EXPANDED POLYETHYLENE FLEXIBLE FOAM
[EIRI/EDPR/8261] J.C.: 6172XL
INTRODUCTION
Polyolefin (PO) foams are manufactured by many producers in a variety of processes and are classified as low density (25-250 kg/m3) or high density (250-700 kg/m3). The market has expanded relative to other foamed plastics, especially in japan.
Most polyolefin foams are made from low density polyethylene [9002-88-43] (LDPE). Copolymers such as the more flexible ethylene vinyl acetate [24937-78-8] (EVA) and more rarely, highdensity polyethylene [9002-88-4] (HDPE) are also found, finally, foams may be produced from linear low-density polyethylene (LLDPE), copolymer of ethylene and other olefins (1-butene to 1-octene) which is synthesized with a Ziegler catalyst. Polpropylene [9003-07-0] (PP) awhich is more resistant to heat deformation, stiffer and tougher than polyethylene, was first processed into foamed sheets in the 1960s. Today, a polypropylene copolymer with a few percent ethylene is also utilized.
Among foaming plastics, cellular polyethylene is a light plastic mateirals produced by the extrusion of a polyethylene compound containing an intimately dispersed chemical blowing agent. Extrusion can be accomplished with conventional equipment. A recent innovation in plastics materials, cellular polyethylene has demonstrated a number of interesting distinct properties. Which have suited it for. wire and cable coating because the excellent basic properties of solid polyethylene flexibility, tonghness, low moisture absorption, abrasion and chemical resistance and low electrical loss characteristics are retained with a significant reduction in specific gravity.
This material is composed essentially of unconnected hollow cells. During extrusion polyethylene compound exponds 100% resulting in a composition which is 50% inert gas. Becouse of this certain properties are improved.
COST ESTIMATION
Plant Capacity 910.64 Meters/Day
Land & Building (600 sq.mt.) Rs. 48.60 Lac
Plant & Machinery Rs. 1.35 Cr
Working Capital for 1 Month Rs. 18.81 Lac
Total Capital Investment Rs. 2.07 Cr
Rate of Return 17%
Break Even Point 76%
CONTENTS
INTRODUCTION
USES & APPLICATIONS OF POLYOLEFIN FOAMS
PROPERTIES & CHARACTERISTICS OF POLYOLEFIN FOAMS
FIRE BEHAVIOUR OF POLYOLEFIN FOAMS
PROPERTIES & CHARACTERISTICS OF RAW MATERIALS POLYETHYLENE
LOW DENSITY POLYETHYLENS (BRANCHED CHAIN)
BLAVING AGENT AZODICARBONAMIDE
B.I.S. SPECIFICATION
MARKET SURVEY
TRADE NAMES OF COAMED AND FOAMABLE PLASTICS
MANUFACTURING PROCESS FOR EXPANDED POLYETHYLENE FLEXIBLE FOAM (LOW DENSITY FOAM) (25-250 KG/M3)
CROSS-LINKED FOAMS
BATCH PROCESS FOR MOULDED CROSS-LINKED FOAM
MANUFACTURING PROCESS FOR EXPANDED POLYETHYLENE FLEXIBLE FOAM USING BLOWING AGENT AND CROSSLINING AGENT
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE EXPANDED POLYETHYLENE FLEXIBLE FOAM
MANUFACTURING PROCESS OF EXPANDED POLYETHYLENE FLEXIBLE FOAM ANOTHER PROCESS FOR CROSS-LINKED SHEETS (IRRADIATION PROCESS)
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CROSS-LINKED SHEETS OF POLYETHYLENE FLEXIBLE FOAM
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
EXTRUDERS
BOILER
TUNNEL HEATING
SUPPLIERS OF RAW MATERIALS
BLOWING AGENT (AZODICAR BONAMIDE)
DICUMYL PEROXIDE
RAW MATERIALS CALCULATIONS
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
ADDRESSES OF STATE INDUSTRIAL DEVELOPMENT CORPORATIONS
ADDRESSES OF FINANCIAL INSTITUTIONS
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
SUGGESTED STEPS
ECONOMIC ADVANTAGE IN SETTING UP THE PROJECT IN INDIA
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)
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