Algeria, Horoccp funisia

folloue

Page 13/

Arab Repu>lic Total

Setts 4,000 t

550 t 1>5OO t 4J.000 t

Tableware

1,000 tl

500 t 3,000 t

Sanitary ware

4>000 3*000 t 3.000 t 10,000 t

complete breakdown of Ceramic requirements in North Africa is

Required new capacity

Requirements in 1980 Required iIbw c

in 198f>

Capacity in 1964-67

cerrjaics * stoneware stojitjware Algeria

Libya Moroccfa

Tunisii

UAR Sudan

10,000 25,4-00 10,400 6,500

consumption

is, oyerfeupplied.

growth in I98O imately

these figures must be added requirements in electro-porcelain,

amounts to 2,-590' tone per yo^r of ceramic imports. On the assumption that

>n of insulators as oz ether ceramic products,

o ng j,4 times grontur, or in.other

tons per ye'.ar. It inay thus be

J

further expansion of 2,000 tons..per yejj

Page 14"

of a factory to produce electro-porcelain in Worth Africa in I98O, with a capacity of 7,000 tons per y; ar, would bo a reasonable preposition. It would

"be difficult to cover total requirements/ because the estimated quantity of

6,^Q0I tone pet year also1,includes glass, insulators end. a proportion of special

insulators. .~W- -.--. - •-.■■■ , ,

IV. INPUTS

In the manufacture of ceramics the.following are required: olays burnt white, kaolin burnt white, feldspar, pure sand, pure limestone (whore appropri

ate), nephelinic "syenite, plastic clay's, gypsum'arid glazing.

y that, with the exception of kaolin, there are deposits of

.,.$heee raw 'materials in-North Africa,'especially in the Hercynian areas, but

these deposits have not teen adeqmatoly.studied arid no satisfactory information , ..JkS available,..- The queetionr-of-domestic raiTmatarisls does not, however, play an

essential part. .It should bo notad that-,it is never possible to find pure kaolin, as kaolin is always 'contaminated with sand, quarts, micai etc.; and to produce processed kaolin at an acceptable price, a minimum production is required. Nevertheless, it -would be reasonable to extract kaolin in large, quantities, and tc sell the washed and ccncantrzited kaolin tc a number of ceramic factories. With regexd to ths economics of a ceramic factory, it is

■■always- more advantageous to" buy tho raw'materials on the world market rather than on the domestic market, because on the former it is .always...possible- to select the best"quality available cheaply, whereas the choice on the domestic

market depends upon existing deposits. Naturally, for the countries themselves

it is always-beneficial tc use domestic raw materials. As the potentialities of: the North African countries are not known, we shall consider the economics of the ceramics factories on the basis of utilizing imported raw materials, whilst at the same time taking into account the possible use of domestic raw ^materials

whenever-these are known to axist and axe being extracted.

■ Before making ouz- calculations, it is necessary to lay down certain 4>xa«r...

*eauisities. It aay be ^suic&d that fit will prove possible ,to find the basic .';

raw materials, but at_-fche e^e time it must be reckoned that imports of pure

T.69-07

Page 15/

kaolip and of a certain proportion of other raw materials will be requi]

This lieport is divided into two groups: ceramic stoneware and white c<

g porcelain, china and 'vitreous ware.

feramic stSneware

(i)

Ja) The'following products are made from ceramic stoneware: pipii ponduits and guttering (including angles and bends), setts, flags

.paving, and,stoneware for industrial and agricultural uses. It woi Hot be' reasonable to propose the establishment of specialized fact<

*r each of these products; but it would be possible, at this stt propose that factories be established for the manufacture of varioi beramio stoneware products. Proposals regarding the establishment

Specialized factories should be framed on the basis of accurate kno|jj.edge

oncerning the essential prerequisites, such as the properties of aterials and their location, etc.... , ,

(b) In order to meet the requirements for ceramic stoneware in No:

ifrioa up to I98O, on the basis of the foregoing assumptions, we me advance the following proposals:

~ Establishment of five factories producing ceramic stonewaret 01 Morocco, one in Algeria or Tunisia, and one in Libya, each with

capaoity of 8,000 tons per year; and two further factories in Li' each with a capacity of 12,000 tons per year;

A manufacturing programme, having on average the following chara

tics:

14 per cent piping, conduits and guttering;

60 per cent unglazed setts;

