Detailed Project Report on powder manufacturing unit for purepolyester & epoxy

POWDER MANUFACTURING UNIT
FOR PUREPOLYESTER & EPOXY
[CODE NO. 2063]

The success of powder coatings from its earliest beginnings in 1960’s is unmistakable. More than twenty years after they first entered the market powder coatings in the 80s  has  now become a commercial and technical success.

Powder can  be  described as solid paint.   It  is  applied through special gun which electrically charges the particles  and deposits  them on to an earthed article.  The charge  allows  the particles to remain adherent to the substrate and when baked  the particles fuse together and cross link the polymers to form  hard abrasion resistant coating.

There is an liner increasing variety of powder coatings to choose from and the final selection will depend on the end use and requirement of coated substrate.

The  thermo setting system the polymer is a   low  molecular weight  species  which  melts and  flows  decreasing  fusion  and undergoes  to a thermoset cured condition.  Once  this  condition has  been  achieved  it  can no longer  be  remelted  to  plastic condition.

The  iron linking reaction occurs in  thermosetting  powders between  the reactive group of resins like epoxy, polyester  etc. and  those  of  curing  agents.  To achieve  a  smooth  film  the polymers must flow out to a continuous and even film before  cure is initiated.

Powder  is in variably a composite, balancing the  softening temperature with the melt viscosity or fusion characteristic  and the  speed  of  cross  linking .   The  components  required  for manufacture of thermosetting powders are as follows :-

     1.   Polymers

     2.   Hardeners, Catalyst, Curing agents

     3.   Pigments, extenders

     4.   Flow control additives.

Resins having a softening point between 700C to  1100C  are usually employed.  Resins of lower melting point have tendency to 'Cake"  in the powder form on storage and furthermore  have  very poor 'edge coverage'.

Alternatively those of higher melting point will give better  'edge coverage' but have very poor flow and 'Orange peel defect.

The  applications  curing  and properties  required  in  the coating influence the choice of curing agent to be used with  the particular type of polymer to be used in the formulation.

The  hardener  should  be  unreactive  at  room  temperature remaining  latent  at  upto 100oC and should  react  fully  below 1800C.   The  reaction  should  not be so  rapid  as  to  prevent complete flow out of the fused resins as this would lead to  very poor flow of the powder.


COST ESTIMATION

Plant Capacity                                               4.00 Ton./day
Land & Building (3000 Sq.Mtr)                    Rs. 2.67 Cr
Plant & Machinery                                          Rs.1.50   Cr
W.C. for 2 Months                                           Rs. 4.90  Cr
Total Capital Investment                               Rs.9.27  Cr
Rate of Return                                                26%
Break Even Point            52%


•    INTRODUCTION    
•    PROPERTIES    
•    USES AND APPLICATION    
•    B.I.S. SPECIFICATION    
•    MARKET POSITION    
•    CMEMISTRY OF POWDER COATINGS POLYMERS    
•    PRESENT MANUFACTURERS    
•    FORMULATION OF POWDER COATINGS    
•    MANUFACTURING PROCESS    
•    PROCESS FLOW SHEET FOR POWDER COATING MANUFACTURING    
•    APPLICATION TECHNIQUES    
•    ELECTROSTATIC FLUIDIZED BED    
•    PRINCIPLES OF PLANT LAYOUT    
•    PLANT LOCATION FACTORS    
•    EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
•    PROJECT IMPLEMENTATION SCHEDULES    
•    PLANT LAYOUT    
•    SUPPLIERS of RAW MATERIALS    
•    SUPPLIERS 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