hdpe pipe manufacturing unit

HDPE PIPE MANUFACTURING UNIT

[CODE NO.4389]  

High-density polyethylene (HDPE) is a polyethylene thermoplastic made from petroleum. It is known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97g/cm3 or 970Kg/m3. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand much higher temperatures (120°C for short periods, 110°C continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally required autoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions.

HDPE pipes are important plastic products which have wide range of applications. These have more tensile strength in comparison to other plastic pipes. These are being used for Sprinkler Irrigation System, potable water supply and sewerage purpose. Their low cost, easily installation and better durability make them ideal for the purpose. They also offer very good resistance to most of the chemicals and have excellent electrical insulation properties. These pipes are also used for circulation of acids in various chemical industries due to their acid resistant quality.

The demands of HDPE Pipes are likely to increase due to their wide use in various sectors in India. Apart from its regular uses, such as for irrigation system, water supply, sewerage, it is being used by Department of Telecommunication for conduit for optical fiber cables. Looking to its increased demand, it appears to be good scope for setting up new small scale industries. Hence the product has good market potential.

CLASSIFICATION

(A) Pipes shall be classified according to the grade of materials as MRS; Polyethylene pipes and classified by the raw materials used in the production of attachments. A MRS material strength value of 20°C is also shown by the internal pressure for 50 years.

Raw material class MRS(MPa) value

PE  63 6.3

PE  80 8.0

PE  100 10

(B) Pipes by pressure rating (PN) corresponding to the maximum shall be classified permissible working pressure at 3WC, as follows:

The pressure grades available according to European standards are:

• PN 2.5 - max pressure 2.5 bar

• PN 4   - max pressure 4   bar

• PN 6   - max pressure 6   bar

• PN 10  - max pressure 10  bar

• PN 16  - max pressure 16  bar

Color codes used to indicate the pressure grades on the pipes are:

