Detailed Project Report (DPR) on Colour and Additives Master Batches

COLOUR AND ADDITIVES MASTER BATCHES

[EIRI/EDPR/1616] J.C.: 417INR, 417US$

INTRODUCTION

As the name Suggests the predispersed colors or color concentrates contain a high ropertion (20-50% or even more) of pigment by weight uniformly dispersed in a suitable carrier resin. The carrier resin may be a liquid or solid. In the former case the product is a liquid dispersion while in the latter case the product is known as solid predispered colour.  Liquid dispersions may be available as low viscosity materials for plastisols, or high viscosity pastes for thermoplastics. Solid concentrates in the form of powders they are suitable for use in powder resins. These concentrates are usually marketed for specific or a group of related  plastics. Some so called universal dispersions are also available in the market.

The carrier resin is selected upon the type of polymer to be processed.   Concentrates,  when added to the base  polymer  (let down resin) in specified proportion, give the desired quantity of the  colour in the finished product for the  desired  application the  simplest  example is that of carbon  black  masterbatch  for polyethene.   A concentrate containing 25% carbon black in a suitable grade of polyethene is formulated.  This when added in 10% proportion (10 parts of concentrate + 90 parts of natural PE)gives 2.5% carbon black in the finished product eg.  polytheylene film.  The carrier may generally be a mixture of one or  more polymers  with one or more surfactants.  The carrier is usually other than the plastic to be coloured.  Low melting polyamides have excellent pigment dispersion characteristics and hence are suitable for the job as a carrier.  Ethylene vinyl acetate and LDPE are often used as dispersion media in predispersed colouts which  are to be used for define resins due  to  their  better dispersion  properties,  capacity for high pigment  loadings  and compatibility with a variety of other resins.  For solution vinyl coatings a co-polymer resin is frequently used which  provided high shear.

Polymer granulates with a high percentage of additives, higher than in the end use, are called masterbatch. In later production steps, such as injection moulding, film or fibre production, those granulates are mixed with the raw polymer for colouring or the targeted modification of certain properties.

Advantages: In comparison to pastes, powders or fluid additives, using masterbatch increases the process stability. The reason lies in the exactly defined pigment quantity in each granulate. Additionally: Since there is no handling of large powder masses and therefore the environment and the work station are not being polluted, masterbatch is regarded to be a very good processing material.

COST ESTIMATION

Plant Capacity                                       4.00 Ton/Day                   
 Land & Building (1500 Sq.Mtr)                 Rs. 2.12 Cr
Plant & Machinery                                    Rs.55.00  Lacs         
W.C. for 3 Months                                     Rs.2.76 Cr       
Total Capital Investment                            Rs. 5.53  Cr             
Rate of Return                                                37%  
Break Even Point                                           40%

CONTENTS

INTRODUCTION

USES AND APPLICATIONS

PROPERTIES

COMPATIBILITY OF COLOUR CONCENTRATES

TESTING OF PIGMENT DISPERSIONS

SELECTION OF COLOURANTS

FACTORS WHICH AFFECT SELECTION OF COLOURANT

B.I.S. SPECIFICATIONS

RAW MATERIALS

COLOURANTS FOR POLYETHYLENE:-

INORGANIC PIGMENTS:-

INORGANIC PIGMENTS SUITABLE FOR POLYETHYLENE ARE GIVEN IN THE FOLLOWING LIST:

ORGANIC COLORANTS

COLOURANTS FOR VINYL PLASTICS

FLEXIBLE PVC

INORGANIC COLORANTS

ORGANIC PIGMENTS

RIGID PVC

SOME IMPORTANT ORGANIC PIGMENTS SUITABLE FOR RIGID PVC ARE GIVEN BELOW:

COLOURANTS FOR ABS

SELECTION OF COLORANTS

INORGANIC PIGMENTS

ORGANIC COLORANTS

COLOURANTS FOR NYLON

COMPOUNDING & PROCESSING CONSIDERATIONS

INORGANIC PIGMENTS

ORGANIC COLORANTS

COLORANTS FOR POLYPROPYLENE

COLORANTS

IMPORTANT ORGANIC PIGMENTS SUITABLE FOR  POLYPROPYLENE  ARE GIVEN BELOW:

COLOUR COMPOUNDING PROCESSING & EQUIPMENT

DISPERSION OF PIGMENTS & COMPOUNDING EQUIPMENTS

(I) COLOR DRY BLEND

(II) PIGMENT PLSDYIVIDER PASTE

(III) COMPOUNDED COLORS

(IV) PIGMENT CONCENTRATES

METHODS OF PIGMENT DISPERSION

THERE ARE THREE BASIC DISPERSION PROCESSES FOR PIGMENT PLASTIC SYSTEMS:

