masterbatch (filler) (polypropylene and calcium carbonate based)

MASTERBATCH (FILLER) (POLYPROPYLENE AND CALCIUM CARBONATE BASED)

[CODE NO.4407] 

A Masterbatch is a concentrated mixture obtained by the distribution of colours and additives into a polymer carrier by heat treatment and in-particularly a high shear mixing extruder. The mixture is then cooled, cut and formed into granules via a pelletiser. The production of masterbatch creates great demands on the compounding process: The pigment and additive parts need to be merged into the base polymer completely homogeneously.

The alternatives to applying masterbatches are obtaining a fully compounded material from raw materials on site. In comparison with pure pigments, masterbatches need extra storage space and longer lead times. Another drawback is additional exposure of heat to both the carrier and the additive; which is essential for marginally thermal stable pigments. 

As masterbatches are premixed compositions, they use and mitigates the problems with the additive deficient dispersion. The blend of the additive in the masterbatch is higher than in the end polymer, but the additive properly dispersed in the master resin. In a way, they are associated with the use of ferroalloys for combining alloying components to steels.

Masterbatches are highly concentrated with high \"let down ratios\", one ton of a natural polymer can fit into a 25 kg bag. Masterbatches dilute nature, allows higher accuracy in dosing of expensive components. Masterbatches solid crystals are solvent free and tend to have a longer shelf life as the solvent in the polymer won't evaporate. They generally contain 40-65 per cent additives, but the range can be altered from 15-80 per cent in few additional cases. Liquid Masterbatches allow highly precise dosing and instant change of colour between machine runs.

Filler masterbatch (Calcium Carbonate Masterbatch) is known as the ultrafine dispersion with the guarantee of no agglomeration, ensure the whiteness, glossier and smooth surface for the articles. This filler – the concentration of CaCO3 powder or Talc powder in the filler polymer base to modify vary properties of the plastic articles or the base plastic polymers.

It is intended to prepare a Feasibility Report to install 3000 Tons/Year Masterbatch production facility from Polypropylene (PP) and Calcium Carbonate raw materials as a Green Field Project.

COST ESTIMATION

Plant Capacity                                   10 Ton/Day

Land & Building (2500 sq.mt.)  Rs. 2.80 Cr

Plant & Machinery                              Rs. 2.18 Cr

Working Capital for 0.5 Months      Rs. 90  Lac

Total Capital Investment                  Rs. 6.20 Cr

Rate of Return                                    42%

Break Even Point                              54%

• • INTRODUCTION
• • TYPES
• • USES/APPLICATION
• • SELECTION OF COLOURANTS
• • BIS SPECIFICATION
• • MARKET OVERVIEW
• • FORMULATION
• • RAW MATERIALS
• • SUPPLIERS OF RAW MATERIALS
• • MANUFACTURING PROCESS STEPS/PROCESS FLOW
• • ENGINEERING DESIGN CONSIDERATIONS
• • ETP FACILITY
• • SEWAGE AND WASTE WATER EFFLUENT
• • WASTE GENERATION & MANAGEMENT/GREEN BELT
• • PLANT/MACHINERY (BROADLY)
• • SUPPLIERS OF PLANT & MACHINERIES/TURNKEY
• • UTILITIES PER MONTH (ESTIMATED)
• • PRINCIPLES OF PLANT LAYOUT
• • PLANT LOCATION FACTORS
• • HEALTH SAFETY AND ENVIRONMENT
• • ANTICIPATED ENVIRONMENTAL IMPACTS
• • MITIGATION MEASURES (PROPOSED)
• • HSE REQUIREMENT
• • SAFETY & OCCUPATIONAL MEASURE
• • PROPOSED IMPLEMENTATION SCHEDULE
• • PROJECT FINANCIALS
• • PRELIMINARY PLANT LAYOUT
• • CONCLUSIONS

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)