Detailed Project Report on P.V.C. Compounding (Fresh) for Cables and PVC Pipes

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P.V.C. COMPOUNDING (FRESH) FOR CABLES AND PVC PIPES

[EIRI/EDPR/1611] (J.C. 412)

INTRODUCTION

Indian plastics industry is one of the largest in the Asian Region. It had a modest beginning in the late twenties when articles like combs, soap boxes, ash trays etc. began to be manufactured in the country from imported raw materials. Three are about fifty materials identified as plastics and the list is being extended continuously. Plastics are classified as thermoplastics and thermo sets on the basic of the polymerization method adopted to produce the basic plastic material as on the basic of the primary raw materials source. Polyvinyl chloride comes under thermoplastics. Polyvinyl chloride (PVC) polymers or resins are the most important constituents of PVC compounds and are classified into bulic or mass polymers, emulsion polymers, suspension polymers and paste-forming polymers. There is a fifth type known as solution polymers which is used for coating applications.

Compounding of PVC resin is done in three steps, namely

1. Premixing 2. Fusion or gelation 3. Pelletizing or granulation. Mixing of the ingredients to a high degree of homogenization is called (premixing). The premixed material is homogenized during Fusion or Gelation. In the third step namely pelletization or granulation the homogenous mass is produced in a suitable form for smooth processing. Hence it is possible to avoid one or more of the steps with the help of modern processing equipment.

Although plastic industry in India experienced many ups and downs in the 70's it has made considerable progress not only in the output and range of plastics raw materials produced and consumed but also in learning and absorbing better processing technology as well as the manufacture of more and better machine.

COST ESTIMATION

Plant Capacity 120 MT/Day

Land & Building (3.8 Acres) Rs. 3.75 Cr

Plant & Machinery Rs. 25.50 Cr

Working Capital for 1 Month Rs. 17.68 Cr

Total Capital Investment Rs. 48.61 Cr

Rate of Return 42%

Break Even Point 43%

CONTENTS

INTRODUCTION

DEVELOPMENT IN PVC COMPOUND

PHYSICAL APPEARANCE?

WHAT PHYSICAL PROPERTIES DOES THE COMPOUND NEED TO HAVE?

HOW WILL THE MATERIAL BE PROCESSED?

BASE MATERIAL

ADDITIVES

MATERIAL DEVELOPMENTS

PVC PERFORMANCE

SOFT PVC (A PLASTICIZED PVC):-

PIGMENTS:-

RIGID (OR UNPLASTICIZED) PVC:-

USES AND APPLICATION

COMMERCIAL PVC COMPOUNDS:- GENERAL OUTLINE OF TYPES

BUREAU OF INDIAN STANDARDS SPECIFICATION

MARKET SURVEY

THE RISE

THE FALL

WIRE AND CABLE INSULATION

EVEN THOUGH WITH ITS NUMEROUS MERITS SUCH AS:

THE INDIAN POLYMER INDUSTRY:-

THE CHANGING SCENARIO:-

INDUSTRY GROWTH

CONSUMPTION PATTERN OF PVC IN INDIA

GLOBAL DEMAND OF PVC

THE PROCESSING SECTOR

PRESENT MANUFACTURERS OF PVC COMPOUND

RENEWABLE PVC COMPOUNDING AND ITS DETAILS

RENEWABLE PLASTICIZERS

RENEWABLE PVC COMPOUND

ENVIRONMENTAL IMPACT AND TOXICOLOGY

THE CALCULATION IS SUMMARIZED BELOW

RIGID PVC COMPOUNDING MATERIALS

RESIN

STABILIZERS

STABILIZER-LUBRICANT PACKAGE

FILLERS

PIGMENTS

PROCESSING AIDS

IMPACT MODIFIERS

LUBRICANTS

EXTERNAL LUBRICANTS

INTERNAL LUBRICANTS

EXTERNAL/INTERNAL LUBRICANTS

FORMULATION FOR DIFFERENT GRADES OR P.V.C.

PROCESS OUTLINE OF PVC COMPOUNDING

TYPICAL FORMULATION OF PVC COMPOUNDS

UNPLASTICISED RIGID PVC PIPES

WIRES & CABLES (ELECTRICAL)

FORMULATION OF PVC COMPOUND FOR PVC PIPE

PROCESS OF MANUFACTURE

RAW MATERIAL QUALITY ASSURANCE, EVERY STEP OF THE WAY

RELIABLE, PROVEN PVC COMPOUNDING CAPABILITY

PROCESS FLOW DIAGRAM

PVC PIPE COMPOUND PROCESS AND FORMULATIONS

POLYVINYL CHLORIDE (PVC) PIPE COMPOUND

POLYVINYL CHLORIDE (PVC) PIPE RESIN

STABILIZER ADDITIVE

CALCIUM STEARATE ADDITIVE

PARAFFIN WAX ADDITIVE

POLYETHYLENE WAX ADDITIVE

PIGMENTATION ADDITIVE

CALCIUM CARBONATE ADDITIVE

ACRYLIC PROCESS AID/IMPACT MODIFIER ADDITIVE

SUPPLIERS OF RAW MATERIALS

POLYMERS: POLYVINYL CHLORIDE (PVC)/RESINS

STABILIZERS

PLASTICIZERS’

CALCIUM STEARATE

C.P.W

SUPPLIERS OF PLANT AND MACHINERY

GRANULES EXTRUSION MACHINES

HIGH SPEED MIXER

AIR COMPRESSOR

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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