Color Code                                    PE Pressure Grade 

Yellow                                        PN 4

Red                                           PN 6

Blue                                          PN 10

Green                                         PN 1

HDPE Pipes for following grades/sizes/pressure rating

PE 63 PN 2.5 DN 63 to 110

PE 63 PN 4   DN 40 to 110

PE 63 PN 6   DN 32 to 110

PE 63 PN 8   DN 32 to 110

PE 63 PN 10  DN 32 to 110

PE 63 PN 12.5 DN 32 to 110

PE 63 PN 16  DN 32 to 110

PE 80 PN 2.5 DN 90 to 110

PE 80 PN 4   DN 50 to 110

PE 80 PN 6   DN 40 to 110

PE 80 PN 8   DN 32 to 110

PE 80 PN 10  DN 32 to 110

PE 80 PN 12.5 DN 32 to 110

PE 80 PN 16  DN 32 to 110

PE 100 PN 6  DN 50 to 110

PE 100 PN 8  DN 40 to 110

PE 100 PN 10 DN 32 to 110

PE 100 PN 12.5 DN 32 to 110

PE 100 PN 16 DN 32 to 110

COST ESTIMATION

Plant Capacity                               116 Ton/Day

Land & Building (20,000 sq.mt.) Rs. 15.00 Cr

Plant & Machinery                         Rs.  7.49 Cr

Working Capital for 1 Month       Rs. 29.80 Cr

Total Capital Investment              Rs. 53.03 Cr

Rate of Return                                32%

Break Even Point                           41%

• INTRODUCTION
• CLASSIFICATION
• COLOR CODES USED TO INDICATE THE PRESSURE GRADES  ON THE PIPES ARE:
• HDPE PIPES FOR FOLLOWING GRADES/SIZES/PRESSURE RATING
• CHARACTERISTICS
• USES AND APPLICATION
• INDUSTRIES
• SPECIAL SERVICES
• APPLICATIONS
• SUBMARINE PIPELINES
• LAYING ON THE WATERBED:
• LAYING IN DREDGED CHANNELS:
• LAYING BY THE FLUSHING-IN METHOD:
• RELINING - NEW PIPES IN OLD
• SEWER PIPES
• SLURRY TRANSPORTATION
• IRRIGATION
• DOMESTIC GAS DISTRIBUTION
• CHEMICAL PROCESS PIPING
• B.I.S. SPECIFICATION
• SEQUENCES IN HDPE PIPES
• MANUFACTURING PROCESS OF HDPE PIPES
• MECHANICAL INSPECTION
• OTHER QC TESTS CAN INCLUDE:
• PROCESSING DETAILS OF HDPE PIPES
• EXTRUDER
• FEED HOPPER
• BARREL
• SCREW
• DIE
• WATER COOLING TUB
• PROCESS FLOW CHART
• EXTRUSION PROCESSING LINE FOR HDPE PIPES
• RAW MATERIALS HANDLING
• EXTRUSION BASICS
• FIGURE: TYPICAL SINGLE STAGE, SINGLE SCREW EXTRUDER (RESIN FLOW FROM RIGHT TO LEFT)
• FIGURE: TYPICAL EXTRUSION SCREW
• FIGURE: TYPICAL RESIN MIXING DEVICES
• FIGURE: MIXING  PINS
• FIGURE: FLUTED  MIXER
• FIGURE: HELICAL MIXER
• EXTRUDERS
• BREAKER PLATE/SCREEN PACK
• DIE DESIGN
• FIGURE: TYPICAL PIPE DIES
• FIGURE: PIPE DIE WITH SPIDER DESIGN
• FIGURE: PIPE DIE WITH BASKET DESIGN
• PIPE SIZING
• FIGURE: EXTERNAL SIZING SYSTEMS
• FIGURE: VACUUM TANK SIZING
• FIGURE: INTERNAL (PRESSURE) SIZING FOR SMALL AND MEDIUM  PIPE DIAMETERS
• FIGURE: TYPICAL PE PROFILE WALL PIPE FROM ASTM STANDARD F894
• FIGURE: TYPICAL PROFILE WALL SECTION SHOWING BELL END (RIGHT) AND SPIGOT ENG (LEFT)
• COOLING
• PULLERS
• TAKE-OFF EQUIPMENT
• SAW EQUIPMENT AND BUNDLING
• SEQUENCES IN HDPE PIPE FITTING MANUFACTURE
• MANUFACTURING PROCESS OF HDPE PIPE FITTING
• INJECTION MOLDED FITTINGS
• FIGURE: TYPICAL PE PIPE FITTINGS
• FIGURE: SOCKET TEE
• FIGURE: BUTT TEE
• FIGURE: SOCKET ELBOW
• FIGURE: 90° BUTT ELBOW
• FIGURE: SADDLE FUSION FITTINGS
• FIGURE: BUTT FLANGE ADAPTER/STUB END
• FIGURE: CONSTRUCTION AND MODE OF OPERATION OF A RECIPROCATING SCREW INJECTION UNIT (COURTESY OF HOECHST CELANESE CORPORATION)
• FABRICATED FITTINGS
• THERMOFORMED FITTINGS
• ELECTROFUSION COUPLINGS
• INJECTION MOLDED COUPLINGS
• FIGURE: TYPICAL FABRICATED FITTINGS
• QUALITY CONTROL/QUALITY ASSURANCE TESTING
• WORKMANSHIP, FINISH AND APPEARANCE
• DIMENSIONS
• RAW MATERIALS
• A. HDPE GRANULES
• B. BLACK MASTER BATCH
• C. ANTI-OXIDANT
• QUALITY CONTROL OF HDPE PIPES
• VISUAL INSPECTIONS
• MECHANICAL INSPECTION
• OTHER QC TESTS CAN INCLUDE:
• TECHNICAL DETAILS OF HDPE PIPE MANUFACTURE
• INCOMING RAW MATERIAL INSPECTION
• RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
• RESIN STORAGE AND CONVEYANCE
• RESIN FEEDING
• TESTING
• (A) TYPE TEST
• (B) ACCEPTANCE TEST
• (C) LONGLTUDINAL REVERSION PERFORMANCE TEST
• APPRATUS
• 1. AIR OVEN
• 2. THERMOMETER
• TEST SPECIMENS
• PROCEDURE
• MARKING
• OVERVIEW OF HDPE PIPES
• MICRO DUCTS IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
• TELECOM IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
• MARKET POSITION OF INDIAN HDPE PIPES
• OPPORTUNITIES OF HDPE PIPES
• MARKET BY APPLICATION
• MARKET BY GRADE TYPE
• MARKET BY DIAMETER TYPE
• MARKET BY PRESSURE RATING
• GLOBAL MARKET POSITION OF HDPE PIPES
• INDIAN PLASTIC PIPES MARKET
• TYPES OF PLASTIC PIPES APPLICATION
• MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
• INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
• BARGAINING POWER OF SUPPLIERS
• BARGAINING POWER OF BUYERS
• INTERNAL RIVALRY
• ENTRY
• THREAT OF SUBSTITUTES
• GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
• OTHER MEASURES
• SWOT ANALYSIS
• STRENGTHS
• WEAKNESSES
• OPPORTUNITIES
• THREATS
• SEWER RINGFIT PIPES AND SEWER SELFIT PIPES
• DOMESTIC USE
• INDUSTRIAL
• OTHER
• HDPE PIPES DIMENSION
• MANUFACTURERS/SUPPLIERS OF HDPE PIPE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF HDPE GRANULES
• SUPPLIERS OF BLACK MASTER BATCH
• SUPPLIERS OF ANTIOXIDANT
• SUPPLIERS OF COMPLETE HDPE PIPE PLANT
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF EOT CRANE
• SUPPLIERS OF POWER TRANSFORMER
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFLUENT TREATMENT PLANT
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSOR
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• TORNOVER (FIRST YEAR) ON MONTHLY BASES

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)