Calcium Carbonate Based Masterbatch (Filler) (Capacity: 38 MT/Day)

CALCIUM CARBONATE BASED MASTERBATCH (FILLER) 

[EIRI/EDPR/4526] J.C.: 2743XL

INTRODUCTION

Calcium carbonate, CaCO3, is one of the most common compounds on Earth, making up about 7% of Earth’s crust. It occurs in a wide variety of mineral forms, including limestone, marble, travertine, and chalk. Calcium carbonate also occurs combined with magnesium as the mineral dolomite, CaMg (CO3)2. Stalactites and stalagmites in caves are made of calcium carbonate, as are a variety of animal products, notably coral, seashells, eggshells, and pearls.

Calcium carbonate has two major crystalline forms—two different geometric arrangements of the calcium ions and carbonate ions that make up the compound—aragonite and calcite. All calcium carbonate minerals are conglomerations of various-sized crystals of these two forms, packed together in different ways and containing various impurities. The large, transparent crystals known as Iceland spar, however, are pure calcite.

In its pure form, calcium carbonate is a white powder with a specific gravity of 2.71 in the calcite form or 2.93 in the aragonite form. When heated, it decomposes into calcium oxide (CaO) and carbon dioxide gas (CO2). It also reacts vigorously with acids to release a froth of carbon dioxide bubbles. 

Calcium carbonate deposits can be formed in seawater when calcium ions dissolved from other minerals react with dissolved carbon dioxide (carbonic acid, H2 CO3). The resulting calcium carbonate is insoluble in water and sinks to the bottom.

Most of the calcium carbonate deposits found today were formed by sea creatures millions of years ago when oceans covered much of what is now land. They manufactured shells and skeletons of calcium carbonate using the calcium ions and carbon dioxide in the oceans, just as clams, oysters, and corals do today. When these animals died, their shells settled on the sea floor. Now, long after the seas have gone, they have been compressed into thick deposits of limestone.

COST ESTIMATION

Plant Capacity            38 MT/Day  

Land & Building (3500 sq.mt.)    Rs. 3.64 Cr    

Plant & Machinery                    Rs. 4.29 Cr 

Working Capital for 0.5 Months    Rs. 2.22 Cr 

Total Capital Investment          Rs. 10.49 Cr 

Rate of Return                          57%

Break Even Point                      43%

CONTENTS

INTRODUCTION

CALCIUM CARBONATE

KEY FACTS

OTHER NAMES:

FORMULA:

ELEMENTS:

COMPOUND TYPE:

MELTING POINT:

SOLUBILITY:

FILLER (MATERIALS)

TYPES

KAOLIN

MAGNESIUM HYDROXIDE (TALC)

WOLLASTONITE (CASIO3)

GLASS MICROSPHERE FILLER (LEFT) AND FIBER FILLERS (RIGHT)

FLY ASHES

NANOFILLERS

POLYMER FOAM BEADS

MASONRY FILLER

OTHER FILLERS

TABLE OF FILLER MATERIALS AND PHYSICAL PROPERTIES

MASTERBATCHES

TYPES OF MASTERBATCH

WHITE MASTERBATCH:

BENEFITS

BLACK MASTERBATCH:

FEATURES:

APPLICATIONS:

COLOUR MASTERBATCH:

ADDITIVE MASTERBATCH:

APPLICATIONS OF ADDITIVE MASTERBATCH:

SPECIAL EFFECT MASTERBATCH:

MECHANICAL PROPERTIES

TENSILE STRENGTH

ELASTIC MODULUS

IMPACT RESISTANCE (TOUGHNESS)

WEAR RESISTANCE

FATIGUE RESISTANCE

THERMAL DEFORMATION

CREEP

WELDABILITY OF PLASTIC FILLERS

APPLICATIONS OF FILLER IN PLASTIC INDUSTRY

USES / APPLICATIONS

GENERAL USAGE OF MASTERBATCH (MB)

MASTERBATCH IS USED IN THE FOLLOWING AREAS:

APPLICATION

IN PVC PIPES PRODUCTION

IN PRODUCING PLASTIC DOORS, CEILING PANELS, FRAMES

IN POWER CABLES PRODUCTION

IN BLOWING FILMS PRODUCTION

IN SPINNING PRODUCTION

IN PLASTIC COMPOSITES PRODUCTION

SELECTION OF COLOURANTS

FACTORS WHICH AFFECT SELECTION OF COLOURANT

CALCIUM CARBONATE FILLERS FOR RAFFIA

WHAT IS RAFFIA TECHNOLOGY AND ITS OUTPUTS

OTHER APPLICATIONS

WHICH ARE RECOMMENDED CALCIUM CARBONATE FILLERS FOR RAFFIA

COMMON APPLICATIONS OF HDPE/PP CALCIUM CARBONATE FILLER IN RAFFIA

WOVEN SACKS

ADVANTAGES OF CACO3 MASTERBATCH

CALCIUM CARBONATE MASTERBATCH IS AN ADDITIVE WITH VARIOUS ADVANTAGES, INCLUDING:

• WHITENESS:

• ECONOMICAL: 

• STRENGTH AND RIGIDITY: 

• HEAT CONDUCTIVITY

• SIZE STABILITY:

• ANTIFRICTION AND ANTI-SLIP 

• PRODUCTION EFFICIENCY AND IMPROVED PROCESSING 

• ENVIRONMENTAL FRIENDLY

BIS SPECIFICATION

FORMULATION

RAW MATERIALS

POLYPROPYLENE (PP)

CALCIUM CARBONATE 

ZINC OXIDE 

DIOCTYL PHTHALATE

STEARIC ACID 

CD STEARATE

ANTIOXIDANTS (2, 5 DI-TERT - BUTYL HYDROQUINONE) 

PIGMENT

MANUFACTURING PROCESS STEPS / PROCESS FLOW

EXTRUDING & GRANULATION

MIXING AND COMPOUNDING METHOD 

CARRIER MATERIAL

LET DOWN RATIO

DISPERSION

PROCESSING

SINGLE-STAGE PROCESS

TWO-STAGE PROCESS

PROCESS SCHEMATIC

PROCESS FLOW

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

MARKETS:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

COST OF SITE

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

DUST EMISSIONS ARE ONE OF THE MOST SIGNIFICANT IMPACTS. 

ANTICIPATED ENVIRONMENTAL IMPACTS 

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

MARKET POSITION

GLOBAL CALCIUM CARBONATE FILLER MASTERBATCH MARKET: SEGMENT ANALYSIS

THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET ANALYSIS BY TYPES IS SEGMENTED INTO:

THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET INDUSTRY RESEARCH BY APPLICATION IS SEGMENTED INTO:

BASED ON APPLICATIONS, THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET FROM 2018 TO 2028 COVERS:

PLANT & MACHINERIES SUPPLIERS

WEIGHING MACHINES

FILLING MACHINE

LABORATORY TESTING EQUIPMENTS

COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS

COOLING TOWER

MATERIAL HANDLING EQUIPMENTS

INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS

POLLUTION CONTROL EQUIPMENTS

BOILERS

AIR COMPRESSORS

PROCESS EQUIPMENTS

STORAGE TANKS

D.G. SETS

POWER TRANSFORMERS

ETP PLANTS

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

CONSULTANT / TURNKEY

RAW MATERIAL SUPPLIERS

TALC

DIOCTYL PHTHALATE

ANTIOXIDANT

POLYPROPYLENE

CALCIUM CARBONATE

STEARIC ACID

ZINC OXIDE

TITANIUM DIOXIDE

PIGMENTS

CADMIUM STEARATE

MACHINERY PHOTOGRAPHS

KNEADER EXTRUDER MACHINE

PELLETIZER

SCRAP GRINDER

AIR BLOWERS

WEIGHING MACHINES

FILLING MACHINE

COOLING TOWER

BOILERS

AIR COMPRESSORS

STORAGE TANKS

SUBMERSIBLE WATER PUMP

RAW MATERIAL PHOTOGRAPHS

TALC

DIOCTYL PHTHALATE

POLYPROPYLENE

CALCIUM CARBONATE

STEARIC ACID

ZINC OXIDE

TITANIUM DIOXIDE

CADMIUM STEARATE

PRODUCT PHOTOGRAPHS

PRELIMINARY LAYOUT

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)