Detailed Project Report on PU Based Footwears

PU BASED FOOTWEARS

[EIRI/EDPR/1395] J.C. 172 

INTRODUCTION

Polyurethane is widely defined as a polymer material containing a huge amount of urethane group. Despite the chemical reaction between the NCO group and the hydroxyl compound that was originally found in the 19th century, the basic addition polymerization reaction of diisocyanate with alcohols to produce polymers, which is a polyurethane reaction, was not discovered and established until 1937 by Dr. Otto Bayer and co-worker in the laboratories of I. G. Farben Industrie. Chemical Co. in Germany. Between 1945 and 1947, millable elastomers, coatings and adhesives, the first commercial applications of polyurethane polymers, were developed. This was followed by the flexible polyurethane foams in 1953 and rigid polyurethane in 1957.

Polyurethanes can be manufactured in an extremely wide range of density and stiffness and have a broad range of applications. The densities of polyurethanes range from 6 to 1,220 kg/m3 and polymer stiffness of polyurethanes range from elastomers to flexible, rigid and hard plastics. The global polyurethanes consumption has been growing at an average rate of over 7% annually for the last 15 years. Thus, it is not surprising that polyurethanes are all around us, from shoes to sofas, insulation panels to automobiles, playing an important role in many ways in our daily life.

In the past, polyurethanes were usually made with petroleum polyols. With the dwindling and non-renewable petroleum resource, some novel polyols made from vegetable and seed oil have been investigated for their potential of replacing the petroleum polyols. of particular interest is a group of polyols derived from soybean oil.

These new polyols, however, have some major disadvantages limiting its applications when compared with petroleum polyols:

1. The alcohol groups in the petroleum polyols are primary which are 3.3 times more reactive with isocyanates than the secondary ones in the new polyols.

2. The saturated fatty acid in these new polyols is not reactive and adversely impacts the properties of polyurethane foams.

3. Most of these new polyols are not cost competitive against the petroleum polyols due to multiple steps involved and/or solvent consumption.

COST ESTIMATION

Plant Capacity            1000 Pairs/Day

Land & Building (10,000 sq.mt.)    Rs. 11.25 Cr

Plant & Machinery                    Rs. 1.40 Cr

Working Capital for 2 Months    Rs. 2.43 Cr

Total Capital Investment          Rs. 15.77 Cr

Rate of Return                          15%

Break Even Point                      64%

CONTENTS

INTRODUCTION

SUPPLEMENTARY ACTIVITIES

GENERAL FUNCTIONAL REQUIREMENTS FOR SHOE SOLES

GENERAL MANUFACTURING PROCESS

THE CONSTRUCTION OF SPORTS SHOE SOLES

IMPORTANCE OF POLYURETHANE IN SHOE INDUSTRY AND ITS PROPERTIES

PHOTODEGRADATION IS REALLY TWO DISTINCT PROCESSES

GLOBAL PU FOOTWEAR INDUSTRY

SHOE MAKING- HOW SHOES ARE MADE

PROCESS OF MANUFACTURE

PROCESS DESCRIPTION:

ADDRESSES OF SUPPLIERS/MANUFACTURERS OF COMPLETE SHOE MAKING MACHINES

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)