Detailed Project Report on ms barrels for pulp and oil packaging

MS BARRELS FOR PULP AND OIL PACKAGING

 [CODE NO.4118] J.C.: 2264XL 

The drums (also called barrels in common usage) are steel cylindrical containers for storing and shipping bulk cargo. The Grade B drums are made from cold rolled sheets of mild steel. The Grade B drums are commonly used for storage and transportation of lubricating oils and other non- hazardous chemicals. Type 1 drums are double seamed and have 1.25 mm sheet thickness. With the development of spiral seam construction which provides stronger seam joint so as to withstand any drop caused during transportation and handling it has been possible to reduce the thickness of the drums to 1.00 mm from 1.25 mm. These drums have been introduced as alternative to the conventional double seam drums and have been included under the same Grade B as Type 2. Both Type 1 & 2 drums have two rolling beads and hoops to facilitate easy rolling and also provide rigidity. Type 2 drums also have 2 sets of corrugations located symmetrically on either side of the rolling hoops to provide additional strength. These steel drums used for shipment of chemicals and petroleum products have a standardized bunghole arrangement, with one 50 mm and or one 50mm and one 20 mm threaded bunghole on opposite sides of the top. Screwed closures as per IS 1784 are fitted over them. Pumps to facilitate entry or exit of materials can be mounted on them.

A drum is a cylindrical container used for shipping bulk cargo. Drums can be made of steel, and are generally used for the transportation and storage of liquids. Drums are often certified for shipment of dangerous goods. The construction of drum needs to meet applicable regulations and is usually matched for compatibility with the specific product shipped. Drums are also called barrels in common usage. 

The drums are typically made of steel with a ribbed outer wall to improve rigidity and for rolling. The lids can be welded or secured with a head gasket and bolt ring. Drums can also be made of durable plastic or paperboard. They are commonly used for transporting oils, fuels, chemicals, and dry goods. The barrels are, made of 1mm and 1.25mm thickness CRCA sheet. Availability of steel locally and opening up of the Indian economy resulted in a spurt in demand and consequently, the growth of barrel and drum plants across India accelerated. 

Construction Material:

Most drums are made of either carbon steel or stainless steel. Stainless steel offers better chemical resistance than carbon steel. So, if your plant uses aggressive chemicals or if there is a wide range of liquids the drum may come in contact with, a stainless steel drum will be more versatile and handle more jobs. The drums can also be lined for added corrosion resistance.

Steel Thickness:

The thickness of the metal is important depending on the reason you’re using a drum. Thicker drums are recommended for shipping hazardous liquids, as they’re stronger than thinner drums. Plus, the thicker the drum, the more weight and pressure it can handle. Most drums show something like this – 1.5/1.2/1.2 mm – when describing the thickness of the drum, but what does that mean? This shows the thickness of the different parts of the drum – lid/body/base. In the above example, that would mean that the lid is 1.5 mm thick, the body is 1.2 mm thick and the base is 1.2 mm thick. Most drums fall in the range of 0.9 – 1.5 mm thick.

Open or Closed Head:

Drums are either open head (lid can be removed) or tight/closed head (lid is permanently secured). Open-head drums are typically used in situations where frequent addition or extraction of the contents occurs. Open-head drums make it easier to work with solids and thicker liquids (soils, absorbents, syrups, glues, oils, etc.) while tight-head drums are typically used with lower viscosity liquids.

The lid on an open-head drum is typically attached with a nut and bolt ring, which can be tightened to a particular torque to meet UN Rating requirements. You can also use quick-opening lever lock rings for easy access and closure, eliminating the need to use tools every time you want to remove the lid. New Pig has developed a unique latching lid system that enables users to open and close an open-head drum with one hand and no tools.

The latching lid system is the most convenient, easiest way to access your drum.

Bung Threading:

If you intend to use funnels to add liquids to your drum, or if you intend to add pump fittings for pumping liquids out of your drum directly into one of your processes, you will need to know what type of bung (top opening) is on the lid. A tight/closed-head drum would typically have 2 bungs, one 2” and one ¾” in diameter. The threads on the bungs are almost always NPT (National Pipe Taper), but occasionally could be Buttress type instead. NPT threads are a fine thread and Buttress threads are a coarse thread. They also have different head styles, which may require a specialized tool for tightening.

Unlike straight pipe threading that is used to join two pieces of pipe together, NPT-threaded fittings will pull tight to make a liquid-tight seal. Most steel drums have NPT-threaded bung openings and caps. Buttress threads are also designed to form a liquid-tight seal, but are larger and coarser than NPT threads. Buttress threads are also known as “saw threads” and are designed to handle high stress, such as tightening a funnel into the bung opening. Typically, Buttress-threaded openings and caps are found on plastic drums rather than steel.

