Detailed Project Report on EPDM Rubber Profiles (Weather Strips, Industrial Mono Strips etc.)

EPDM RUBBER PROFILES (WEATHER STRIPS, INDUSTRIAL MONO STRIPS ETC)

[EIRI/EDPR/1492] J.C. 277

INTRODUCTION

Ethylene - propylene Rubber (EPM and EPDM)

Ethylene Propylene Diene Monomer Rubber, also named as EPDM in short, is the polymer of ethylene and propylene. Large scale commercial production began in 1963 and the current overall global consumption of EFPM are 800,000 tons per year. EPDM is polyolefine - categorized and has excellent performance of vulcanization and its gravity is the lowest among all rubbers.

These are radon copolymers of the two hydrocarbons ethylene and propylene with the ethylene varying from 40 to 70% by weight. This produces a saturated rubber, EPM, which has to be vulcanized with peroxide systems. Small quantities of a third monomer are, therefore added to produce ethylene-propylene terpolymers (EPDM) which can be vulcanized with sulphur in the usual way. Both types have outstanding resistance to sunlight, ozone and all forms of aging and weathering; together with a capacity to accept large loadings of extender oil and fillers without undue loss of physical properties. So far, their use in tyres has been limited mainly due to processing difficulties, although blends with up to 20% of EPDM have been successfully adopted by some manufacturers, particularly for sidewalls. Recent developments indicate more extensive use of EPDM in tyres. Non-tyre applications for EPDM include automobile components, roller coverings, acid hose, general building applications, reservoir linings and roofing sheet. Another important application for EPM and EPDM is in electric cable insulation.

EPDM (Ethylene Propylene Diene Monomer) Rubber has outstanding resistance to aging, weathering, ozone, oxygen and many chemicals. It offers excellent high and low temperature stability, plus steam and water resistance. In general, EPDM has dynamic and mechanical properties between natural rubber and SBR.

COST ESTIMATION

Land & Building (3000 Sq.Mtr)                  Rs 3.96 Cr
Plant & Machinery                                       Rs.2.00 Cr         
W.C. for 3 Months                                        Rs.4.49 Cr         
Total Capital Investment                             Rs. 8.60 Cr              
Rate of Return                                             36%   
Break Even Point                                        43%

CONTENTS

INTRODUCTION

ETHYLENE - PROPYLENE RUBBER (EPM AND EPDM)

PROPERTIES OF EPDM RUBBER

EPDM RUBBER MATERIAL PROPERTIES

THE MAJOR PROPERTIES OF EPDM GRANULES ARE AS FOLLOWS:

1. EXCELLENT CHEMICAL STABILITY:

2. GOOD ELASTICITY:

3. VIVID COLOR:

4. MADE FROM EPDM RUBBER:

5. EPDM CONTENT:

6. CONTAINING NO HAZARDOUS MATERIAL, NON-TOXIC AND ODORLESS AND SAFE.

7. LOW HEAT ABSORBENCY FOR BAREFOOT WALKING.

8. ECONOMIC AND EASY MAINTENANCE:

SPECIFICATION: 7

TABLE 1. -  PROPERTIES OF ETHYLENE-PROPYLENE ELASTOMERS

APPLICATION OF EPDM RUBBER

FEATURE OF EPDM ELASTOMERS

MAJOR PRODUCERS OF EPDM

CHEMISTRY AND MANUFACTURING PROCESSES

TABLE II – CURE-SITE DIENE TERMONOMERS IN ETHYLENE-PROPYLENE ELASTOMERS

EPDM PROFILES:

EPDM RUBBER PROFILE

SPECIALIZATION:

MARKET SURVEY

INDUSTRY OVERVIEW IN 2011

GLOBAL THE EPDM MARKET CAPITALIZATION WILL REACH $ 6.5 BILLION BY 2017

GLOBAL DEMAND FOR EPDM (ETHYLENE PROPYLENE DIENE MONOMER) IS SET TO INCREASE BY 1.5 MILLION TONS BY 2020

SUPPLY SCENARIO -PERIOD 2012

FUTURE INSTALLED CAPACITY AND PRODUCTION ESTIMATES FROM 2011 TO 2020 (IN METRIC TONNES)