25 per cent glazed setts; ,

1 per cent stoneware for industrial and agricultural, usei Energy requirements for manufacture:

Piping, conduits and guttering 80 kWh/t ... 11,20 kflh/t

72

95

setts Glazed setts - -

Industrial stoneware 80

43.20

23,75

0.80

78,95 kW/h/t

in

>ris—

"ft. *

Page 16/

- Productivity relating to various capacities:

capacity 12,000 tons

per year

100 tons per worker

per year 14*00 75 tons per worker

per year 45.00 40 tons per worker

per year 10.00 90 tons per worker

per year 0.90

Average production 69»9O

Piping, conduits and guttering Unglazed;setts

Glazed setts

Industrial stone-

- Fuel requirements*

Piping, conduits ..

and guttering "1,800 kcal/kg ..•

; Unglazed setts 2,000 » Glaaed setts 2,500 ■"

Industrial stoneware 1,800 "

Average production

8,000 tons per year

90 tons per worker per year 12.60 65 tons per worker

per year 39*00 35 tons per worker

per year 8.75 v

80 tohs per worker per year 0.80

61.15

1,

2, 252 200

625 18 095

koal/kg

n n 11

kcal/kg

- Cost of raw materialss

Kaolin $21 per ton

Clay . $14 per ton

Pegmatite (feldspar) $17-20 per ton Nephelinic syenite $17-20 per ton Pure quartz $18-20 per ton Metallic colourant $300 per ton

- Composition and cost of raw materials:

Setts

Quartss- • 10$ at $18 = 1.8 Pegmatite or syenite 30$ at $20 = 6.0 Kaolin or clay 57% at $21 =12.0 Colourant 3# at $300= 9*0

Total $18.8 per ton

Piping and stoneware 10% at $12 s 1.2 20% at $17 <= 3.4 at $14 =9*5 at $300= 6.0

$20.1 per ton T.69-07

■% Page 17 -

Average cost of raw materials:

.- Piping, conduita and.guttering

Unglazed setts Glazed setts

Industrial stoneware

Average cost

»t UO. -■ 2.80 at $29 = 17.40."

25% at $30 -■ "7V50-- 1% at $20 =■ ..0.2Q...

$27*90 p<

The import prices of various products in Europe and:- in West

19eL andinv-North Africa during the period 196O-1965, are shown in

and ere as follows: '

,662 4(3)

,6621.4(4)

662^(5) 663.9(1)

662

Europe

32.5/tons H8.1./tons

$366i6/tons

West Africa

$i66.8/tons

$209.2/tons

$245.0/tons 1,220.4/tons

-ton

during IV

Lea

8117.2/|lns

• 78-i/|ns

$143.5/

$276.0/

The prices proposed for manufactured products, taking into accounj

3s indicated in the;foreign trade statistics are as.follows:

Europe West Africa " North Africaj

117 118

.4(3) 14% at $ 32.5/tons- $4.5/tons at $ 167/tons-$ 23.4/tons

661.4(4) 60%at $1i8.l/tons= $79.9/tons at $ 208/tons-$125-4/tons

66J!.4(5) 25% at $194.0/tonS = $48, 5/tons .at $ 245/tons = $ ^1.3/*ba» it^m

66J.9(1) 1% at $366.6/tons = • 3-7/tons at ^ ,220/tons « $ 12,2/tons JA|T^

ins

the

rAverage price $127*6/tons $222.3/tons

(o| On the basis of these prerequisites, it has been possible to

An»ex V the following results relating to the proposed new factories,

inf dollars per year :

T.B9-O7

$126,0

Page

TABLE 7

Capacity (tons per

Amortization ;" ' '($

Maintenance Interest Insurance and miscellaneous Wages and Salaries Charges, holidays Profits

Raw materials Fuel

Electricity Turnover Value added

Production costs ($

{iij Ceramic*

year)

> pei1 year)

H II

II ' It II II n it it ii

»

per ton)

Morocco

8

31, 26, 1,131,

141.

,000

580 290 230

4

i of porcelain, china

■. :; !

A]

42 21

1,137

142

and

Lgeri

8

246 58 33

17:

164;

16, 313j 223j ,840 ,740 ,940 740, .2 '■

a-Tunisia

,000

,000 ,240 ■■■

,600

,920 ,000 ,400 ,600 ,200

44,869 22,880 1,141,100 400 142.6

vitreous ware

. ■;., Libya .8

16, 25, 1,124,

140.