COST ESTIMATION

Plant Capacity                                  1167 Nos/Day

Land & Building (4000 sq.mt.)        Rs. 1.64 Cr

Plant & Machinery                              Rs. 1.61 Cr

Working Capital for 1 Month          Rs. 2.79 Cr

Total Capital Investment                   Rs. 6.17 Cr

Rate of Return                                    34%

Break Even Point                                55%

• INTRODUCTION
  
• CONSTRUCTION MATERIAL:
• STEEL THICKNESS:
• OPEN OR CLOSED HEAD:
• BUNG THREADING:
• BARRELS AND DRUMS
• GALAVINISED DRUM
• GOOSENECK DRUM
• COMPOSITE DRUM
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• MARKET OVERVIEW OF MS DRUMS AND BARRELS
• SCOPE OF THE REPORT
• PRESENT MANUFACTURERS/SUPPLIERS OF M.S. DRUMS AND BARRELS
• STEPWISE PROCEDURE FOR MANUFACTURING MS BARRELS
• BEAD EVOPORATOR (HYDRAULIC TYPE)
• MULTI CORRUGATION MACHINE:
• DOUBLE EXTEND FLANGING MACHINE (HYDRAULIC)
• POWER PRESS AND DIES (TOP & BOTTOM)
• PRECURLING MACHINE:
• SEMI AUTOMATIC END SEAMING MACHINE
• PROCESS FLOW DIAGRAM
• PROCESS FLOW SHEET FOR BODY PRODUCTION
• PROCESS FLOW SHEET FOR TOP AND BOTTOM PRODUCTION
• PROCESS FLOW SHEET FOR ASSEMBLING OF BODY WITH TOP & BOTTOM
• MANUFACTURING PROCESS
• PRINCIPLE OF METAL BARREL PRODUCTION
• (1) THE BASIC PRINCIPLE OF THE DRUMS MACHINING
• THE BASIC PROCESSING METHODS:
• (2) STEEL DRUM MATERIAL LEVEL IN PROCESS PRINCIPLE
• (3) THE PROCESS OF STEEL PLATE SHEAR PRINCIPLE
• (4) THE BARRELS ARE ROLLING PROCESS PRINCIPLE
• (5) BARRELS WELDING PROCESS PRINCIPLE
• (6) BARRELS FLANGING PROCESS PRINCIPLE
• (7) CORRUGATED ROLL FORMING PRINCIPLE OF RING BARS
• (8) BARRELS BULGING PRINCIPLE
• RAW MATERIALS/COMPONENTS
• PROCESS
• 1. MATERIAL PREPARATION:
• 2. STEEL BARREL BODY FORMING:
• SEAMWELDING
• THE ELECTRODE PRESSURE
• WELDING TIME AND REST TIME
• WELDING SPEED
• BODY WELDING PARAMETERS.
• 3. DRUM BOTTOM AND DRUM LIDS PRODUCTION:
• 4. DRUM SEALING
• 5. COATING AND PAINTING
• 6. TESTING
• (A) LEAKAGE TEST
• (B) DROP TEST
• (C) HYDRAULIC PRESSURE TEST
• DETAILS OF BARREL [MS] MACHINERY
• 1. SHEARING MACHINE
• 2. DOUBLE EDGE GRINDING MACHINE
• 3. ROUND ROLLING MACHINE
• 4. SPOT WELDING
• 5. SIDE SEAM WELDING MACHINE
• 6. BEAD EXPANDER (HYDRAULIC TYPE)
• 7. MULTI CORRUGATION MACHINE (ROTARY TYPE)
• 8. HORIZANTAL 205 LTRS BARREL CORRUGATION MACHINE
• 9. HORIZANTAL 205 LTRS BARREL BUMP FLANGING MACHINE
• 10. FLANGING MACHINE (ROTARY TYPE)
• 11. DOUBLE ENDED FLANGING MACHINE (HYDRAULIC)
• 12. POWER PRESS AND DIES (TOP AND BOTTOM)
• 13. PRE CURLING MACHINE
• 14. SEMI AUTOMATIC END SEAMING MACHINE (FOR DRUMS & BARELLS)
• MAIN FEATURES OF THIS MACHINE ARE:
• QUALITY CONTROL SYSTEM
• DESCRIPTION OF PLANT AND MACHINERY
• CHINA PLANT AND MACHINERY FOR M.S BARREL AND DRUM
• DRUM MAKING MACHINES AND THE RELATIVE SPECIFICATIONS:
• 1. LOADING MACHINE
• 2. FLATTENING MACHINE
• 3. SHEARING MACHINE
• 4. ROLL FORMING MACHINE
• 5. RING WELDING MACHINE
• 6. RIB FORMING MACHINE
• 7. HOOP ROLLING FORMING MACHINE
• PLANT LAYOUT
• COMPLETE PLANT AND MACHINERY SUPPLIERS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF POWER PRESS
• SUPPLIERS OF SHEARING MACHINE
• SUPPLIERS OF ROLLING MACHINE
• SUPPLIERS OF ROLLING MACHINE
• SUPPLIERS OF BENDING MACHINE
• SUPPLIERS OF MECHANICAL PRESS
• SUPPLIERS OF UNCOILING MACHINE
• SUPPLIERS OF SHEET LAVELING MACHINE
• SUPPLIERS OF PUNCHING PRESS
• SUPPLIERS OF SEAM WELDING MACHINE
• SUPPLIERS OF SPOT WELDING MACHINE
• SUPPLIERS OF LEAK TESTING MACHINE
• SUPPLIERS OF SCREEN PRINTING MACHINES
• SUPPLIERS OF DG SETS
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSURE
• SUPPLIERS OF PLATEFARM WEIGHING MACHINE
• SUPPLIERS OF POWDER COATING MACHINE
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF M.S. SHEET
• SUPPLIERS OF CRCA SHEET
• SUPPLIERS OF PICKLING ACIDS
• SUPPLIERS OF WELDING ELECTRODE
• SUPPLIERS OF POWDER COATING MATERIALS

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)