Detailed Project Report on silicone foam manufacturing for railway

SILICONE FOAM MANUFACTURING FOR RAILWAY
[CODE NO.3782]  


Silicone foam is a synthetic rubber product used in gasketing, sheets and firestops. It is available in solid, cured form as well as in individual liquid components for field installations.

Silicone foams are lightweight products derived from liquid silicone ingredients that are cast onto a liner and cured in an oven. Low density silicone foams have open cell structure that may allow moisture to pass through the cell structure. Open cell silicone foam can be compressed to collapse the cells offering a water tight seal. In contrast, higher density silicone foam products will have a higher proportion of closed cells compared with medium or low density grades. As with all gaskets, with the proper deflection, a good long term weather seal can be achieved.


What is Silicone Foam?

Silicone foam products are manufactured from platinum cured, liquid silicone rubber. The raw compound is expanded and dispensed on a continuous casting line, then heat cured. The expansion process is controlled to create a range of products having different densities, softness/firmness and cell structures. Silicone foam materials typically have a smooth skin on one or both sides due to the casting process. Open cell silicone foams are widely used for cushioning, dust sealing or light water sealing. Closed cell silicone foam materials are used for outdoor gaskets, wash-down gaskets and resilient cushioning pads. Expanded silicone foam products have a firmness range from Ultra Soft to Extra Firm, allowing engineers to select the best product for their application.


COST ESTIMATION


Plant Capacity                    0.50 MT/Day             
Land & Building                 Rs. 12.57 Cr                        
Plant & Machinery               Rs. 68 Lacs                       
Working Capital for 2 Month     Rs. 90 Lacs     
Total Capital Investment        Rs. 14.44 Cr
Rate of Return                    6%                   
Break Even Point             80%            


INTRODUCTION    
WHAT IS SILICONE FOAM?    
PROPERTIES OF SILICON FOAM    
ADVANTAGES    
USES AND APPLICATION    
USES    
APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUCACTURING PROCESS    
RAW MATERIAL    
(1) POLYSILOXANES AS A RUBBER POLYMER    
(2) FINALLY DIVIDED SILICA FILLERS AGENT    
(3) AZODICARBONAMID FOAMING AGENT    
(4) DIACYL PEROXIDE VULCNISING AGENT    
PEROXIDE VULCANIZATION    
EXAMPLES OF CO-VULCANIZATION AGENTS USED DURING
   PEROXIDE VULCANIZATION    
(A) SLABSTOCK    
(B) MOULDING
THE PROCESS OF FOAM PRODUCTION CAN BE DIVIDED INTO THE FOLLOWING STEPS:    
1) COMPOUNDING AND MATURING    
COMPONENT (A) IS AN ORGANOPOLYSILOXANE HAVING THE
    GENERAL FORMULA:    
2) FOAMING AND GELLING    
3) VULCANISATION    
4) WASHING AND DRYING    
MANUFACTURERS/SUPPLIERS OF SILICON FOAM    
MARKET POSITION    
GLOBAL OPEN CELL SILICONE FOAM MARKET SEGMENTATION    
THE TOP LEADING MARKET PLAYERS:    
IMPORT DATA OF SILICONE FOAM SHEETS    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
LIST OF APPROVED VENDOR FOR SUPPLIER OF SEAT AND BEARTH
   IN INDIAN RAILWAY    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF POLY SILOXANE    
SUPPLIERS OF DIACYL PEROXIDE    
SUPPLIERS OF AZODICARBON AMIDE    
SUPPLIERS OF SILICA FILLER    
SUPPLIERS OF COMPLETE RUBBER    
PROCESSING PLANT    
SUPPLIERS OF RUBBER CURRING OVEN
SUPPLIERS OF BOILERS    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF RUBBER TESING EQUIPMENTS    
SUPPLIERS OF MOLDS
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
JIGS AND FIXTURE    
SUBMERSIBLE WATER PUMP


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)