sbr rubber sheets, shoe sole & footwear manufacturing

sbr rubber sheets, shoe sole & footwear manufacturing
sbr rubber sheets, shoe sole & footwear manufacturing
ISBN: PROJECT REPORT
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Styrene - Butadiene Rubber (SBR)
SBR is the largest tonnage synthetic rubber being made all over the world. It accounts for about 60% of the synthetic rubber production and more than 30% of all the rubber consumed. It is a copolymer of butadiene and styrene. The most common SBR is having approximately 25% styrene and 75% butadiene with a random distribution of monomers. There are about 500 grades of this rubber including a large proportion of oil-extended forms and masterbatches of SBR with carbon black. SBR exhibits good abrasion resistance and hence its major application is in tyre sector, especially in passenger car tyres. Other important applications include soles and heels for the footwear, floorings, mats and other domestic items, conveyor belting, hose, rollers, cycle tyres, buffers, gaskets and a large number of other industrial components. About 90% of the SBR produced is by emulsion polymerisation and the rest by solution polymerisation. In addition, about 10% of all the SBR produced is marketed in latex form and is used for applications such as carpet backing, paper coating and latex foam. There is also a small but growing quantity used in adhesives such as butadiene styrene vinyl pyridine for making tyre cord adhesives.

SBR Rubber

SBR Rubber can be compounded to provide very fine abrasion, wear, and tensile qualities. SBR can be readily substituted for natural rubber in many applications with significant cost savings. Resilience is about the same as natural rubber.
•  Available in Black or Red Colors

SBR Red Rubber
Red Rubber is a general service SBR rubber compound of excellent quality. This heat resistant material has been calendared and vulcanized under the strictest control.

Characteristics:
Popular flange gasket material for hot or cold water, air and steam (not exceeding 100 PSI). All mating flanges wherever a quality rubber sheet is required. Remarks: Deforms to uneven flanges.
•  Available in full rolls
•  Available in sheets
•  Can be supplied in cut-to-width strips
•  Operating Temperatures: -22 F to 158 F.


Types of SBR
 
SBR is derived from two monomers, styrene and butadiene. The mixture of these two monomers are polymerised by two basically different processes: from solution (S-SBR) or as an emulsion (E-SBR).[2]


Emulsion polymerisation
 
E-SBR produced by emulsion polymerisation is initiated by free radicals. Reaction vessels are typically charged with the two monomers, a free radical generator, and a chain transfer agent such as an alkyl mercaptan. Radical initiators include potassium persulfate and hydroperoxides in combination with ferrous salts. Emulsifying agents include various soaps. By "capping" the growing organic radicals, mercaptans (e.g. dodecylthiol, control the molecular weight, and hence the viscosity, of the product. E-SBR is more widely used. Typically, polymerizations are allowed to proceed only to ca. 70%, a method called "short stopping". In this way, various additives can be removed from the polymer.
 
Solution polymerisation
 
Solution-SBR is produced by an anionic polymerization process. Polymerisation is initiated by alkyl lithium compounds. Water is strictly excluded. The process is homogeneous (all components are dissolved), which provides greater control over the process, allowing tailoring of the polymer. The organolithium compound adds to one of the monomers , generating a carbanion that then adds to another monomer, and so on. Relative to E-SBR, S-SBR is increasingly favored because it offers improved wet grip and rolling resistance, which translate to greater safety and better fuel economy, respectively.

MARKET  SURVEY CUM  DETAILED  TECHNO 
ECONOMIC FEASIBILITY  REPORT covers
 


INTRODUCTION
PRODUCT DESCRIPTION
SBR Rubber
Types of SBR
Emulsion polymerisation
CHEMISTRY AND PRODUCTION
Typical  Recipe for SBR Emulsion Polymerization
Properties of E-SBR   
Mechanical Properties
Electrical Properties
Cure Properties
Types of SBR
Uses of SBR
TYPICAL APPLICATIONS FOR E-SBR POLYMERS
PROCESS FLOW SHEET
MICROBLACK UNIT OPERATIONS
Sequence of additives used during compounding
Machinery Used for Rubber Compounding
EVA AS MATERIAL
PRESSING SECTION
POLYVINYL CHLORIDE AS A MATERIAL
INJECTION MOLDING
POLYURETHANE AS A MATERIAL
The RIM process
Styrene Butadiene Rubber manufacturer
Address of Machine Manufacturer
B.I.S. SPECIFICATION
MARKET SURVEY
SCOPE OF RUBBER SHEETS
USES & SCOPE
CONSUMPTION OF RUBBERS
GRADE WISE PRODUCTION OF SYNTHETIC RUBBER
STATE WISE CONSUMPTION OF SYNTHETIC RUBBER
MANUFACTURES OF RUBBER SHEETS FOR SHOES SOLES
Hard microcellular soling, midsole based on pilene EVA
MANUFACTURING PROCESS OF EVA RUBBER SHEET FOR SHOE SOLES
PROCESS FLOW DIAGRAM FOR EVA RUBBER SHEET FOR SHOE SOLE
OTHER METHOD FOR THE MANUFACTURE OF EVA RUBBER SHEET
PROCESS FLOW DIAGRAM OF EVA SHEET
MICROCELLULAR SOLING PROCESS
(MANUFACTURING PROCESS FOR MICROCELLULAR SHEETS)
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
General plant layout
UTILITIES
IMPLEMENTATION SCHEDULE
EFFLUENT TREATMENT AND DISPOSAL
Tolerance Limits for Industrial Effluent Discharge
Typical Waste Solids Characteristics
Equipment Requirements
MANPOWER
SUPPLIERS OF PLANT & MACHINERY

  • RUBBER MIXING MILL
  • RUBBER COMPRESSION MOULD
  • RUBBER VULCANIZER
  • BOILER
  • RUBBER MACHINES (KNEADERS, EXTRUDERS AND HYDRAULIC PRESS)
  • CALENDERING MACHINERY
  • DOUBLE SHAFT PADDLE MIXER
  • WATER STORAGE TANKS

SUPPLIERS OF RAW MATERIALS

  • PRECIPITATED SILICA
     
  • NATURAL RUBBER   
     
  • SYNTHETIC RUBBER
     
  • ZINC OXIDE
     
  • STEARIC ACID
     
  • Synthetic rubber manufacturer
     

Addresses of Machinery and Equipment Suppliers

 

APPENDIX

 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

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