Industry Overview
Polyester resins are unsaturated synthetic resins produced through the reaction of dibasic organic acids with polyhydric alcohols. Common raw materials include maleic anhydride, phthalic acid, isophthalic acid and glycols such as ethylene glycol. Water formed during esterification is continuously removed to drive the reaction toward completion. The resulting polyester is commonly dissolved in styrene, which reduces viscosity and enables cross-linking during curing.
Unsaturated polyester resins are thermosetting materials that cure through a free-radical polymerization mechanism, generally using organic peroxide initiators such as benzoyl peroxide or methyl ethyl ketone peroxide. Accelerators may also be used to achieve practical curing rates at workshop temperatures. Excessive initiator or catalyst levels can cause excessive heat generation, charring, ignition, product fracture or undesirable rubbery characteristics.
Polyester resins are widely used in composite applications, including sheet moulding compound, bulk moulding compound, fiberglass-reinforced plastic products, marine structures, washable wall panels and cured-in-place pipe systems. They are also used in polyester concrete overlays for roads and bridges. Orthophthalic polyester resin is generally regarded as an economical standard laminating resin, while isophthalic polyester resin offers improved water resistance and is preferred in applications such as marine composites. Different resin systems can be formulated using various acids, glycols, monomers and additives to achieve specific performance characteristics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (4000 sq.mt.) | Rs. 16.21 Cr |
| Plant & Machinery | Rs. 1.41 Cr |
| Working Capital for 1 Month | Rs. 4.55 Cr |
| Total Capital Investment | Rs. 22.36 Cr |
| Rate of Return | 24% |
| Break Even Point | 47% |
Content Index
- INTRODUCTION
- RAW MATERIAL
- COMPONENTS OF POLYESTER RESINS
- TYPES OF POLYESTER RESINS
- SATURATED POLYESTER RESIN
- UNSATURATED POLYESTER RESIN
- FIRE RESISTANT POLYESTER RESIN
- ELECTRICAL RESISTANT POLYESTER RESIN
- LOW STYRENE EMISSION POLYESTER RESIN
- ISOPHTHALIC POLYESTER RESINS FOR FIBERGLASS FABRICATIONS
- THE DIFFERENT POLYESTER RESINS
- CHARACTERISTICS AND BENEFITS OF POLYESTER RESIN
- PERFORMANCE CHARACTERISTICS
- SUGGESTED USE
- RECOMENDED CATALYST
- TYPICAL LIQUID RESIN PROPERTIES
- TYPICAL CAST UNFILLED RESIN PROPERTIES
- ADVANTAGE OF POLYESTER RESIN
- POLYESTER RESIN OFFERS THE FOLLOWING ADVANTAGES:
- PROPERTIES OF ISOPHTHALIC POLYESTER RESIN AND ORTHOPHTHALIC POLYESTER RESIN
- PROPERTIES AND USES
- A. FORMULATION DEPENDENT PROPERTIES
- B. REACTION DEPENDENT PROPERTIES
- CHARACTERISTIC OF JET UNDER THE CONDITIONS OF CURE: CURED RESIN PROPERTIES:
- PHYSICAL PROPERTIES OF CURED RESIN:
- ELECTRICAL PROPERTIES OF CURED RESIN:
- B.I.S. SPECIFICATIONS
- MARKET OVERVIEW OF UNSATURATED POLYESTER RESIN
- WORLD CONSUMPTION OF UNSATURATED POLYESTER RESINS - 2018
- GLOBAL UNSATURATED POLYESTER RESIN MARKET SHARE, BY END USE, 2019 (%)
- GLOBAL UNSATURATED POLYESTER RESINS: MARKET TAXONOMY
- BY PRODUCT TYPE
- BY END-USER INDUSTRY
- CONSUMPTION OF UNSATURATED POLYESTER RESIN
- TOP FIVE EXPORT DESTINATIONS OF UNSATURATED POLYESTER RESIN
- UNSATURATED POLYESTER RESIN
- MANUFACTURING PROCESS OF UNSATURATED POLYESTER RESIN
- REACTION
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF UNSATURATED POLYESTER RESIN (USING POLYETHYLENE TEREPHTHALATE AS MAIN RAW MATERIAL)
- PROCESS FLOW DIAGRAM
- PROCESS IN DETAILS
- PROCESS DETAILS
- BLENDING OPERATION:
- PACKAGING:
- CHEMISTRY OF UNSATURATED POLYESTER RESIN
- TECHNICAL DETAILS OF UNSATURATED POLYESTER RESIN MANUFACTURE
- REACTION MECHANISM
- THE CURING OF UNSATURATED POLYESTER RESINS
- MONOMERS
- THE POLYMERISATION PROCESS
- FIG.: STRUCTURE OF METHYL ETHYL KETONE PEROXIDE
- SYNTHESIS OF ISOPHTHALATE UPR
- FORMULATION OF ISOPHTHALATE UPR
- POLYESTER RESIN (FOR REINFORCED PLASTICS) G. P. GRADE
- FORMULATION:-
- PROPERTIES OF (REINFORCED GRADE POLYESTER RESIN)
- POLYESTER RESIN (LAMINATE GRADE):-
- FORMULATION - 1
- PROCESS OF MANUFACTURING OF POLYESTER RESIN (LAMINATE GRADE)
- POLYESTER VARNISH PREPARATION:-
- MANUFACTURING PROCESS OF POLYESTER RESIN (ELECTRICAL GRADE)
- POLYESTER G:-
- POLYESTER VARISH:-
- UNSATURATED POLYESTER RESINS
- RAW MATERIALS
- USING PHTHALIC ANHYDRIDE AS A MAIN RAW MATERIAL
- USING POLYETHYLENE TEREPHTHALATE AS A MAIN RAW MATERIAL
- TECHNICAL DATA SHEET OF ORTHOPHTHALIC POLYESTER RESIN
- PHYSICAL PROPERTIES:
- APPLICATION:
- PACKING AND SHELF-LIFE:
- SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)
- SUPPLIERS OF RAW MATERIALS (GLOBAL)
