Detailed Project Report on Cell Cast Acrylic Sheet

CELL CAST ACRYLIC SHEET

[EIRI/EDPR/1442] J.C. 223

INTRODUCTION

Acrylic plastic refers to a family of synthetic, or man-made, plastic materials containing one or more derivatives of acrylic acid. The most common acrylic plastic is polymethyl methacrylate (PMMA), which is sold under the brand names of Plexiglas, Lucite, Perspex, and Crystallite. PMMA is a tough, highly transparent material with excellent resistance to ultraviolet radiation and weathering. It can be colored, molded, cut, drilled, and formed. These properties make it ideal for many applications including airplane windshields, skylights, automobile taillights, and outdoor signs. One notable application is the ceiling of the Houston Astrodome which is composed of hundreds of double-insulating panels of PMMA acrylic plastic.

Like all plastics, acrylic plastics are polymers. The word polymer comes from the Greek words poly, meaning many, and meros, meaning a part. A polymer, therefore, is a material made up of many molecules, or parts, linked together like a chain. Polymers may have hundreds, or even thousands, of molecules linked together. More importantly, a polymer is a material that has properties entirely different than its component parts. The process of making a polymer, known as polymerization, has been likened to shoveling scrap glass, copper, and other materials into a box, shaking the box, and coming back in an hour to find a working color television set. The glass, copper, and other component parts are still there, but they have been reassembled into something that looks and functions entirely differently.

The first plastic polymer, celluloid, a combination of cellulose nitrate and camphor, was developed in 1869. It was based on the natural polymer cellulose, which is present in plants. Celluloid was used to make many items including photographic film, combs, and men's shirt collars.

In 1909, Leo Baekeland developed the first commercially successful synthetic plastic polymer when he patented phenol formaldehyde resin, which he named Bakelite. Bakelite was an immediate success. It could be machined and molded. It was an excellent electrical insulator and was resistant to heat, acids, and weather. It could also be colored and dyed for use in decorative objects. Bakelite plastic was used in radio, telephone, and electrical equipment, as well as counter tops, buttons, and knife handles.

Acrylic acid was first prepared in 1843. Meth acrylic acid, which is a derivative of acrylic acid, was formulated in 1865. When meth acrylic acid is reacted with methyl alcohol, it results in an ester known as methyl methacrylate. The polymerization process to turn methyl meth acrylate into poly methyl meth acrylate was discovered by the German chemists Fittig and Paul in 1877, but it wasn't until 1936 that the process was used to produce sheets of acrylic safety glass commercially. During World War II, acrylic glass was used for periscope ports on submarines and for windshields, canopies, and gun turrets on airplanes.

COST ESTIMATION

Plant Capacity            4800 sq.ft./Day

Land & Building (5000 sq.mt.)    Rs. 7.18 Cr

Plant & Machinery                    Rs. 1.41 Cr

Working Capital for 2 Months    Rs. 1.58 Cr

Total Capital Investment          Rs. 10.81 Cr

Rate of Return                          38%

Break Even Point                      43%

CONTENTS

INTRODUCTION

USES OF POLYMETHYLMETHACRYLATE IN ORTHOPAEDIC SURGERY

MARKETS

ANNUAL PRODUCTION OF POLY (POLYMETHYL METHACRYLATE)

MANUFACTURE OF ACRYLIC SHEET

CLEANER TECHNOLOGY IN THE ACRYLIC CAST SHEET PRODUCTION

ENVIRONMENTAL IMPACT EVOLUTION OF THE ACRYLIC SCRAP RECYCLE

FLOW SHEET FOR THE PRODUCTION OF CELL CAST ACRYLIC SHEET

SUPPLIERS/MANUFACTURERS OF CELL CAST ACRYLIC SHEET

OTHER RELATED INFORMATIONS

LOW MOISTURE ABSORBING ACRYLIC SHEET

DEVICE FOR CASTING ACRYLIC SHEETS

TRANSPARENT BULLET-RESISTANT ACRYLIC SHEET

FIRE RESISTANT POLY(METHYL METHACRYLATE) COMPOSITION

FLAME RETARDANT POLYMETHYL METHACRYLATE COMPOSITIONS

PROCESS FOR PRODUCING POLYMETHYL METHACRYLATE

PREPARATORY EXPERIMENTS

SUPPLIERS OF PLANT AND EQUIPMENTS

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)