Detailed Project Report on adhesive manufacturing (water based, solvent based and acrylic based)

ADHESIVE MANUFACTURING (WATER BASED, SOLVENT BASED AND ACRYLIC BASED)
[CODE NO. 2097]

Latex   based  adhesives  are  of  special  importance   for cementing  porous  surfaces  due to their  ability  to  wet  such surfaces.   On  the  other angle the porosity  allows  the  latex adhesive  to  dry  out thus  producing a  strong  coherent  film.  Sodium   silicate,  glue,  albumen  gums  and  starch  etc.   are compatible  with  natural latex and exert a  stabilizing  action.  The  latex  rubber in the adhesive film imparts  flexibility  and strength  and protects and bond against dynamic fatigue.
Latex based adhesives contain a rubber latex, adhesion modifiers,  plasticizers, curatives, fillers such as whiting  and kaolin, thickness e.g. cellulose derivatives and other  additives e.g.   antioxidants,   surfactants  antifoams   (Octyl   alcohol, silicons),    antifreeze,   stabilizers    corrosion    inhibitor colourants, deodorants, and reodorants etc.
Shoe  industry,  both  or leather and  rubber  based  types, utilities quite a good amount of adhesives, large number of which are  based  on  animal glues,  now-a-days  various  thermoplastic materials other than those based on animal glues are in use, e.g. adhesives  based  on  PVC, polyvinyl butyl,  rubber  natural  and synthetic,  methyl cellulose and celluloid etc.  Water  resistant casein glues are also employed for this purpose.
The  rubber  solution which are  manufactured  by  synthetic rubber  are  called as "synthetic rubber adhesives".  It  is   an important item for shoes and rubber industries in the joining  of two layers or more than two rubber layers of shoe layers or  shoe parts  and  soles.  The rubber solutions have  some  public  uses also,  such  as,  in cycle puncture and  heavy  vehicle  puncture fixing.

The  use of adhesives is also in the bursting of  tyres  and tubes.  When tyres burst, we require adhesive for joining to  the burst.  The  types and tubes are very necessary item  for  cycle, auto  rikshaw, heavy vehicle etc. The adhesive gives a  new  list for these tyres and tubes when it joint to the puncture or burst.

To adhesive for leather to leather and leather to rubber may also  be  made  by latex rubber based. It helps in joining two layers  of leather and rubber, shoe parts and soles. It is also used tyres and tubes manufacturing, for joining the two layers or joining the two ends of tubes.

1.   In this type of solution, the reclaimed rubber is  dissolved in dissolved in the  solvent  and  the solution  is not vulcanised.

2.   This type of solutions are heated for vulcanization, they contain some other ingredient like accelerator etc.

3.   Solution which get vulcanized by themselves and are usually supplied in two parts.
          
Some large scale units in the country almost monpolised the manufacture  and  marketing  of these  products.   Recently  much progress  has  been  made in the small scale sector, specially because technical know-how is indigenously available. The  rubber solutions are  manufactured  according  to required by the purchaser.

The  colour  of the solvent is depend on the  raw  materials which are used in the solvent processing.

     S.R.  Adhesive is  a important  class  of  adhesive  having multiple applications.

Substances may attach to surfaces and develop the internal or cohesive strength necessary to hold materials together  while cooling from  the liquid to the solid state, while losing solvent or  during chemical section substances called  pressure-sensitive adhesive  generally  do not undergo  phase change in  order  to
hold materials together.

Many types of Adhesives are currently in use and there is no adequate  single system of classification for all  products.  The adhesives industry has generally employed classification based on end  use,  such  as metal to  metal  adhesives,  wood  adhesives, general  purpose adhesives, paper and packaging adhesives and  so on.

Apart from end-use, adhesives may be classified according to physical  form,  chemical composition, method of application, various processing factors (eg setting section), and suitability for particular service requirements or environments.

A   good  adhesive  should  have  the  following   desirable properties :-

     a)   Maximum mechanical strength.
     b)   Minimum  setting  time  of quick  development  of  bond strength.
     c)   Resistance to moisture
     d)   Resistance to moisture
     e)   Resistance to the deterioration by ageing
     f)    Freedom from fire and toxicity hazards.
     g)   Ability  to  withstand  temperature  variations  or  it
            should produce a flexible anticracking bord.
     h)    Freedom from objectionable odor.
     i)     Freedom from fire and toxicity.

As can be easily inferred from the above no single adhesives can  have  all  the  above desirable properties. Adhesive for particular industrial application is selected according  to  the more important service conditions required. To achieve  desirable properties,  certain modifying agents like plasticizers, stiffners, driers  and  fillers etc, are incorporated  in  the adhesives.

Application Area for Adhesive Bonding

Adhesives are used  for  bonding  of  surfaces,  when  the mechanical  bonding methods result in distortion, discoloration, corrosion and other troubles. Sometimes adhesive bonding is used due to reduced cost and performance improvement. Adhesive bonding is sometimes used to complement other fastening methods  in  an assembly.

Adhesives may be used for bonding for dissimilar materials, such as  combinations of metals, rubbers, plastics, foamed materials, fabrics, wood etc.,  and for metals  which  may constitute  a  corrosion  couple eg. iron  to  copper  or  brass.
   

COST ESTIMATION

Plant Capacity                                               1.25 MT./day   
Land & Building (2000 Sq.Mtr)                   Rs. 2.74 Cr
Plant & Machinery                                         Rs.46.76 Lacs
W.C. for 1 Month                                            Rs. 51.38 Lacs
Total Capital Investment                              Rs.  3.79  Cr
Rate of Return                                              42%
Break Even Point                                         42%

INTRODUCTION                                            
USES AND APPLICATION                                        
STRUCTURAL ACRYLIC ADHESIVES                                
OTHER APPLICATIONS                                        
B.I.S.SPECIFICATION                                        
PROPERTIES OF ACRYLIC BASED ADHESIVE                            
CONCISE SUMMARY OF PHYSICAL PROPERTIES OF ACRYLIC ADHESIVES        
MARKET SURVEY                                            
PRESENT MANUFACTURE OF S.R ADHESIVE                            
PROPERTIES OF LATEX BASED ADHESIVES VERSUS SOLVENT BASED ADHESIVE    
ADVANTAGE OF LATEX ADHESIVE OVER RUBBER SOLUTION                
RAW MATERIALS                                            
FORMULATIONS FOR WATER BASED LATEX ADHESIVES                    
PROCESS OF MANUFACTURE                                    
FLOW SHEET                                            
MANUFACTURING PROCESS OF SYNTHETIC RUBBER ADHESIVE (SR ADHESIVE) LIKE PIDILITE TYPE                                        
PROCESS FLOW DIAGRAM FOR SYNTHETIC RUBBER ADHESIVE    (SR
ADHESIVE) LIKE PIDILITE TYPE                                    
MANUFACTURING PROCESS OF RUBBER ADHESIVE                    
PROCESS FLOW SHEET FOR MANUFACTURING OF RUBBER ADHESIVE        
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF PRESSURE-
SENSITVE ADH ESIVE FOR BOPP TAPES (ACRYLIC BASED)                
EMULSION POLYMERISATION                                    
PROCESS FLOW SHEET                                        
TESTING OF ADHESIVES                                        
PLANT LAYOUT                                            
SUPPLIERS OF  CONSULTANTS                                    
SUPPLIERS OF RAW MATERIALS SUPPLIERS                            
SUPPLIERS  OF PLANT & MACHINERY SUPPLIERS                        


APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET