HDPE PIPE MANUFACTURING UNIT
[CODE NO.4127]
High-density polyethylene (HDPE) is a polyethylene thermoplastic made from petroleum. It is known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97g/cm3 or 970Kg/m3. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand much higher temperatures (120°C for short periods, 110°C continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally required autoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions.
HDPE pipes are important plastic products which have wide range of applications. These have more tensile strength in comparison to other plastic pipes. These are being used for Sprinkler Irrigation System, potable water supply and sewerage purpose. Their low cost, easily installation and better durability make them ideal for the purpose. They also offer very good resistance to most of the chemicals and have excellent electrical insulation properties. These pipes are also used for circulation of acids in various chemical industries due to their acid resistant quality.
The demand of HDPE Pipes are likely to increase due to their wide use in various sectors in India. Apart from its regular uses, such as for irrigation system, water supply, sewerage, it is being used by Department of Telecommunication for conduit for optical fiber cables. Looking to its increased demand, it appears to be good scope for setting up new small scale industries. Hence the product has good market potential.
CLASSIFICATION
(A) Pipes shall be classified according to the grade of materials as MRS; Polyethylene pipes and classified by the raw materials used in the production of attachments. MRS material strength values of 20°C is also shown by the internal pressure for 50 years.
Raw material class MRS(MPa) value
PE 63 6.3
PE 80 8.0
PE 100 10
(B) Pipes by pressure rating (PN) corresponding to the maximum shall be classified permissible working pressure at 3WC, as follows:
The pressure grades available according to European standards are:
• PN 2.5 - max pressure 2.5 bar
• PN 4 - max pressure 4 bar
• PN 6 - max pressure 6 bar
• PN 10 - max pressure 10 bar
• PN 16 - max pressure 16 bar
Color codes used to indicate the pressure grades on the pipes are:
Color Code PE Pressure Grade
Yellow PN 4
Red PN 6
Blue PN 10
Green PN 1
HDPE Pipes for following grades/sizes/pressure rating
PE 63 PN 2.5 DN 63 to 110
PE 63 PN 4 DN 40 to 110
PE 63 PN 6 DN 32 to 110
PE 63 PN 8 DN 32 to 110
PE 63 PN 10 DN 32 to 110
PE 63 PN 12.5 DN 32 to 110
PE 63 PN 16 DN 32 to 110
PE 80 PN 2.5 DN 90 to 110
PE 80 PN 4 DN 50 to 110
PE 80 PN 6 DN 40 to 110
PE 80 PN 8 DN 32 to 110
PE 80 PN 10 DN 32 to 110
PE 80 PN 12.5 DN 32 to 110
PE 80 PN 16 DN 32 to 110
PE 100 PN 6 DN 50 to 110
PE 100 PN 8 DN 40 to 110
PE 100 PN 10 DN 32 to 110
PE 100 PN 12.5 DN 32 to 110
PE 100 PN 16 DN 32 to 110
COST ESTIMATION
Plant Capacity 20 Tons/Day
Land & Building (10,000 sq.mt.) Rs. 4.18 Cr
Plant & Machinery Rs. 7.38 Cr
Working Capital for 1 Month Rs. 4.38 Cr
Total Capital Investment Rs. 16.17 Cr
Rate of Return 25%
Break Even Point 57%
- INTRODUCTION
- CLASSIFICATION
- CHARACTERISTICS
- USES AND APPLICATION
- INDUSTRIES
- SPECIAL SERVICES
- APPLICATIONS
- SUBMARINE PIPELINES
- RELINING - NEW PIPES IN OLD
- SEWER PIPES
- SLURRY TRANSPORTATION
- IRRIGATION
- DOMESTIC GAS DISTRIBUTION
- CHEMICAL PROCESS PIPING
- B.I.S. SPECIFICATION
- HEADQUARTERS
- SALES OUTLET
- PROCESS OUTLINES OF HDPE PIPES EXTRUSION
- PROCESSING DETAILS OF HDPE PIPES
- EXTRUDER
- FEED HOPPER
- BARREL
- SCREW
- DIE
- WATER COOLING TUB
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- EXTRUSION PROCESS
- WORKING PRINCIPLE
- EXTRUSION PROCESS PARAMETERS
- ADVANTAGES
- DISADVANTAGES
- RAW MATERIALS
- QUALITY CONTROL OF HDPE PIPES
- VISUAL INSPECTIONS
- MECHANICAL INSPECTION
- OTHER QC TESTS CAN INCLUDE:
- DESCRIPTION OF MANUFACTURING PROCESS
- INCOMING RAW MATERIAL INSPECTION
- RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
- RESIN STORAGE AND CONVEYANCE
- RESIN FEEDING
- TESTING
- (A) TYPE TEST
- (B) ACCEPTANCE TEST
- (C) LONGLTUDINAL REVERSION PERFORMANCETEST
- APPRATUS
- 1. AIR OVEN
- 2. THERMOMETER
- TEST SPECIMENS
- PROCEDURE
- MARKING
- MARKET POSITION OF INDIAN HDPE PIPES
- OPPORTUNITIES OF HDPE PIPES
- MARKET BY APPLICATION
- MARKET BY GRADE TYPE
- MARKET BY DIAMETER TYPE
- MARKET BY PRESSURE RATING
- GLOBAL MARKET POSITION OF HDPE PIPES
- THE INDIAN PLASTIC PIPES MARKET
- TYPES OF PLASTIC PIPES APPLICATION
- MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
- INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
- BARGAINING POWER OF SUPPLIERS
- BARGAINING POWER OF BUYERS
- INTERNAL RIVALRY
- ENTRY
- THREAT OF SUBSTITUTES
- GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
- OTHER MEASURES
- SWOT ANALYSIS
- STRENGTHS
- WEAKNESSES
- OPPORTUNITIES
- THREATS
- SEWER RINGFIT PIPES AND SEWER SELFIT PIPES
- DOMESTIC USE
- INDUSTRIAL
- OTHER
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF HDPE PIPE
- SUPPLIERS OF RAW MATERIALS
- HDPE GRANULES
- SUPPLIERS OF BLACK MASTER BATCH
- SUPPLIERS OF ANTIOXIDANT
- SUPPLIERS OF COMPLETE HDPE PIPE PLANT
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- EFFULENT TREATMENT PLANT
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSOR
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
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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