>000

r040

,280 ,680

6

;

; 2 X

792 187 108

57-

"422j Libya

12,00c

,000 ,200 ,000

^600 .500 42,200 1,008,

669, 77, .. 75, 3,440, 2,264.

143.

,000 600

640 750 700 6

(a)- These ceramics inolude the.whole range of the following products:

gl»aed and unglazed setts (?.n white porous ceramics), tableware and pottery

oeramics for sanitary purposes^ ornamental and artistic ceramioa, oeramict

for industrial uses and ceramic containers. For the moment, we must

assume a programme of manufacture for each factory consonant with the

level'of consumption for these products, without envisaging any special

ization by factories. But such specialization must be envisaged in the future, and it is also legitmate to hope that production by craftsmen and artists will ensue, as occurs in other countries that have a tradi"tio» of T.69-07

e/cn. h/inr;/wpj

Page 19

manufacturing these products. Factories manufaoture a certain pn of ceramics unvarnished (biscuit ceramics) and sell them to handii certres where they are decorated, painted and glazed. In.this re;

must take into account the combined manufacture of various produc the somewhat more complicated equipment employed in the epecializi factories and with higher rates of unitary investment,

(b) At present, in view of the fact that the requisite conditioi

not yet well-known, it is possible to proposes

- Establishment of eight factories produoing white ceramics:

one in Morocoo, one in Algeria and one in the United^ Arab Republic, each with a capacity of 10,000 tons per yearj of

two in Libya, each with afcapacity of 12,500 tons pe.r year;

and one in the United Arab Republic, one in Tunisia and one in Sudan, each having a capacity of 7>000 tons per year;- - ., Establishment of a factory produoing electro-porcelain, with

a capacity of 5,000 tons per year;

According tc Annex IV the percentages of products and their

are as follows:

are

662.4(4) 7,170 tons per year = 662.4(5) 28,660 v " » » 812.2 15,700 " » "

663.9(1) 145

663.9(2) 1,250 666.4 5?880 666.5

666.6

Selling price in Europi |

11,890 1,990

at $ 118 per ton .

at $ 194 ■•■ » # at $ 370 " " .

* 7'SI7

1

8%2%

16%3%

at Z 366 at % 875 at $ 790

T.69-G7

at $1,327 Average production

In North Afrioa, we must reckon with average production costs

between $350 and $400 per ton for fine ceramics.

8

Page 20

- Requirements .in kffh and fuel

662.4 i«0 kWh/ton'« 49.0 kWh

663.9 130 666 120 812.2 110

2.6 32.4

24.2 Average production 108.2 ktfh

2,800 kcal/kg.

3,300 « 3,800 »

t- ■

3,400 «

1,372 kcal 66 "

1,026 » 748 "

3,212 kcal/kg 0.34 tons per tor

fuel oil

- Produ0tivit.v Capacity;

662.

663.

666 812.

.4 ..

.9

,2

7,

42 5 19 34

000

t/p

It tl II

tons per year

.a. 20.6 0.1 5.1 7. "5 Average production 33.3

10,

t t t . t

t/p.

OOf

45 5 21 36

a.

tone per year

t/p, a.

1!

n 11

22.1 0.1 5.7 7.9 35-8 t/p

1

• a*

,500

47 5 23 38

tons per year

t/p.a.

it n 11

. 23.0 0.1 6.2 8.4 37-7

- Composition and cost of raw materials 10$ at $20 per ton Pegmatite (feldspar) 30$ at 828 ".

Kaolin at $60 n

Average production

+ 6$ glaze at $330 per ton 10$ gypsum at ^40 per ton

7$ fire clay at $100 per tonJJ7.00

Average production $75.40 *er ton

$s.

$36.

$46.

|18.

$ 4.

, s 7.

00 40 00

40 per ton 00

00 00

e/cn.14/ine/wi

Page 21

%■ The cost uf fuel vs'xies vor^ widely as bet-ween the African countries. The w>.>rld price uf fuel oil; is appr

ton' and the 'cost of natural gas about 43 to V5 Por 1)000 ju.m. At preBcnt time, fuel ,-il is being used in Tunisia at a cc»pt o-f 326.7 ten -which is' approximately double the uorld price. In these^ caloul|||t

Ibe

er

ve are reckoning n the fallowing fuel o-jsts, base><! c*n national staj^stixs1

Algeria'

** Libya Tunisia

: Sudan

: In future, it must be anticipated th^t costs will be lower, n,

:i8.

v15.

