MASTERBATCH (FILLER) (POLYPROPYLENE AND CALCIUM CARBONATE BASED)
[CODE NO.4407]
A Masterbatch is a concentrated mixture obtained by the distribution of colours and additives into a polymer carrier by heat treatment and in-particularly a high shear mixing extruder. The mixture is then cooled, cut and formed into granules via a pelletiser. The production of masterbatch creates great demands on the compounding process: The pigment and additive parts need to be merged into the base polymer completely homogeneously.
The alternatives to applying masterbatches are obtaining a fully compounded material from raw materials on site. In comparison with pure pigments, masterbatches need extra storage space and longer lead times. Another drawback is additional exposure of heat to both the carrier and the additive; which is essential for marginally thermal stable pigments.
As masterbatches are premixed compositions, they use and mitigates the problems with the additive deficient dispersion. The blend of the additive in the masterbatch is higher than in the end polymer, but the additive properly dispersed in the master resin. In a way, they are associated with the use of ferroalloys for combining alloying components to steels.
Masterbatches are highly concentrated with high \"let down ratios\", one ton of a natural polymer can fit into a 25 kg bag. Masterbatches dilute nature, allows higher accuracy in dosing of expensive components. Masterbatches solid crystals are solvent free and tend to have a longer shelf life as the solvent in the polymer won't evaporate. They generally contain 40-65 per cent additives, but the range can be altered from 15-80 per cent in few additional cases. Liquid Masterbatches allow highly precise dosing and instant change of colour between machine runs.
Filler masterbatch (Calcium Carbonate Masterbatch) is known as the ultrafine dispersion with the guarantee of no agglomeration, ensure the whiteness, glossier and smooth surface for the articles. This filler – the concentration of CaCO3 powder or Talc powder in the filler polymer base to modify vary properties of the plastic articles or the base plastic polymers.
It is intended to prepare a Feasibility Report to install 3000 Tons/Year Masterbatch production facility from Polypropylene (PP) and Calcium Carbonate raw materials as a Green Field Project.
COST ESTIMATION
Plant Capacity 10 Ton/Day
Land & Building (2500 sq.mt.) Rs. 2.80 Cr
Plant & Machinery Rs. 2.18 Cr
Working Capital for 0.5 Months Rs. 90 Lac
Total Capital Investment Rs. 6.20 Cr
Rate of Return 42%
Break Even Point 54%
- • INTRODUCTION
- • TYPES
- • USES/APPLICATION
- • SELECTION OF COLOURANTS
- • BIS SPECIFICATION
- • MARKET OVERVIEW
- • FORMULATION
- • RAW MATERIALS
- • SUPPLIERS OF RAW MATERIALS
- • MANUFACTURING PROCESS STEPS/PROCESS FLOW
- • ENGINEERING DESIGN CONSIDERATIONS
- • ETP FACILITY
- • SEWAGE AND WASTE WATER EFFLUENT
- • WASTE GENERATION & MANAGEMENT/GREEN BELT
- • PLANT/MACHINERY (BROADLY)
- • SUPPLIERS OF PLANT & MACHINERIES/TURNKEY
- • UTILITIES PER MONTH (ESTIMATED)
- • PRINCIPLES OF PLANT LAYOUT
- • PLANT LOCATION FACTORS
- • HEALTH SAFETY AND ENVIRONMENT
- • ANTICIPATED ENVIRONMENTAL IMPACTS
- • MITIGATION MEASURES (PROPOSED)
- • HSE REQUIREMENT
- • SAFETY & OCCUPATIONAL MEASURE
- • PROPOSED IMPLEMENTATION SCHEDULE
- • PROJECT FINANCIALS
- • PRELIMINARY PLANT LAYOUT
- • 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)
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