Polyurethane Foam (Production Rate – 360 TPA)

POLYURETHANE FOAM (PRODUCTION RATE – 360 TPA)

[EIRI/EDPR/4586] J.C.: 2803XL

INTRODUCTION

Polyurethane foams are materials with a low weight-to-strength ratio, desirable insulating properties and a strong tendency for energy absorption. Broadly, foams come in three types – polyurethane (PU), memory foam and latex rubber foam. PU foam and Memory foam both are polyurethanes but memory foam has additional chemical composition to provide the contraction and retention. So, it is important to understand Polyurethane Foams in detail and the cost structure. At its core, manufacturing polyurethane foam is similar to making a cake. You have a batter and then you bake it (causing it to expand) and you get a fluffy cake. Similarly, you have a chemical mix which when exposed to a blowing agent and a catalyst causes the mix to expand and cool down to become foam.

Polyurethane foams are prepared by the reaction of a polyisocyanate with a polyol in the presence of a blowing agent, a surfactant, and a catalyst without external heating of the foaming system. The principle of preparation of urethane foams is based on the simultaneous occurrence of two reactions, i.e., polyurethane formation and gas generation in the presence of catalyst and surfactant, as shown below. While polyurethane polymers are used for a vast array of applications, their production method can be broken into three distinct phases. First, the bulk polymer product is made. Next, the polymer is exposed to various processing steps. Finally, the polymer is transformed into its final product and shipped.

PU Foams come in two types – flexible and rigid PU foams. In flexible polyurethane foams, the major blowing agent is water and, at the same time, auxiliary blowing agents, i.e., low–boiling–point inert solvents such as CFC–11, methylene chloride, can be used. But in the case of rigid polyurethane foams, the major blowing agent has been CFC–11, which vaporizes due to the exothermic reaction of polyurethane formation.

The foams that are generally used in the mattresses that have already found their way into your homes are largely adulterated. They contain calcium carbonate as an inexpensive filler, to make up the ‘mass’ of the mattress. The higher the adulteration, the slower the foam comes back into shape.

Fundamentally, foam quality is measured by its ability to come back into shape after usage (compression). IFD Test is one of the tests to clearly understand the quality of any foam 

COST ESTIMATION

Plant Capacity            1.2 MT/Day  

Land & Building (1730 sq.mt.)    Rs. 1.55 Cr    

Plant & Machinery                    Rs. 1.59 Cr 

Working Capital for 4 Months    Rs. 2.26 Cr 

Total Capital Investment          Rs. 5.71 Cr 

Rate of Return                          23%

Break Even Point                      60%

CONTENTS

INTRODUCTION

PROPERTIES 

RESILIENCE

SOLVENT RESISTANCE

ANTIBACTERIAL PROTECTION

YELLOWING AND DISCOLORATION

LOW FIRE RETARDANCY

USAGE AND APPLICATION

ADVANTAGES 

MARKET OVERVIEW

MARKET DYNAMICS

COVID-19 IMPACT

SEGMENTS INSIGHT

PRODUCT INSIGHTS

APPLICATION INSIGHTS

REGIONAL INSIGHTS:

THE KEY PLAYERS OPERATING IN THE POLYURETHANE FOAM MARKET ARE:

BIS SPECIFICATION

FOAMING PROCESS

FOAM CURING

QUALITY CONTROL

MANUFACTURING PROCESS 

PROCESS FLOW 

ENGINEERING DESIGN CONSIDERATIONS

PLANT & MACHINERY

REQUIRED MACHINE FEATURES

SUPPLIER OF PU FOAM

SUPPLIER OF RAW MATERIALS

SUPPLIER OF CHEMICALS 

SUPPLIER OF PLANT AND MACHINERY

SUPPLIER OF PRODUCTION LINE

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF EXHAUST FAN

SUPPLIERS OF TESTING EQUIPMENTS

ETP FACILITY

GREEN BELT

SEWAGE AND WASTE TREATMENT FACILITY

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROJECT IMPLEMENTATION MANAGEMENT

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS

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)