Detailed Project Report on Flex Banner Substrate Used In Digital Printing

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FLEX BANNER SUBSTRATE USED IN DIGITAL PRINTING

[EIRI/EDPR/1010] J.C.: 9649

INTRODUCTION

Polyester/vinyl chloride polymer laminates used as Flex Banner

It has been found difficult to produce laminates of linear polyesters such as polyethylene terephthalate and vinyl chloride polymers since these two types of polymers do not usually adhere well to each other; indeed polyethylene terephthalate is often used as a release layer for sheets or films of vinyl chloride polymers.

This method provides a well adhered laminate of a synthetic linear polyester and a plasticised vinyl chloride polymer, the effective bonding between these two particular polymers being promoted by an intermediary primer coating comprising a certain polymeric composition.

According to the present method there is provided a laminate comprising a layer of a synthetic linear polyester, a plasticiser-free polymeric primer coating applied to at least one surface of the polyester layer and comprising a cross-linked composition comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, and at least one layer made from a plasticised vinyl chloride polymer composition which is bonded to the linear polyester layer through the intermediary of the primer coating.

According to another apsect of the method there is provided a process for the production of a laminate which comprises applying an aqueous or organic dispersion of a polymeric primer composition to at least one surface of a layer of a synthetic linear polyester, said primer composition comprising a plasticiser-free cross-linkable composition comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, removing the dispersing medium and cross-linking the primer composition, and bonding to one or both sides of the polyester layer, through the intermediary of the primer coating so formed, a layer made from a plasticised vinyl chloride polymer composition.

According to a further aspect of the method there is provided the use of a plasticiser-free cross-linkable composition, comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, for the production of a primer coating for a layer of a synthetic linear polyester which coating acts, when cross-linked, as an adhesion-promoting agent between the layer of polyester and a layer made of a plasticised vinyl chloride polymer which is bonded thereto.

The above defined primer coating promotes excellent adhesion between the linear polyester layer and the plasticised vinyl chloride polymer layer. An example of a composition used for the primer coating comprises a copolymer of ethyl acrylate, methyl methylacrylate and methacrylamide, which has been cross-linked with an ethylated melamine/formaldehyde condensation product. The primer composition is preferably cross-linked with the aid of a suitable added cross-linking catalyst, e.g. ammonium chloride, ammonium nitrate, ammonium thiocyanate, ammonium dihydrogen phosphate, ammonium sulphate, diammonium hydrogen phosphate, para toluene sulphonic acid, maleic acid stabilised by reaction with a base, or morpholinium para toluene sulphonate. The cross-linking is preferably effected before the laminating operation begins.

COST ESTIMATION

Plant Capacity 2400 sq.ft./Day

Land & Building (1000 sq.mt.) Rs. 65.00 Lac

Plant & Machinery Rs. 17.00 Lac

Working Capital for 3 Months Rs. 48.77 Lac

Total Capital Investment Rs. 1.33 Cr

Rate of Return 83%

Break Even Point 31%

CONTENTS

INTRODUCTION

POLYESTER/VINYL CHLORIDE POLYMER LAMINATES USED AS FLEX BANNER

METHOD 1

METHOD 2

INTRINSIC VISCOSITY

STIFFNESS

WEAR LOSS

DENSITY OF EACH OF THE FILMS CONSTITUTING THE LAMINATE FILM

METHOD 1

METHOD 2

METHOD 3

METHOD 4

METHOD 5

METHOD 6

METHOD 7

DROP-OUT

STIFFNESS

WEAR LOSS

METHOD 9

METHOD 10

METHOD 11

METHOD 12

METHOD 13

METHOD 14

LAMINATED POLYESTER FILM AS FLEX BANNER

(GRAFTED MOIETY OF POLYESTER GRAFT COPOLYMER)

(POLYMERIZATION INITIATOR AND OTHER ADDITIVES)

(POLYESTER BASE FILM)

1) ADHESIVE PROPERTY I

2) ADHESIVE PROPERTY II

3) HYDROGEN BONDING COMPONENT OF THE SURFACE ENERGY (ΓS H)

4) BLOCKING PROPERTY

5) GLASS TRANSITION TEMPERATURE (TG)

6) APPARENT SPECIFIC GRAVITY

7) PERCENT LIGHT TRANSMISSION

METHOD 1

METHOD 2

METHOD 3

POLYESTER LAMINATES USED AS FLEX BANNER

(I) EVALUATION OF POLYESTER RESINS

(IA) CONTENT OF CYCLIC ACETAL DIOL UNITS

(IB) GLASS TRANSITION TEMPERATURE

(IC) INTRINSIC VISCOSITY

(ID) MELT VISCOSITY

(IE) MELT STRENGTH

(II) EVALUATION OF LAMINATE WITH BACKING PAPER

(IIA) MOLDABILITY

(IIB) HEAT SEAL STRENGTH

(IIC) FRAGRANCE PRESERVATION

(IID) ADSORPTIVITY

(III) EVALUATION OF LAMINATE WITH BACKING RESIN FILM

(IIIA) HEAT SEAL STRENGTH

PRODUCTION METHODS 1-2

METHOD 1

METHOD 2

METHOD 3

METHOD 4

LAMINATED POLYESTER FILM AND LAMINATED FILM AS FLEX BANNER

METHOD 1

METHOD 2

HIGHLY PLASTICIZED LAMINATED VINYL FABRIC

IT IS THEREFORE AMONG THE OBJECTS OF THE PRESENT METHOD TO PROVIDE:

EXTRUSION

TOP COATING - LUSTER CONTROL

TOP-COATING APPARATUS

LAMINATION

FABRIC CONSTRUCTION - FIGS. 2 AND 3

VINYL CHLORIDE POLYMER LAMINATE

METHOD 1

MANUFACTURING PROCESS OF LAMINATED POLYESTER FILM

[POLYESTER FILM]

[COATING LAYER]

[POLYMER BINDER]

POLYESTER 1:

POLYESTER 2:

ACRYLIC 1:

ACRYLIC 2:

URETHANE:

FINE PARTICLES 1:

FINE PARTICLES 2:

INDUSTRIAL FEASIBILITY

METHODS OF MANUFACTURE

MANUFACTURER/EXPORTER

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)

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