Detailed Project Report on manufacturing of pvc/pu synthetic leather

MANUFACTURING OF PVC/PU SYNTHETIC LEATHER 

 [CODE NO.4331] 

For many years a range of leather like materials has been in use for sockings, linkings and uppers. They are all based of fabrics, usually woven and mainly of cotton. These base cloths should be carefully selected to give the requisite physical properties for shoe uppers and they may be coated with oil or PVC or rubber compound, Cellulose derivatives or synthetic resin (plastics). The surface may be smooth, with high polish or matt effect, or embossed with designs, many of which simulate leather or fabrics. All these coated materials are totally impermeable to air and water, ventilation must therefore achieved by suitable shoe design. The earliest type of leather cloth was American Cloth, the coating being of linseed oil. This was followed by nitrocellulose coating. Both are practically obsolete for uppers, being superseded by plastic coatings, but they are used for sockings.

Plastic sheetings are also used for uppers of cheaper qualities of shoes. For shoe uppers the unsupported sheeting has proved unsatisfactory in making and the more usual upper materials consist of a specially woven fabric coated with a plastic film, nearly always plasticized PVC. Since this synthetic resin the most freely available in all country. The many constructional difficulties are gradually being overcome and owing to the impenetrable nature of a plastic film, the more general finishes cannot be used. PVC upper materials may be cleaned with petroleum cleaners without determinant to the luster of the surface and additional polish may be given by means of wax creams or light polishing on the rotary brush. PVC leather cloth is the most useful plastic. It has two grades, flexible or rigid which give by means of wax creams or light polishing on the rotary brush. PVC leather cloth is the most useful plastic. It has two grades, flexible or rigid which give it considerable scope. The flexible leather sheet is used for articles of clothing such as boot and shoe, sales, heels and uppers etc. In fact the range of products is so wide that it is impossible to state all of them.

PVC leather cloth is also known in other words as Artificial leather which is becoming increasingly popular all over the world because of shortage of actual leather and high cost of the same. Artificial leather is specially suitable for upholstery, shoe upper, attachicases, brief cases and all kinds of bags. It is water repellent and is chemically inert. It is much cleaner both in production and in use beside being competitive in price. Present inductions show that artificial leather goods have good export potential.

How it is possible to manufacture artificial leather in the small scale sector because of the introduction of automatic machines by the world renowned manufacturers of Japan, Akatsuki machinery works Ltd., who have exported already about 2,000 such plants to South East Asia and Middle East countries. The plant designed by them is continuous one line system, ensuring uniform quality of production of artificial leather as well as less labour costs. With the embossing device one can have plain as well as engraved designs manufactured. Colour of coatings would be according to your choice.

Now, the machineries for PVC leather cloth are being manufactured in India by a India renowned manufacturers. A list of such manufacturers is given at the end of this report.

PVC leather cloth is manufactured by applying a coating of PVC paste on cotton cloth. The cloth has a coating with a glossy surfaced and smoothness to tough. It is used in air-proof and water-proof packing and also for decoration. It is extensively used in such applications which require a water proof media and strength. It is comparatively a new technique and has widely growth prospects. In India the manufacture of PVC leather cloth is very limited and there exists lot of scope for new industries in this field.

PVC leather cloths do not get affected by Heat or water. It is a substitute of natural leather cloth.

PVC leather cloth industry cloth industry has now become very common and the manufacturing technique is very simple.

COST ESTIMATION

Plant Capacity                                    12,000 Mtrs./Day

Land & Building (5000 sq.mt.)  Rs. 3.21 Cr

Plant & Machinery                              Rs. 4 Cr

Working Capital for 1 Month           Rs. 3.09 Cr

Total Capital Investment                  Rs. 10.53 Cr

Rate of Return                                    56%

Break Even Point                               38%

INTRODUCTION

SYNTHETIC LEATHER

SPECIFICATION AND FEATURES OF SYNTHETIC LEATHER

FEATURES OF SYNTHETIC LEATHER

FAUX LEATHER

TYPES OF FAUX LEATHER

PLEATHER

FIGURE 2: PLEATHER: PVC BASED (ON LEFT), PU BASED (ON THE RIGHT)

