Detailed Project Report (DPR) on crumb rubber manufacturing unit

CRUMB RUBBER MANUFACTURING UNIT
[CODE NO.3414]  


Crumb rubber is the name given to any material derived by reducing scrap tires or other rubber into uniform granules with the inherent reinforcing materials such as steel and fiber removed along with any other type of inert contaminants such as dust, glass, or rock.

Crumb rubber is manufactured from two primary feedstocks: tire buffings, a byproduct of tire retreading and scrap tire rubber. Scrap tire rubber comes from three types of tires: passenger car tires, which represent about 84 percent of units or approximately 65 percent of the total weight of U.S. scrap tires; truck tires, which constitute 15 percent of units, or 20 percent of the total weight of U.S. scrap tires; and off-the-road tires, which account for 1 percent of units, or 15 percent of the total weight of U.S. scrap tires. End product yields for each of these tire types are affected by the tire’ s construction, strength and weight. On average, 10 to 12 pounds of crumb rubber can be derived from one passenger tire.


COST ESTIMATION

Plant  Capacity                                             :       3000.00 Kg./day  
land & Building (Rented)                            :    Rented
Plant & Machinery                                        :    Rs.  31.00 Lacs
Working Capital for 1 Month                       :    Rs.  13.31 Lacs
Total Capital Investment                            :    Rs.  50.31 Lacs
Rate of Return                                             :    49%
Break Even Point                                        :    64%

INTRODUCTION    
CRUMB RUBBER    
UTILIZING CRUMB RUBBER FROM SCRAP TIRES    
CRUMB RUBBER RECYCLING & GRADING    
COMPOSITION    
GRADING    
GOVERNMENT WORKING ON TYRE RECYCLING NORMS    
CRUMB RUBBER STANDARD & GLOSSARY OF TERMS    
THERE ARE SEVERAL ASTM STANDARDS THAT APPLY TO CRUMB RUBBER:    
CRUMB RUBBER GLOSSARY OF TERMS    
CLASSIFIER SCREEN    
CRACKER MILL    
CRYOGENICS    
GRANULATOR    
HAMMER MILL    
INCH    
MESH    
MICRO MILL    
MILLIMETER    
SCREEN    
SIEVING    
CRUMB MESH SIZE RANGE IN EACH MARKET CATEGORY    
MOULDING TECHNOLOGY    
SPRAY TECHNOLOGY    
THE ADVANTAGES OF THE SPRAY TECHNOLOGY ARE AS FOLLOWS:    
BOND AGENT SELECTION AND MIX DESIGN    
SPRAYING DEVICES AND PROCESSES    
USES AND APPLICATION    
FLOORING    
SEALANTS    
ROOFING    
WATERPROOF MEMBRANES    
PROPERTIES    
SPECIFICATION OF CRUMB RUBBER    
SIZES AVAILABLE    
PACKAGING    
CRUMB RUBBER IN ATHLETIC FIELD    
OVERVIEW OF TYRE RECYCLING IN INDIA    
RECLAIMED RUBBER BUSINESS    
MARKET OVERVIEW OF CRUMB RUBBER    
MAJOR MARKETS FOR CRUMB RUBBER:    
CRUMB RUBBER PARTICLE SIZE MEASUREMENT    
INCH, MILLIMETER, MESH    
QUALITY IS KEY    
MANUFACTURERS/SUPPLIERS OF CRUMB RUBBER    
DIFFERENT PROCESSES    
TO MANUFACTURE CRUMB RUBBER    
AMBIENT MECHANICAL GRINDING:    
CRYOGENIC GRINDING:    
UTILIZATION OPTION OF CRUMB RUBBER    
UTILIZATION OPTIONS FOR CRUMB RUBBER:    
RUBBERIZED ASPHALT    
RUBBERIZED ASPHALT TECHNOLOGIES    
CRUMB RUBBER MANUFACTURING TECHNOLOGY    
AMBIENT PROCESS    
CRYOGENIC PROCESS    
FINE GRIND - AMBIENT METHOD    
DETAILED MANUFACTURING PROCESS FOR    
THE PRODUCTION OF CRUMB RUBBER METHOD FOLLOWED    
1. PRELIMINARY WASHING OF SCRAP RUBBER (USED TYRE) IN
      WASHING TANK AND DIRT REMOVAL.    
2. DRYING    
3. PRE-CUTTING OF RUBBER SCRAP
4. CHOPPING    
5. MAGNETIC SEPARATION    
6. GRINDING    
7. SCREENING    
8. PACKING    
PROCESS FLOW DIAGRAM FOR THE MANUFATURE OF CRUMB RUBBER
   (METHOD FOLLOWED)    
HEALTH AND ENVIRONMENTAL IN CRUMB RUBBER MANUFACTURING    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT & MACHINERIES    


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