DEMAND DRIVERS AND GROWTH TILL 2020

PATTERN OF APPLICATION SECTOR WISE DEMAND

EPDM DEMAND SET TO INCREASE BY 1.5 MILLION METRIC TONS BY THE YEAR 2020

PROJECTED DEMAND SUPPLY SCENARIO – PERIOD 2020

EPDM RUBBER USED SHRED GRAPH AREA WISE

MARKET SURVEY OF EPDM RUBBER PRODUCTS INCLUDING PROFILES IN INDIA FROM 2006 TO 2013

APPARENT CONSUMPTION OF EPDM PRODUCTS INCLUDING PROFILES FROM 2006 TO 2013

ESTIMATED DEMAND OF EPDM PRODUCTS FROM 2014 TO 2020

DEMAND SUPPLY GAP TILL 2019-20

RAW MATERIALS REQUIRED

PROCESS FLOW SHEET OF MANUFACTURE

FORMULATION AND PROCESSES OF EXTRUDED EPDM PROFILE

NR/EDPDM BLENDS FOR EXTRUDED PROFILE WEATHER-STRIP

TABLE-1 FORMULATIONS OF NR/MODIFIED –EPDM BLENDS FOR INITIAL EXTRUSION TRIALS

SMALL SCALE EXTRUSION TRIALS

TABLE-2 RHEOMETER CHARACTERISTICS OF COMPOUNDS FOR INITIAL EXTRUSION TRIALS

A MONSANTO MDR 2000E AT 180OC

NR / EPDM BLENDS FOR EXTRUDED PROFILE WEATHERSTRIP

TABLE-3 NR AND EPDM MASTERBATCH FORMULATIONS FOR LARGE SCALE MIXING AND EXTRUSION TRIALS OF SOFT AND MEDIUM SOFT BLEND COMPOUNDS

FORMULATION DEVELOPMENT AND PROCESSING

TABLE-4 EXTRUSION RATINGS OF LARGE SCALE MIXING TRIAL COMPOUNDS

TABLE-5 PHYSICAL PROPERTIES OF LARGE-SCALE MIXING TRIAL COMPOUNDS

TABLE-6 RESISTANCE OF LARGE SCALE MIXING TRIAL

COMPOUNDS TO AGEING IN AIR FOR 7 DAYS/70OC

FORMULATION DEVELOPMENT AND PROCESSING

TABLE-7 FORMULATIONS OF NR AND EPDM MASTERBATCHES FOR IMPROVED COMPRESSION SET PROFILES.

TABLE 8 EFFECT OF CURE SYSTEM ON COMPRESSION

SET OF NR/MODIFIED-EPDM BLENDS

COMPOUND FORMULATION OF EPDM WEATHER STRIP

COMPOUND FORMULATIN OF INDUSTRIAL MONO STRIP

RAW MATERIAL CALCULATION

FOR INDUSTRIAL MONO STRIP

FORMULATION

EPDM TEST FORMULATION-1

EPDM TEST FORMULATION-2

EPDM PROFILE MAKING MACHINE

SCHEMATIC FIGURE OF EPDM PROFILES PRODUCTION LINE

DIFFERENT TYPES OF EPDM PROFILE MANUFACTURE WITH SAME MACHINERY

DETAILS OF MACHINERY AND EQUIPMENT'S

RUBBER EXTRUSION

PRODUCTION LINE FOR RUBBER PROFILES PRODUCTION

SCHEMATIC FIGURE OF PROFILES PRODUCTION LINE

TYPES OF EXTRUDERS

SINGLE SCREW EXTRUDER:

TWIN SCREW EXTRUDER:

DIE FLOWS

A TYPICAL PROFILE EXTRUSION DIE

RUBBER PROFILE PRODUCTION LINE MODELS

RUBBER PROFILE PRODUCTION LINE

BLOCK DIAGRAM OF THE PRODUCTION

BLOCK DIAGRAM OF THE PRODUCTION PROCESS

VACUUM CALIBRATING STAND

HAUL-OFF

CUTTING MACHINE

TILT STACKER

RAW MATERIAL

TECHNICAL KNOW-HOW AVAILABLE AT FOLLOWING ADDRESS

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

IMPLEMENTATION SCHEDULE

EFFLUENT TREATMENT AND DISPOSAL

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

LIST OF EPDM BASED PRODUCTS MANUFACTURER IN INDIA

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF RAW MATERIAL/EPDM/SYNTHETIC RUBBER

CARBON BLACK

INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER

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)