PVC Pipes and Fittings (Production Capacity- 10 TPD)

PVC PIPES AND FITTINGS (PRODUCTION CAPACITY – 10 TPD)

[EIRI/EDPR/4550] J.C.: 2767XL

INTRODUCTION

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes.

PVC Pipes and fittings are often used in the following circumstances:

For drinking water pipe distribution systems, both main and supply lines

Sewer and discharge pipe systems

Due to its non-metallic nature, the material used is totally resistant to all forms of metallic corrosion.

Aggressive water resulting from high sulphate soils and low hardness water will not attack PVC pipes.

Our pipes are therefore resistant to a wide range of industrial waters and chemicals and offer an advantage in long-term systems life and manufacture costs.

Being made of a tasteless and odorless material, PVC pipes remain neutral to all transported fluids.

PVC is completely inert and is widely used for transporting liquids made for human consumption.

Because of their mirror-smooth inside surface, PVC pipes have minimum flow head loss. There is also no buildup of inside deposits, a particular advantage in the construction of sewerage systems.

The physical properties of PVC pipes are not affected by neither direct sunshine, nor wind or rain. However, to avoid surface browning due to long exposure to direct sunlight, it is recommended that the pipes are kept protected from direct sunlight.

Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to travel on PVC pipes. They therefore offer added safety when used for electrical installations, both domestic and industrial.

PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel pipes. This cuts down transportation costs and facilitates installation when in difficult and remote places. Installation is quick and easy with a complete line of fittings either with the solvent glue weld sockets or the rubber seal socket joints. In either case, a leak-proof joint is assured. Subsequent maintenance work is also carried out with a minimum of complication and cost.

PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when plasticized or softened with other chemicals has some rubber-like properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC socket or threaded fittings (schedule 80).

PVC Pipe and Fittings have got tremendous demand in India as well as in abroad. To manufacture this, all the machinery and raw materials are available indigenously.

A polyvinyl chloride (PVC) pipe is made from a plastic and vinyl combination material.  The pipes are durable, hard to damage, and long lasting. A PVC pipe does not rust, rot, or wear over time. For that reason, PVC piping is most commonly used in water systems, underground wiring, and sewer lines.

Due to the ability of PVC pipe to withstand extreme movement and bending, it is also increasingly used in earthquake prone areas.  PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of the PVC pipe is also resistant to bacterial contamination, such as E. coli.  Therefore, many water companies rely on PVC pipe in their systems in order to keep them free of contamination.

It is intended to prepare a Feasibility Report to install PVC Pipes and Fitting facility with an installed capacity of 10 TPD as a Green Field Project.

COST ESTIMATION

Plant Capacity            10 MT/Day  

Land & Building (4575 sq.mt.)    Rs. 5.49 Cr    

Plant & Machinery                    Rs. 3.45 Cr 

Working Capital for 0.5 Months    Rs. 1.24 Cr 

Total Capital Investment          Rs. 10.54 Cr 

Rate of Return                          43%

Break Even Point                      48%

CONTENTS

INTRODUCTION

PVC PIPES AND FITTINGS ARE OFTEN USED IN THE FOLLOWING CIRCUMSTANCES:

PROPERTIES OF PVC PIPES & FITTINGS

ADVANTAGES & LIMITATIONS

HANDLING & STORAGE

BIS SPECIFICATIONS

PIPES & FITTINGS

PLUMBING PIPES

APPLICATIONS OF PVC PIPES & FITTINGS

FOR TRANSPORTATION OF WATER:

TUBE WELLS

CHEMICAL PROCESSING PLANT

DUCTING FOR POWER AND COMMUNICATION CABLES:

FOR TRANSPORTATION OF PULVERIZED MATERIALS

ADVANTAGES OF USING PVC PIPES

IT IS ECONOMICAL:

IT RESISTS CORROSION:

NON-ENRUSTATION:

LIGHT WEIGHT:

EASE OF INSTALLATION:

MARKET OVERVIEW

INDIAN MARKET

EMERGING TRENDS IN INDIAN PLASTIC PIPE MARKET

LIST OF INDIAN PLASTIC PIPE COMPANIES

GLOBAL MARKET

GROWTH FACTORS

APPLICATION INSIGHTS

END USER INSIGHTS

REGION INSIGHTS

KEY DEVELOPMENTS

SOME OF THE PROMINENT PLAYERS IN THE GLOBAL POLYVINYL CHLORIDE (PVC) PIPES MARKET INCLUDE:

MANUFACTURERS/EXPORTERS 

RAW MATERIAL 

DIMENSION OF PVC PIPE

PVC PIPE & FITTINGS DIMENSIONS (SCH 40/SCH 80)

PLUMBING PIPES

FORMULATION 

FORMULATION-I

PVC FLEXIBLE PIPES (AGRICULTURAL PIPES)

FORMULATIONS

PROCESS OF MANUFACTURE

MANUFACTURING PROCESS 

TWIN SCREW EXTRUDERS

EXTRUSION DIES

EXTRUSION LINES

A) EXTRUSION SECTION:

B) MELT FORMING SECTION:

C) CONVERSION INTO THE FINAL PRODUCT:

PVC PIPE FITTINGS

PROCESS FLOW 

PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES

PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS

PLASTIC EXTRUSION PROCESS

EXTRUDER HEATER

BLOCK DIAGRAM OF THE PLASTIC EXTRUSION PLANT 

TEMPERATURE SECTION OF PVC PLANT

HEATER SPECIFICATION OF PLASTIC EXTRUSION SYSTEM 

PLASTIC EXTRUSION SCREW

PLASTIC EXTRUSION SCREW MODEL

DETAILS OF INJECTION MOLDING FOR PIPE FITTINGS

PROCESS CYCLE

EQUIPMENT

INJECTION UNIT

INJECTION MOLDING MACHINE - INJECTION UNIT

CLAMPING UNIT

INJECTION MOLDING MACHINE - CLAMPING UNIT

MACHINE SPECIFICATIONS

INJECTION MOLDING MACHINE

TOOLING

MOLD OVERVIEW

MOLD BASE

MOLD CHANNELS

MOLD DESIGN

MOLD - CLOSED

MOLD - EXPLODED VIEW

PRELIMINARY LAYOUT

SUPPLIERS OF PLANT AND MACHINERY 

MOULDS FOR PIPE FITTINGS

HIGH SPEED MIXER

EXTRUDER

PLASTIC SCRAP GRINDER MACHINE

PLASTIC INJECTION MOULDING MACHINE

GENERATOR SET

SUPPLIERS OF RAW MATERIALS

PVC RESIN

CALCIUM STEARATE

LEAD STEARATE

PRECIPITATED CALCIUM CARBONATE

PIGMENT DYE

SEWAGE AND WASTE WATER EFFLUENT 

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:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

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)