Detailed Project Report on Rigid PVC Film Manufacture for Pharmaceuticals Blister Packaging

RIGID PVC FILM MANUFACTURE FOR PHARMACEUTICALS BLISTER PACKAGING

[EIRI/EDPR/1533] J.C. 327

INTRODUCTION

Plastic films (PVC) have got wide uses including for garments and saree packaging. Polyvinyl chloride (P.V.C.) is one of if not the largest single volume plastics material in general use in the world. It is potentially one of the lowest cost materials. The French chemist Regnault first discovered P.V.C. in 1835 and it was initially marketed commercially in 1827. P.V.C. has achieved this market leadership because of its good physical properties, its compounding versatility for a wide variety of applications, its low cost, and processing case. These desirable   properties include self extinguishing characteristics, water, chemical and abrasion resistance, good strength properties and a complete range of colours. The compounds range from soft flexible films, to rigid, high strength products.   Plasticizers lubricants, fillers and stabilizers are used to produce this versatility and it possible to make a compound with a right balance of properties for almost any application. P.V.C. products will melt but will not burn and good weather ability has been achieved by compounding.

There are various theories on compounding of P.V.C. but the PVC processor especially in small scale sector  in India  because of lack of availability  and  high  price of sophisticated equipments instruments testing facilities  trained   technical personnel, raw materials looks forward to something practical which wood  benefit him in knowing the best possible and most economical method of PVC compounding.

Compounding process includes (i) formulation of compound according to the properties desired (ii) Palletizing. The palletizing process is done either by rotary knife cutter or granulator. There are heavy duty and light duty machines, the former for such scrap as extrusion and injection machine purging and waste and the latter for spures and runners, films upholstery material, etc. Small machines are available to be kept by the side of injection presses, extruders etc., and the scrap is used as it is made. It has the advantage of continued use with no scrap, no contamination, no bagging and no transport.

P.V.C. is consumed for manufacture of a vast varieties of products.   Products  are usually made by extrusion, injection rotational, slush, transfer  compression and blow moulding calendering, thermoforming, fluid bed coating,  rotocasting  and foaming procedures.

For the present project report's point of view  restriction in made to cover the manufacture of rigid PVC film for pharmaceuticals blister packaging.

As PVC has been put into O.G.L. groups items the basic  raw material  PVC can be imported without much constraints  therefore raw materials crisis will not also be much in future.

COST ESTIMATION

Plant Capacity            2 MT/Day  

Land & Building (1500 sq.mt.)    Rs. 2.10 Cr    

Plant & Machinery                    Rs. 3.93 Cr 

Working Capital for 3 Months    Rs. 1.33 Cr 

Total Capital Investment          Rs. 7.75 Cr 

Rate of Return                          30%

Break Even Point                      51%

CONTENTS

INTRODUCTION

PROPERTIES

USES AND APPLICATION

OVERVIEW OF PHARMACEUTICALS INDUSTRY

GLOBAL PVC (POLYVINYL CHLORIDE) MARKET

GLOBAL MARKET POSITION OF PLASTIC PACKAGING

RIGID PVC FILM USING BLOWN FILM EXTRUSION

B.I.S. SPECIFICATIONS

RIGID POLYVINYL CHLORIDE (PVC) COMPOUND- SPECIFICATIONS

ASTM STANDARD FOR PVC COMPOUND (RIGID)

PVC COMPOUNDING FORMULATION FOR RIGID FILM FOR PHARMACEUTICAL BLISTER PACKAGING

MANUFACTURING PROCESS OF RIGID PVC FILM FOR PHARMACEUTICAL 

BLISTER PACKAGING (CALENDERING PROCESS)

DETAILS OF CALENDARING PROCESS TO MANUFACTURE PVC FILM

PROCESS FLOW DIAGRAM OF RIGID PVC FILM MANUFACTURE FOR PHARMACEUTICAL BLISTER PACKAGING

PROCESS OF MANUFACTURE OF PVC RIGID FILM BY EXTRUSION PROCESS

EXTRUDERS AND EXTRUTION PROCESS

THE HEAD & DIE ASSEMBLY

PROCESS FLOW CHART PVC FILMS

OTHER COMPOUNDING FORMULATION FOR PVC FILM

GRADES AND DETAILS OF PVC FOR THE PRODUCTION OF RIGID FILM

PROPERTIES AND APPLICATIONS OF EMULSION PVC

GRAFTED COPOLYMERS AS IMPACT MODIFIERS FOR FILMS

GRAFTED COPOLYMERS FOR FLEXIBLE FILMS WITH REDUCED MIGRATION

PVC WITH HIGH MOLECULAR WEIGHT FOR ANTIBLOCKING MATTING AND TEXTURING

RESENT MANUFACTURERS FOR PVC FILM

PLANT LAYOUT

OVER SEAS MANUFACTURES OF RIGID PVC FILM

SUPPLIERS OF RAW MATERIALS

COMPLETE PLANT AND MACHINERY SUPPLIER

ADDRESS OF SUPPLIERS OF PLANT & MACHINERY

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)