Detailed Project Report on hdpe pipe manufacturing unit

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HDPE PIPE MANUFACTURING UNIT
[CODE NO 3364]

It needs to be well understood and noted that HDPE pipe is a kind of flexible plastic pipe that is extensively used for gas and fluid transfer. It is also used to replace the ageing concrete or steel pipelines. This type of pipe is well suited for high pressure pipelines. These pipes are extensively used for various applications such as drainage pipes, storm-water pipes, rural irrigation, slurry transfer lines, electrical and communications conduit, and few more.

It is interesting to note how HDPE pipes are manufactured in the manufacturing unit. To makes these pipes, the HDPE resin is heated and extruded across through a die, determining the diameter of the pipeline. The combination of the size of the die as well as speed of the screw determines the thickness of the pipe. This pipe is mostly black in color due to addition of carbon black to the polyethylene material. This addition of carbon black leads to creation of a UV resistant product.

The HDPE pipe has many different applications. However, most importantly, it is used in the rural and mining environments in various countries as an effective and durable means of gas and fluid transfer. The HDPE pipes have life expectancy of more than 100 years. They are also used much for water and irrigation supply as well as industrial applications.

It is important to note the manufacturing process of HDPE Pipe. In the manufacturing process, the polyethylene raw material is usually pulled down from a silo into the hopper dryer, which in turn removes any kind of moisture from the pellets. This is then pulled by a vacuum pump into a blender, heated by a barrel heater. The raw material is molten at around 180 degree celsius which shapes it into a circular one. The pipe that is newly formed quickly enters the cooling tanks. As polyethylene has high heat capcity, it is important to cool the pipes in stages to avoid any kind of deformation. These pipes are then rolled and cut into specific lengths and sizes as required.

Different die is used for striping of the HPDE pipe having small channels across which the colored material runs through. The striped consist of an integral part of the pipe. It is important that the pipes are colored on the outside for identification / thermal cooling requirements. All these scientific and technical aspects are well taken care of in the HDPE manufacturing unit.

Herewith, we have well covered the benefits, manufacturing, uses as well as life-expectancy of the HDPE pipes. It is important to take care of all these aspects while manufacturing the HDPE pipes in the manufacturing unit. The usage across the water and gas mains, sewer mains, system supply lines, rural irrigation lines as well as drainage pipes – need to be well understood and communicated across all the technical staff handling the manufacturing process of HPDE pipes. It needs to be well noted that HDPE pipes are very flexible as well as durable in nature.

COST ESTIMATION

Plant Capacity               :      8.00 MT./day
land & Building (10000 sq.mt) :   Rs. 3.24 Cr
Plant & Machinery      :   Rs. 3.38 Cr
Working Capital for 1 Month    :   Rs. 1.74 Cr
Total Capital Investment    :   Rs. 8.54 Cr
Rate of Return           :   27%
Break Even Point          :   59%

INTRODUCTION
CLASSIFICATION
THE PRESSURE GRADES AVAILABLE ACCORDING TO EUROPEAN
STANDARDS ARE
COLOR CODES USED TO INDICATE THE PRESSURE GRADES ON
THE PIPES ARE:   HDPE PIPES FOR FOLLOWING GRADES/SIZES/PRESSURE RATING
CHARACTERISTICS
USES AND APPLICATION
RELINING - NEW PIPES IN OLD
SEWER PIPES
SLURRY TRANSPORTATION
IRRIGATION
DOMESTIC GAS DISTRIBUTION
CHEMICAL PROCESS PIPING
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
EXTRUSION PROCESS
WORKING PRINCIPLE
EXTRUSION PROCESS PARAMETERS
ADVANTAGES:
DISADVANTAGES:
RAW MATERIALS
A. HDPE GRANULES
B. BLACK MASTER BATCH
C. ANTI-OXIDANT
DESCRIPTION OF MANUFACTURING PROCESS
INCOMING RAW MATERIAL INSPECTION
RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
RESIN STORAGE AND CONVEYANCE
RESIN FEEDING
TESTING
(A) TYPE TEST
(B) ACCEPTANCE TEST
(C) LONGLTUDINAL REVERSION PERFORMANCE TEST
APPRATUS
1. AIR OVEN
2. THERMOMETER
TEST SPECIMENS
PROCEDURE
MARKING
MARKET POSITION
THE INDIAN SUBCONTINENT AND WATER CRISIS
WATER PIPES AND INFRASTRUCTURE
TEN EXCELLENT REASONS TO CHOOSE HDPE PIPE SYSTEMS INSTEAD
OF OLDER-GENERATION MATERIALS:
FUTURE GROWTH AND MAIN DEMAND DRIVERS ACROSS INDIA’S
PIPE INDUSTRY
THE INDIAN PLASTIC PIPES MARKET
TYPES OF PLASTIC PIPES APPLICATION
MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
INDIAN SCENARIO (2014)
GLOBAL SCENARIO (2014)
PRODUCT WISE BREAK UP OF PLASTIC PRODUCTS EXPORTS IN 2013-2014
INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
BARGAINING POWER OF SUPPLIERS
BARGAINING POWER OF BUYERS
INTERNAL RIVALRY
THREAT OF SUBSTITUTES
GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
OTHER MEASURES LIKE:
PLASTIC PIPES GROWTH IN INDIA IN LAST THREE YEARS AND
FORTH COMING YEARS
USING TIME SERIES FORECASTING METHOD (MOVING AVERAGE)
WE CAN PREDICT FOR 2012-2017:
LIST OF PLAYERS INDIA (LISTED AND UNLISTED)
PLASTIC PIPES: GLOBAL DEMAND (TOTAL 7.5 BN METERS)
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
DETAILED EXPORT DATA OF HDPE PIPE PE
EXPORT DATA OF HDPE PIPE PE
IMPORT DATA OF HDPE PIPE PE
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF HDPE PIPE
SUPPLIERS OF RAW MATERIALS
HDPE GRANULES
SUPPLIERS OF BLACK MASTER BATCH
SUPPLIERS OF ANTIOXIDANT
SUPPLIERS OF COMPLETE HDPE PIPE PLANT
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
EFFULENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
LIST OF PLANT & MACHINERY
(A) EXTRUDER-1
(B) EXTRUDER-2
(C) TESTING INSTRUMENTS
(D) UTILITY

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

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