DRY BLEND DISPERSION

MELT SHEAR DISPERSION

LIQUID DISPERSION

COMPOUNDING EQUIPMENTS

DRY BLENDING

CONTINUOUS MIXERS

MILLING MACHINES & INTERNAL INTENSIVE MIXERS

ROLL-MILLS

EXTRUDERS

SINGLE SCREW EXTRUDERS

COMPOUND-EXTRUDER

TWIN-SCREW EXTRUDER

INJECTION MOLDING MACHINE

ON THE MACHINE COMPOUNDING

MARKET POSITION OF MASTERBATCHES

HOW BIG IS THE MASTERBATCH MARKET IN INDIA ?

EXPORTS GREW BY 35% FOR THE YEAR.

MASTERBATCH MAKERS EXPANDING IN INDIA

GROWTH AND PROSPECT OF PLASTIC INDUSTRY IN INDIA

INDUSTRIAL POLICY

STRUCTURE OF PLASTIC INDUSTRY

GROWTH PROSPECTS – 2014-2015

EMPLOYMENT GENERATION POTENTIAL

PROFILE OF PLASTIC RECYCLING INDUSTRY IN INDIA

STATUS OF POLYMER (PLASTIC) INDUSTRY

POLYMERS (PLASTIC) DEMAND GROWTH IN INDIA

PRESENT MANUFACTURERS/SUPPLIERS OF COLOUR MASTER BATCHES

ANTISTATIC MASTERBATCHES

USES & DOSAGE:

FEATURES;

PACKING & STORAGE;

BENEFITS OF MASTERBATCHES

THE BENEFITS CAN BE SUMMARIZED AS FOLLOWS:

TYPES OF MASTERBATCHES

GENERAL FORMULATION OF MASTERBATCHES

FORMULATIONS

PLASTIC FILLER GRANULES (PP):-

FORMULATION - 1

FORMULATION - 2

1) FORMULATION

COLOURED MASTERBATCH FOR LDPE

1) FORMULATION

COLOUR MASTERBATCH FOR PVC

1) FORMULATION

COLOUR MASTERBATCH FOR PVC

1) FORMULATION

COLOUR MASTER BATCH FOR POLYPROPYLENE

1) FORMULATION

MASTER BATCH FOR ABS

1) FORMULATION

EVA BASED MASTERBATCH

BLACK MASTERBATCH FOR EPDM

PVC GRADE MASTERBATCHES FOR RIGID APPLICATION

PVC GRADE MASTERBATCHES FOR FLEXIBLE APPLICATION

COLOUR  MASTERBATCHES FOR LLDPE

FORMULA-1

FORMULA-2

HDPE BASED MASTERBATCHES

FORMULATION OF ADDITIVE MASTERBATCHES (UV MASTERBATCH)

FORMULA-1

FORMULATION OF COLOUR MASTERBATCH FOR PVC USED IN WIRE & CABLE INDUSTRIES

FORMULATION OF COLOUR MASTERBATCH FOR PVC WIRE & CABLE (EVA GRADE)

PROCESS OF MANUFACTURE

EXTRUDING & GRANULATION

MIXING AND COMPUNDING METHOD OF MASTERBATCHES

CARRIER MATERIAL

LET DOWN RATIO

DISPERSION

PROCESSING

METHODS OF PRODUCING MASTERBATCHES

DISPERSIVE & DISTRIBUTIVE MIXING

SINGLE-STAGE PROCESS

TWO-STAGE PROCESS

PLASTIC TRANSPARENT GRANULES

FOR SHOE LIGHTING SYSTEMS

RAW MATERIALS:-

PLASTICIZER:-

SOLVENTS:-

AROMATICS:-

HIGHER ALCOHOLS:-

CHLORINATED HYDROCARBONS:-

LUBRICANTS:-

COMPOUNDING FORMULATION:-

ANTISTATIC AGENTS:-

GENERAL GUIDELINES FOR INJECTION MOULDING OF SAN

THE GENERAL GUIDELINES ARE :

PROCESS OF COMPOUNDING:-

STEPS:-

MANUFACTURING DIAGRAM

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

TALC

DIOCTYL PHTHALATE

ANTIOXIDANT

POLYPROPYLENE

CALCIUM CARBONATE

ZINC OXIDE

SUPPLIERES OF PLANT AND MACHINERY

EXTRUDER

PLASTIC MIXER

PELLETIZER

SCRAP GRINDER

AIR BLOWERS

WEIGHING MACHINES

FILLING MACHINE

LABORATORY TESTING EQUIPMENTS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)