Detailed Project Report on wpc (plastic composite) board line manufacturing

WPC (PLASTIC COMPOSITE) BOARD
LINE MANUFACTURING
[CODE NO.3386]

Wood–plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220 °C; thus, general-purpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood–plastic composites are boards or lumber used in outdoor decking applications. Although early WPC products were mainly extruded for profiled sections, nowadays, many injected parts made of WPC are being introduced for various industries, including electrical casings, packaging, daily living supplies, and civil engineering applications. Mold and mildew and color fading of WPCs tend to be the durability issues of prime importance for WPCs. Most recent research on WPC durability focuses on studies to better understand the mechanisms contributing to various degradation issues as well as methods to improve durability. Most WPC products in the USA are utilized in building materials with few exceptions for residential and commercial building applications, which means that building codes are the most important national rules for the WPC manufacturers. New developments are being made especially in
the area of nano additives for WPCs including nanocellulose. Recently, the trend of patent registrations for WPCs has shifted to new products or applications instead of the materials itself.


COST ESTIMATION

Plant  Capacity                             :    8400.00 KGS/day
land & Building (4000 Sq.Mtr)   :    Rs. 2.00  Cr
Plant & Machinery                        :    Rs. 1.25  Cr
Working Capital for 2 Months    :    Rs. 3.50  Cr
Total Capital Investment             :    Rs. 6.89  Cr
Rate of Return                              :    37%
Break Even Point                         :    44%


INTRODUCTION    
USES & APPLICATIONS    
OURDOOR APPLICATION OF WPC    
RAW MATERIALS    
POLYMERS    
ADDITIVES    
ADVANTAGE AND DISADVANTAGE OF WPC    
ADVANCE MATERIALS FOR WPC    
WOOD MODIFICATION    
ADDITIVES    
PROFILES    
ASPECT OF WPC DURABILITY    
WEATHERING STUDIES    
FORMULATION OF WPC    
FIGURE  POLYETHYLENE (PE) – BASED COMPOSITE    
DIFFERENT PROCESSES FOR PLASTIC COMPOSITES    
EXTRUSION PROCESSING    
SINGLE-SCREW EXTRUDER    
COUNTER-ROTATING TWIN-SCREW EXTRUSION    
COMPOSITE SYSTEM    
MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS    
PLASTIC COMPOSITE MANUFACTURING TECHNIQUES    
WPC NEW MANUFACTURING TECHNOLOGY    
EXPERIMENTAL STAGES    
PILOT EXPERIMENTATIONS    
PREREQUISITE STAGE    
STAGE 1    
STAGE 2    
PROCESSES EXPERIMENTAL SETTINGS    
MARKET SURVEY    
NEW MARKET- WPC    
FENCING FUTURE    
THREAT FROM THE EAST?    
FEWER, BIGGER PLAYERS    
ADDITIVES CREATE RECIPE FOR GROWTH    
EXPORT OF WPC FROM INDIA    
GLOBAL TREND IN WOOD PLASTIC COMPOSITES    
GLOBAL PRODUCTION OF WPC, AND THE FORECAST    
PRESENT MANUFACTURERS OF    
WOOD PLASTIC COMPOSITE BOARDS LINE    
PROCESS FLOW DIAGRAM FOR PLASTIC COMPOSITE BOARD    
THE WPC (PLASTIC COMPOSITE) MANUFACTURING PROCESS WITH EXTRUSION FORMING    
TECHNICAL DETAILS OF PVC WPC FOAM BOARD LINE    
TECHNICAL/TURNKEY CONSULTANT    
FOR SETTINGUP WPC PLANT    
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)    
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)    
BOILER    75
GENERATOR SET (D.G. SET)    
MANUFACTURERS/SUPLIERS OF PLANT & MACHINERY    
EXTRUDERS    
PRESSING MACHINE    
COOLING TOWERS    
BOILER    
GENERATOR SET (D.G. SET)    
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS    
PLASTIC POLYMERS    
COUPLING AGENT    
ADDITIVES    
RAW MATERIALS CALCULATION    


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