O-PVC PIPE PLANT
[CODE NO.3993]
HISTORY OF O-PVC Pipe
The technology used to produce PVC‐O pipe has come a long way since the first process was developed for commercial production by Yorkshire Imperial Plastics in the 1970’s. Australia was an early adopter of this process, with Vinidex commencing manufacture of PVC‐O pipes back in 1984.
This process involved orientating the pipes off‐line in a separate orientation chamber, inflating the pipes using pressurised hot water. The process was slow and cumbersome and production was very limited
Come the 1990’s, a number of companies including Vinidex began to develop processes that would significantly increase the output of PVC‐O pipe. Out of this work came the in‐line orientation process, where a feedstock pipe from the extruder is stretched over a mandrel or plug under tightly controlled conditions to produce a bioriented PVC pipe. This concept subsequently became the standard process for production of PVC‐O pipes around the world. In Australia, Iplex installed Wavin Apollo PVC‐O lines, whilst Vinidex installed their patented Cornet process, both in NSW.
In 2006, Molecor was formed in Spain by former employees of the Spanish pipe producer Uralita. The company was formed to develop and market a new PVC‐O manufacturing method utilising an off‐line orientation technique, based on pressurised hot air to inflate feedstock pipes. This method on the surface appears to a variant of the Yorkshire process using air instead of water. However, by utilising a preheating oven to bring the feedstock pipes up to the required temperature for orientation, the Molecor process matches the output rates of the in‐line processes.
COST ESTIMATION
Plant Capacity 66.66667 MT/ Day
Land & Building (15000 Sq.Mtr) Rs 8.97 Cr
Plant & Machinery Rs 6.59 Cr
Working Capital for 2 Month Rs 26.48 Cr
Total Capital Investment Rs.42.80 Cr
Rate of Return 22%
Break Even Point 57%
INTRODUCTION
HISTORY OF O-PVC PIPE
ORIENTED POLYVINYL CHLORIDE (OPVC)
DIFFERENT TYPES OF ADDITIVES AND THEIR FUNCTIONS
TYPES OF ADDITIVES
FUNCTIONS OF ADDITIVES
1. PLASTICIZERS
2. STABILIZERS
3. LUBRICANTS
4. IMPACT MODIFIER
5. PIGMENTS
6. PROCESS AIDS
7. REINFORCEMENT
8. FLAME RETARDANT
9. FILLERS
10. COMPATIBILIZERS
THE RAW MATERIALS OF POLYVINYL CHLORIDE (PVC)
CHARACTERISTICS OF POLYVINYL CHLORIDE (PVC) AS A MATERIAL
1. VERSATILITY
2. FIRE RETARDING PROPERTIES
3. DURABILITY
4. CHEMICALS RESISTANT
5. MECHANICAL STABILITY
6. PROCESSABILITY AND MOULDABILITY
TECHNICAL SPECIFICATION OF O-PVC PIPE
FEATURES OF PVC-O CLASS 500 PIPES
ADVANTAGES OF PVC-O PIPE
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS OF O-PVC PIPE
1. RAW MATERIALS
2. MANUFACTURING PROCESS
3. CONTROL POINTS
4. ENVIRONMENTAL AND HYGIENIC CONDITIONS
EXTRUSION PROCESS
WORKING PRINCIPLE
EXTRUSION PROCESS PARAMETERS
ADVANTAGES:
DISADVANTAGES:
DESCRIPTION OF MANUFACTURING PROCESS:
INCOMING RAW MATERIAL INSPECTION
RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
RESIN STORAGE AND CONVEYANCE
RESIN FEEDING
2. SIZING:
3. TRACTION:
4. CUTTING:
QUALITY CONTROL
GENERAL REQUIREMENTS OF PIPES
1. VISUAL APPEARANCE
2. COLOUR
3. OPACITY
INSPECTION AND TESTING
1. LOT AND CONTROL UNIT
2. TESTS ON RAW MATERIAL
3. TESTS ON PIPES
TESTING
(A) TYPE TEST
(B) ACCEPTANCE TEST
(C) MARKING
MARKET POSITION
INDIA PVC PIPES MARKET IS STUDIED BY VARIOUS SEGMENTS:
INDIA PVC PIPES MARKET WAS VALUED AT US$ 3,539.0 MN IN 2018 & IS
PROJECTED TO BE WORTH US$ 5,209.4 MN BY 2027; IT IS EXPECTED TO
GROW AT A CAGR OF 4.5% DURING THE FORECAST PERIOD 2019 - 2027
MARKET INSIGHTS
MARKET GROWTH
KEY FINDINGS OF THE INDIA PVC PIPE MARKET:
PLANT LAYOUT
SUPPLIERS OF O-PVC PIPE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PVC RESIN GRANULE
SUPPLIERS OF PLASTISIZERS
SUPPLIERS OF PVC STABLISERS
SUPPLIERS OF CALCIUM STERATE
SUPPLIERS OF STEARIC ACID
SUPPLIERS OF CHINA CLAY
SUPPLIERS OF PIGMENTS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF COMPELETE PVC PIPE PLANT
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
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
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