NAUGAHYDE

FIGURE 3: NAUGAHYDE

VEGAN LEATHER

FIGURE 4: VEGAN LEATHER

ADVANTAGE AND DISADVANTAGE OF FAUX LEATHER TO REAL LEATHER

ADVANTAGES OF FAUX LEATHER TO REAL LEATHER

DISADVANTAGES OF FAUX LEATHER COMPARED TO REAL LEATHER

USES AND APPLICATION OF SYNTHETIC LEATHER

USAGE OF SYNTHETIC LEATHER

AUTOMOTIVE

FOOTWEAR

FURNISHING

LEATHER GOODS

PU LEATHER

POLYVINYL CHLORIDE (PVC)

CHARACTERISTICS:

AVAILABLE FORMS

WEARING PROPERTIES

DETAILS OF RAW MATERIALS

1. PLASTICISER

2. FILLERS

3. STABILIZER

MARKET OVERVIEW OF SYNTHETIC LEATHER (GLOBAL)

GLOBAL SYNTHETIC LEATHER MARKET SHARE, BY APPLICATION,

INDIAN MARKET POSITION

THE BUSINESS

LEATHER VS ARTIFICIAL LEATHER

PRODUCTION PROCESS

CHALLENGES

REQUIREMENT OF FAUX LEATHER

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS

MANUFACTURING PROCESSES OF SYNTHETIC LEATHER

1. THE FIRST WAY IS CALENDERING WAY.

2. THE SECOND WAY IS RELEASE PAPER WAY

PU LEATHER MANUFACTURING PROCESS

1: FIRST WAY IS WET PU LEATHER MANUFACTURING METHOD

2: SECOND WAY IS DRY PU LEATHER MANUFACTURING METHOD

MANUFACTURING PROCESS IN DETAILS

FORMULA WHICH IS USED FOR MIDDLE COAT

PRODUCTION PROCESS OF FAUX LEATHER

DIRECT COATING PROCESS

TRANSFER COATING PROCESS

WET PROCESSOR COAGULATION

FORMULATION AND PROCESS OF ARTIFICIAL LEATHER OF 

   THERMOPLASTIC POLYURETHANE

LINING:

BED MATERIAL:

THE PRESCRIPTION OF BED MATERIAL FOLLOWING (WEIGHT RATIO):

THE PRESCRIPTION OF LINING FOLLOWING (WEIGHT RATIO):

SPECIFICALLY SET FORTH ARTIFICIAL LEATHER MANUFACTURE METHOD:

POLYURETHANE COATED FABRIC MANUFACTURING PROCESS

THE TRANSFER COATING SYSTEM

PROCESS FLOW DIAGRAM

OTHER COMMERCIAL METHODS

ARTIFICIAL LEATHER WITH CLOTH BASE AND FOAMED PVC FILLER

A FORMULATION OF THE IMPREGNATING PLASTIC PASTE, FOAMABLE 

   OR NON-FOAMABLE, IS AS FOLLOWS:

(A) PREPARATION OF NON-WOVEN MAT:

(B) MANUFACTURE OF ARTIFICIAL LEATHER:

PRODUCT I

PRODUCT II

PRODUCT III

EXAMPLES

EMBODIMENT I

EMBODIMENT II

EMBODIMENT III

ARTIFICIAL LEATHER

LAMINATED ARTIFICAL LEATHER

(I) FOR PVC AS THE FACE LAYER:

(II) WHEN PU IS USED AS FACE LAYER:

INGREDIENT PART BY WEIGHT

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

METHOD FOR FORMING LAMINATED SYNTHETIC LEATHER

FEW IMPORTANT DETAILS DURING PROCESSING

SUPPLIERS OF RAW MATERIAL

PVC RESIN

TITANIUM DIOXIDE

LEAD STEARATE

DIOCTYL PHTHALATE

COLOR PIGMENT

SUPPLIERS FOR PLANT AND MACHINERY [INDIAN]

SUPPLIERS OF PLANT AND MACHINERY

BALL MILLS

COOLING TOWERS & HEAT EXCHANGERS

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)