26.

18.

5 8

i P«l*

It ir it

M

t.

M 11

II II

exceeding to ^16 p^r i&n. The Cw-sts of i r.ity1 was

the United Nations documorit "Report .1 bue Industrial Mission to Al

4

Libya, Muirocoo and Tunisia", in the cse .x consumers with a roaxinn|| coiv

■ i

sumption of some 40 MHh,.as fallows:

! I

Algeria Morocco Tunisia Liliya Sudan

17.20 centimes .Kiyi 20.80 "

18.10 " "

or ,,,34.4

^41 • 6

^36.2 ).O i.O

(c) 4«. tha:-h«*ia of th,.Se

at the folio-wing results in ^{Pox- y.,arB as} in Annex Y.

table 8

Proposed new factories in'* North Africa for the production of fine ceramics

Capacity tens Amortization Maintenance Interest Insurance" and Miscellaneous Wages and Salaries Charges, Holidays Profits

Raw materials Fuel

Sleotricity Turnover Value added.

Unit price

1

per ii

»

tt

11

.,

u

'■»

n

ii ti it per

year

it

»

it

it

it

ti it ii ti

it

» 3

» ton

■ .».

Algeria

10,

'-'

86, 3;7,

,231, 660

663 .. 252 , 90

60

353 ,000 ,000 ,000

,000

,560

35,400 900

■■ 754

700 220 860

J,951 323

,000 ,000

3,

»9«

Morocco

10,

63 45 216

000

920 010

Q99

322

2 1

2 1

7 4

Lifcya

x 1

,635

621 222

148

826

' 82 ,220

,885

131 108 ,680 ,764

^,500 ,400 ,600 ,000

,000

,000

,60«

,000 ,000

,750 ,240 ,590 ,oco 325

Tunisia

7

63 27 2,350

,ooe

,550

r4«°

,750 1 335

486,200 184,800 66,000

44,000

264,500

26,500 660,000 527,800

2 437,200

Sudan

7

43

37

,350 ,000

",32c ,85*

,970

334

Unite* ftrab Reputlio

10,000 +

1,149 436 156

104 618

61 1,560 1,281

«4 }6 5,508 3,389

7,000 ,200 ,800 ,000

,000

,100'

,900

*000 ,800

,040 ,d«o ,640 ,206

■

E/.CN. H/IKR/HP/3

Page 23

V. MARY

U this report, the market for ceramics, and ceramics consumption, in North prican countries have been considered, and ceramics consumption up

1980 hks been estimated in accordance with a method based on the growth o:|

construction, industry in general and private consumption. Future cerami^

consumption will Justify proposals to construct new factories. Calculations

relating to turuover indicate that the proposed factories would be viable,

that i4 would be possible to establish ceramics production on a national to satisfy the i"uture requirements of. th.e North African countries. Indee^,

may ev^n Tie anticipated that they will export ceramic products.

«♦

Tie new factories proposed aro as followsj

Algeris

Morocco

Tunisia

United Arab

Republic Sudan

The

jns 5

One' factory producing white ceramics, with a capacity of 10,000

per year; '

One factory producing ceramic stoneware with a-capacity of 8,000 |fc per yoar;. tw.o factories with a -capacity of 12,000 tons per year ej

and two factories producing white ceramics, with a capacity of 12^00

tons per y..ar each| : I,

One. factory producing ceramic stoneware, with a capacity: of 8,000|;*ons per year, and one factory producing white ceramics, with a oapaoifi of

10,000 tons per yoar; j

!■

One factory producing ceramic stoneware, vith a capacity of 6,000 I;

per year, and one factory producing white ceramics, with a 7)000 tons per year.

