Detailed Project Report on hdpe pipe manufacturing unit

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HDPE PIPE MANUFACTURING UNIT

[CODE NO.4127]

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 demand 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. MRS material strength values 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 20 Tons/Day

Land & Building (10,000 sq.mt.) Rs. 4.18 Cr

Plant & Machinery Rs. 7.38 Cr

Working Capital for 1 Month Rs. 4.38 Cr

Total Capital Investment Rs. 16.17 Cr

Rate of Return 25%

Break Even Point 57%

INTRODUCTION
CLASSIFICATION
CHARACTERISTICS
USES AND APPLICATION
INDUSTRIES
SPECIAL SERVICES
APPLICATIONS
SUBMARINE PIPELINES
RELINING - NEW PIPES IN OLD
SEWER PIPES
SLURRY TRANSPORTATION
IRRIGATION
DOMESTIC GAS DISTRIBUTION
CHEMICAL PROCESS PIPING
B.I.S. SPECIFICATION
HEADQUARTERS
SALES OUTLET
PROCESS OUTLINES OF HDPE PIPES EXTRUSION
PROCESSING DETAILS OF HDPE PIPES
EXTRUDER
FEED HOPPER
BARREL
SCREW
DIE
WATER COOLING TUB
PROCESS FLOW CHART
MANUFACTURING PROCESS
EXTRUSION PROCESS
WORKING PRINCIPLE
EXTRUSION PROCESS PARAMETERS
ADVANTAGES
DISADVANTAGES
RAW MATERIALS
QUALITY CONTROL OF HDPE PIPES
VISUAL INSPECTIONS
MECHANICAL INSPECTION
OTHER QC TESTS CAN INCLUDE:
DESCRIPTION OF MANUFACTURING PROCESS
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 PERFORMANCETEST
APPRATUS
1. AIR OVEN
2. THERMOMETER
TEST SPECIMENS
PROCEDURE
MARKING
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
THE 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
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF HDPE PIPE
SUPPLIERS OF RAW MATERIALS
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
EFFULENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING 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)

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Each report include Plant Capacity, requirement of Land & Building, Plant & Machinery, Flow Sheet Diagram, Raw Materials detail with suppliers list, Total Capital Investment along with detailed calculation on Rate of Return, Break-Even Analysis and Profitability Analysis. The report also provides a birds eye view of the global industry with details on projected market size and then progresses to evaluate the industry in detail.

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