- SUPPLIERS OF COMPLETE PLANT AND EQUIPMENTS FOR UNSATURATED POLYESTER RESINS
- SUPPLIERS OF REACTORS
- SUPPLIERS OF MIXERS
- SUPPLIERS OF STORAGE TANK/ REACTION VESSELS
- SUPPLIERS OF BOILER
- SUPPLIERS OF LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF POLYPROPYLENE GLYCOL
- SUPPLIERS OF PHTHALIC ANHYDRIDE
- SUPPLIERS OF MALEIC ANHYDRIDE
- SUPPLIERS OF POLYETHYLENE GLYCOL
- SUPPLIERS OF STYRENE MONOMER
- SUPPLIERS OF ANTIFOAMING AGENTS
- SUPPLIERS OF STABILIZERS
- PLANT LAYOUT
Appendix
- 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)
Frequently Asked Questions
Unsaturated polyester resin is a thermosetting resin formed by reacting polyhydric alcohols with saturated or unsaturated dibasic acids. The resulting polyester is commonly dissolved in a reactive monomer such as styrene, which lowers viscosity and participates in cross-linking during curing. The resin changes from a liquid or soluble state into a hard, chemically resistant solid through polymerization. Its formulation can be modified with different acids, glycols, monomers, pigments, fillers and other additives to obtain properties suitable for specific composite and industrial applications.
Polyester resin manufacture commonly uses polyols and dibasic organic acids as the principal raw materials. Glycols such as ethylene glycol and acids or anhydrides such as phthalic acid, isophthalic acid and maleic anhydride can be used depending on the desired resin formulation. Styrene is frequently used as the reactive monomer to reduce viscosity and facilitate cross-linking. Other formulation components can include initiators, accelerators, inhibitors, thixotropic agents, pigments, fillers and additives for chemical or fire resistance.
Unsaturated polyester resin is cured through free-radical polymerization and cross-linking of the polyester chains. An organic peroxide initiator generates free radicals that react with unsaturated sites in the resin and reactive monomer, commonly styrene. The reaction links the molecular chains into a three-dimensional network and converts the resin into a solid thermoset material. Accelerators may be incorporated or added to promote curing at practical workshop temperatures. Because curing is exothermic, initiator levels and processing conditions must be properly controlled.
Orthophthalic and isophthalic polyester resins differ primarily in their acid component and resulting performance characteristics. Orthophthalic polyester resin is commonly used as an economical standard laminating resin for general composite applications. Isophthalic polyester resin generally provides improved water resistance and is therefore preferred in applications where resistance to moisture and demanding environmental conditions is important, including marine composites. The appropriate grade depends on the required mechanical, chemical, water-resistance and processing characteristics of the finished product.
Polyester resins are widely used in composite and molded products across several industries. Applications described in the report include sheet moulding compound, bulk moulding compound, fiberglass-reinforced plastic wall panels, marine structures and cured-in-place pipe systems. They can also be used in polyester concrete overlays for roads and bridges. Polyester resins are particularly important in composite fabrication because they can be formulated for different performance requirements and cured without the high pressures required by some other molding systems.
Common polyester resin additives include catalysts or initiators, accelerators, thixotropic agents, pigments, fillers and additives for chemical or fire resistance. Inhibitors may also be incorporated during resin manufacture to slow spontaneous gelling and extend storage life. The resin may be supplied in a basic form or with selected additives already incorporated. Formulation depends on the intended molding process and the required properties of the finished composite, while catalyst and accelerator selection influences curing behavior and processing time.
Styrene is used in unsaturated polyester resin both to reduce viscosity and to participate in the cross-linking process during curing. The lower viscosity makes the resin easier to handle and process, while styrene reacts with the unsaturated sites in the polyester chains to form a three-dimensional polymer network. This allows the initially liquid resin to become a solid without generating a conventional reaction by-product during cross-linking. The report notes that styrene can be present at levels up to 50%, depending on the formulation and application.
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