Detailed Project Report on calcium carbonate filler masterbatch

CALCIUM CARBONATE FILLER MASTERBATCH

 [CODE NO. 2055]

Calcium carbonate filler masterbatch is made with super fine calcium carbonate and other high quality special additives based in LLDPE carrier.

CaCO3 filler masterbatch not only cuts down production costs by replacing a part of virgin polymer during extrusion, injection and blow molding progressing but  also increases ouput, improves production conditions as well as a number of physical and chemical properties of finished products.

Advantage

CaCO3 Filler Masterbatch for plastic:
Cost Benefits
Production Increase
Quality Benefits
Enviroment Protection
Durability
Extensive applications
Reasonable rates
     
Masterbatch (MB) is a solid or liquid additive for plastic used for coloring plastics (color masterbatch) or imparting other properties to plastics (additive masterbatch). Masterbatch is a concentrated mixture of pigments and/or additives encapsulated during a heat process into a carrier resin which is then cooled and cut into a granular shape. Masterbatch allows the processor to colour raw polymer economically during the plastics manufacturing process.

The alternatives to using masterbatches are buying a fully compounded material (which may be more expensive and less open to e.g. color variability of the product), or compounding from raw materials on site (which is prone to issues with achieving full dispersion of the colorants and additives, and prone to preparing more material than what is used for the production run). In comparison with pure pigments, masterbatches require more storage space and their lead times are longer. Another disadvantage is additional exposure of heat ("heat history") to both the carrier and the additive; this may be important e.g. for marginally thermally stable pigments.

As masterbatches are already premixed compositions, their use alleviates the issues with the additive or colorant clumping or insufficient dispersion. The concentration of the additive in the masterbatch is much higher than in the end-use polymer, but the additive is already properly dispersed in the host resin. In a way their use is similar to uses of ferroalloys for adding alloying elements to steels.

The use of masterbatches allows the factory to keep stock of fewer grades of the polymer, and to buy cheaper natural polymer in bulk.

The masterbatches can be fairly highly concentrated (in comparison with the target composition), with high "let-down ratios"; e.g. one 25 kg bag can be used for a tonne of natural polymer. The relatively dilute nature of masterbatches (in comparison with the raw additives) allows higher accuracy in dosing small amounts of expensive components. The compact nature of the grains of solid masterbatches eliminates problems with dust, otherwise inherent for fine-grained solid additives. Solid masterbatches are also solvent-free, therefore they tend to have longer shelf life as the solvent won't evaporate over time. The masterbatch usually contains 40-65% of the additive, but the range can be as wide as 15-80% in extreme cases.

The carrier material of the masterbatch can be based on a wax (universal carrier) or on a specific polymer, identical or compatible with the natural polymer used (polymer-specific). E.g. EVA or LDPE can be used as carriers for polyolefins and nylon, polystyrene can be used for ABS, SAN, and sometimes polycarbonates. When a carrier different than the base plastic is used, the carrier material may modify the resulting plastic's properties; where this could be important, the carrier resin has to be specified. The usual ratio of masterbatch to the base resin is 1 to 5 percent. Several masterbatches (color and various additives) can be used together.[1] The carrier can also double as a plasticizer (common for liquid masterbatches) or a processing aid.

The machines are usually fed with premixed granules of the host polymer and the masterbatch. The final mixing then gets done in the screw and extrusion part of the machine. This is sometimes prone to adverse effects, e.g. separation of the masterbatch and the base material in the machine's hopper. The masterbatch can be also added directly to the machine's screw, as a free-flowing solid or in case of a liquid masterbatch by e.g. a peristaltic pump. Such use of liquid masterbatches allows highly accurate dosing and quick change of color between machine runs.

COST ESTIMATION

Plant Capacity                                               2.00 MT/day
Land & Building (600 Sq.Mtr)                     Rs.88.00 Lacs
Plant & Machinery                                        Rs.20.00 Lacs
W.C. for 2 Months                                         Rs.34.41 Lacs
Total Capital Investment                             Rs.1.51 Cr
Rate of Return                                              22%
Break Even Point                                          62%

INTRODUCTION                                            
USES AND APPLICATIONS                                    
PROPERTIES & CHARACTERISTICS                                
B.I.S. SPECIFICATIONS                                        
FILLER MASTERBATCH AND ITS AVAILABLE GRADE                    
TECHNICAL DATA SHEET OF CALCIUM CARBONATE FILLER
MASTER BATCH                                            
PARTICLE SIZE OF CALCIUM CARBONATE FILLER MASTERBATCH        
MECHANISM OF ADDITIVES                                    
CALCIUM CARBONATE FILLED PP CO POLYMER COMPOUNDING COST        
RAW MATERIALS                                            
FORMULATION OF CALCIUM CARBONATE FILLER MASTERBATCH        
FORMULATION OF CALCIUM CARBONATE FILLED MASTERBATCH        
MANUFACTURING PROCESS OF CALCIUM CARBONATE FILLER
MASTERBATCH                                            
PROCESS FLOW DIAGRAM                                    
OVERVIEW OF PLASTIC INDUSTRY IN INDIA                        
MARKET POSITION OF MASTERBATCHES                            
IMPORT DATA OF FILLER MASTERBATCH                        
EXPORT DATA OF CALCIUM CARBONATE MASTERBATCH                
PRESENT MANUFACTURERS/SUPPLIERS OF CALCIUM CARBONATE FILLER MASTERBATCHES                                          
OTHERS FORMULATIONS                                    
PLANT LAYOUT                                            
SUPPLIERS OF RAW MATERIALS                                
SUPPLIERES OF PLANT AND MACHINERY                            


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