One factory .producing white ceramics, with a capacity of 7,000 tcjljs

per year, and another with a capacity of 10,0Q0 tons per year;

One factory producing white ceramics, with a capacity of 7,Qi0 tcnjfi

per year, ;

and

it

aggregated figures, in the form uf operating accounts of these facj ies, wilH be found in Table 9 below;

TA3LE 9

Operating aoocunts of the ceramics factories proposed, fur North Africa in Ig80

Capacity in tons;

Stoneware White ceramics Amortization '31000 Maintenance "

Interest "

Insurance and

Miscellaneous "

llages and Salaries"

Charge s,holidays "

Profits

R^-w materials Fuel

Electricity Turnover"

Value added

10,000 663,0 252.0 90.0

60.0 353.6 35-4 900.0 754-0

.86.7

37.2 3,231.9 1,952.0

32,000 25,too 2,673.8

867-0 363.6

223.5 1,412.5

141.2

'3,541.6 2,777.8

235.6 209.3 12,445-9 7,769.1

8,000 10,000 909.4 310.2 1*3.6

77.9 517.6 51.8 1,213.6 977-2

95.5 71.3 4,348.1 2,692.4

8,000 7,000 732.6 243.0 99.6

61". 9' 428.5

42.9 973.6 751.0 108.5 49.8 3/491-4 2,177.6

17,000 1,149-2 436^8 156.0

104.0 61b.0

61.9

1,560.0 1,281.8 104.0 36.8 5,508.5 3,309-1

7,000 486.2 184.8 66.0

44.O

264.5 26.5

660.0

527.8- 43.3 37.9

2,341.0 1,437.2

UAR ■ Eleotro- p or eel air.

7,000 486.2 164.8 66.0

44.O 264.5 26.5

660.0 650.0 45.0 39.0

1?437.2

Sub- region

48,000 76,000 6,613-2 2,293.8 898.8

*?■

(I) 662.4(3)

1960 . 1961

1962 1963 . -1964 1965 (II) 662.4(4)

1960 1961 1962 1963 1964 1965

(III) 662.4(5) . 1 "960

1*961

. 1962

1963 1964 1965

tons Piping, conduits

■■ ■■■ 47 ■

52 50

Unglazed setts.

2,204

735

520

Consumptio-n of

Iberia

V

ceramics Libya tons and guttering

5,031

1,760 3,396

flags and

274,278

1.10,855

288 2,149

paving,

5,-939 9,818

45,189 246,537

in North Africa Morocco tone

4 3

■5 7

hear til and wall

337,921 461,401

Glazed setts, flags and paving, hearth and

3,817

1,345

920

566,771.

202,114

3,263 4,607

393,268

418,074

482 493

-

920 59.0 516

341 1,032 138 3,824 976

42

tiles

48,401 45,2.52 .

12 114,922 .70,749

77,789 . wall tiles

1,851

2,253 . 2,263 2,307 3,236 2,795

269,691 290,045 356,502 312,605 501,422 449,870

2 2 3 3 3 3

tons

51 37

20

-

57.

56

187 151 63 10a 331 446

,277 ,748 ,050

,605 ,660 ,289

o-sia

4,369 2,607 1,498 71 5,467 6,519

30,584 29,077 13,072

36,655 ;

53>G77.

85,645 .

321,482 410,474 451,416

538,294 551,763 516,845

Su tons

21

7

548 364 235

1,783 919

i

A

98,103 73,7H 38,884

(VI)

AMEX I (Contd)

Consumption of ceramics in Nnrth Africa

Algeria tone

Litya tons

Morocco

tons $

Tunisia tons

(IV) 812.2

1960 1961 1962 1963 1964 1965

Sinks, wash "basins, bidets, water closet pans, urinals, "baths and like sanitary fittings

4,233 82,503

979

1,333

747 780

188,500

1,086 1,685

464,134

561,711

1,502 1,402

1,182

230,850 272,198 253,110

374,671 391,718 379,475

513 702 733 1,065 740

855

(v) 663.9(1) Laboratory, chemical or industrial wares of ceramic materials

1960 1961 1962 1963 19*4 1965

110 37,566

80 12,359 ^2>526

663.9(2) Other articles of ceramic materials

1960 1961 1962 1963 1964 1965

210 . 4,198

369 65,423

1,862 3,268

6 5 16 19 5 81

12 11 3 6

5

4,701 3,832 8,404 7,655 4,355 18,509

9,065 7,560 4,049 5,630 6,313

1 12 21 1

235 7

25 234 4©

64 58

73

122,262 169,632 186,566 319,235 231,488 287,283

1,351 5,926 5,538 1,426 46,721

9,777

Sudan tons

507 221,133

418 165,358

211 86,211

4 6

3,931 6,-220

#

(VII) 666.4

196O 1961 1962 1963 1964 -1965

(VIII) 666.5

196O 1961 1962 1963 1964 1965

(IX) 666.6

1960 1961 1962 1963 1965

Consumption of ceramics in Hprth Africa

Algeria Libya Morocco

*OHB m V •0118 ■ ~~9 •'JJJW v

Tableware and other articles for domestic or toilet purposes of porcelain or china

33 78,751

634 637,287 178 138,814

251 203,283

630 649,501 305 232,842

147 96,482 " 648 329,581

266 161,370 362 175,574

Tableware aad other articles for domestic or toilet purposes of other kinds of pottery

' 1,535 453,311

2,932 1,228,597 1.253 319,823

1,101 248,933

3,422 917,545 1>13° 268,035

467 154,190 1,218 309,552

362 94,730 928 273,273

Statuettes and other ornaments and articles of personal adornments articles of furniture

33 78,751

148 190,580 28 43,097

16 28,067

98 88,139 24 36,908

. -...-.-.-.._■: %6 jMj&_-_.- ;-;.::iz- _4-_-_-_-_-j^g2:^::.

41 46,446 6,627

4 •

Tunisia

21 125 139 139 304 357

296 687 854 853 465

1,001

21

15 14 7 10 2

i

33, 112,

135, 142, 190, 158,

156,

122, 142, 157,

85,

50,

33 23 22 26

17 8

153 595 552 476 871 237

888 209 616 547 511

290

153 541 ,388

,849 i413 ,539

*

Sudan -tnna . £

788 372,5C-7 1,412 505,261 1,642 733,958

300 453,090 3 5,025

2,500 769*330™*

(Contd)

Imports of ceramics into North Africa

(I) 662,4(3)

■ 1961 1960 1963 1962 1964 1965

(II) 662.4(4)

1960

1961

1962 1963 1964 I965

(III) 662.4(5)

1961

1960

1963

1962

!965 1964

tons-

Piping, conduits and guttering

47 5,031

52 1,821

288 45,189 2,149 246,537

4 ' 341 3 1,032

. 138

5 3,824

7 976

. 42

Unglazed setts^ flags and paving, hearth and wall tile

2,204 274,278

110,855

5,939 337,921 9,818 461,401

482 48,687

495 50^

••• 12

920 114,922

590 70,749 516 77,769 Glazed setts, flags and paving, hearth and wall tiles

3,818 566?9O1

1,205 172,577

3,263^.393,268

418'074

270,882 2,255 296,961 2,799 379,023 2,503 368,743 3,278-503,465 ill?7i59Jr459

tons

51 37

2t

57 56

4,569 2,6O7 1,498

5,467

6,919

187 30,584

64 110 331 447

13,496 37,353 53,953 66,135

UAR tons

2,278 -322,161 2,748 410,615 3,050 451,583 3,605 538,992 3,662 553,475

3,290 517,792

152 497 1,525

359 296 66 2

54,009 44,381

8,383 282

2,840 398,142 2,217 275,251 709 119,957 1,877 142,262

Sudan tons

21

7

1,783 919

.548 98,103 364 73,711

AMTEX I (Contd)

(VI)

Algeria tons

Morocco Tunisia

4 tons £

812.2 Sinks, wash basins, bidets, water closet pans, urinals,

"baths and like sanitary fittings 1960

1961

tons

1963 1964 1965

4,235 83,218

752 19O?637

979 . . . 1,333 1,153

: 1,502

1,086 464,134- 1,402 1,685 561,711 1,182

230,850 513 272,198 :■ 702 253,11t 733- 374,671 1,065 391,718 740 379,475 855 (v) 663.9(1) Laboratory, chemical or industrial wares of ceramic materials

1960 1961 '1962 1963 1964 1965

1.10 3.7,564*.-.

80 12,359 2,526

(VI) 663.9(2) Other articles of ceramic materials 1960'

1961

1963 1964 1965

240- : 4,198- 372 . 66,086

35,526 20,488 7,488

1 3,268

6

■5 16 19 5 81

13 12 3 7 S

2

5,653 3,913 8,404

' 7,655

4,355 18,509

10,160

8,171

4,286 5,938 2,575

1 12 21 1 254 7

4 234 27 16 v13 4

122,262

159,639 186,566 319,235 231,768

287,283

1,331 5,926 6,636

'i,426

47,022 9,870

3,272

148,396 22,043 13,072

5,890 5,286

tons

1,566 684,506 552 247,477 154 68,740 340 147,062 507

418 211

59 28,545 42 . .1.6,645

1 59 37 4

546 7,084 14,489

7,016

221,133 16^,358 86,211

6,220