P.V.C. COMPOUNDING (FRESH) FOR CABLES AND PVC PIPES
[EIRI/EDPR/1611] (J.C. 412)
INTRODUCTION
Indian plastics industry is one of the largest in the Asian Region. It had a modest beginning in the late twenties when articles like combs, soap boxes, ash trays etc. began to be manufactured in the country from imported raw materials. Three are about fifty materials identified as plastics and the list is being extended continuously. Plastics are classified as thermoplastics and thermo sets on the basic of the polymerization method adopted to produce the basic plastic material as on the basic of the primary raw materials source. Polyvinyl chloride comes under thermoplastics. Polyvinyl chloride (PVC) polymers or resins are the most important constituents of PVC compounds and are classified into bulic or mass polymers, emulsion polymers, suspension polymers and paste-forming polymers. There is a fifth type known as solution polymers which is used for coating applications.
Compounding of PVC resin is done in three steps, namely
1. Premixing 2. Fusion or gelation 3. Pelletizing or granulation. Mixing of the ingredients to a high degree of homogenization is called (premixing). The premixed material is homogenized during Fusion or Gelation. In the third step namely pelletization or granulation the homogenous mass is produced in a suitable form for smooth processing. Hence it is possible to avoid one or more of the steps with the help of modern processing equipment.
Although plastic industry in India experienced many ups and downs in the 70's it has made considerable progress not only in the output and range of plastics raw materials produced and consumed but also in learning and absorbing better processing technology as well as the manufacture of more and better machine.
COST ESTIMATION
Plant Capacity 120 MT/Day
Land & Building (3.8 Acres) Rs. 3.75 Cr
Plant & Machinery Rs. 25.50 Cr
Working Capital for 1 Month Rs. 17.68 Cr
Total Capital Investment Rs. 48.61 Cr
Rate of Return 42%
Break Even Point 43%
CONTENTS
INTRODUCTION
DEVELOPMENT IN PVC COMPOUND
PHYSICAL APPEARANCE?
WHAT PHYSICAL PROPERTIES DOES THE COMPOUND NEED TO HAVE?
HOW WILL THE MATERIAL BE PROCESSED?
BASE MATERIAL
ADDITIVES
MATERIAL DEVELOPMENTS
PVC PERFORMANCE
SOFT PVC (A PLASTICIZED PVC):-
PIGMENTS:-
RIGID (OR UNPLASTICIZED) PVC:-
USES AND APPLICATION
COMMERCIAL PVC COMPOUNDS:- GENERAL OUTLINE OF TYPES
BUREAU OF INDIAN STANDARDS SPECIFICATION
MARKET SURVEY
THE RISE
THE FALL
WIRE AND CABLE INSULATION
EVEN THOUGH WITH ITS NUMEROUS MERITS SUCH AS:
THE INDIAN POLYMER INDUSTRY:-
THE CHANGING SCENARIO:-
INDUSTRY GROWTH
CONSUMPTION PATTERN OF PVC IN INDIA
GLOBAL DEMAND OF PVC
THE PROCESSING SECTOR
PRESENT MANUFACTURERS OF PVC COMPOUND
RENEWABLE PVC COMPOUNDING AND ITS DETAILS
RENEWABLE PLASTICIZERS
RENEWABLE PVC COMPOUND
ENVIRONMENTAL IMPACT AND TOXICOLOGY
THE CALCULATION IS SUMMARIZED BELOW
RIGID PVC COMPOUNDING MATERIALS
RESIN
STABILIZERS
STABILIZER-LUBRICANT PACKAGE
FILLERS
PIGMENTS
PROCESSING AIDS
IMPACT MODIFIERS
LUBRICANTS
EXTERNAL LUBRICANTS
INTERNAL LUBRICANTS
EXTERNAL/INTERNAL LUBRICANTS
FORMULATION FOR DIFFERENT GRADES OR P.V.C.
PROCESS OUTLINE OF PVC COMPOUNDING
TYPICAL FORMULATION OF PVC COMPOUNDS
UNPLASTICISED RIGID PVC PIPES
WIRES & CABLES (ELECTRICAL)
FORMULATION OF PVC COMPOUND FOR PVC PIPE
PROCESS OF MANUFACTURE
RAW MATERIAL QUALITY ASSURANCE, EVERY STEP OF THE WAY
RELIABLE, PROVEN PVC COMPOUNDING CAPABILITY
PROCESS FLOW DIAGRAM
PVC PIPE COMPOUND PROCESS AND FORMULATIONS
POLYVINYL CHLORIDE (PVC) PIPE COMPOUND
POLYVINYL CHLORIDE (PVC) PIPE COMPOUND
POLYVINYL CHLORIDE (PVC) PIPE RESIN
STABILIZER ADDITIVE
CALCIUM STEARATE ADDITIVE
PARAFFIN WAX ADDITIVE
POLYETHYLENE WAX ADDITIVE
PIGMENTATION ADDITIVE
CALCIUM CARBONATE ADDITIVE
ACRYLIC PROCESS AID/IMPACT MODIFIER ADDITIVE
SUPPLIERS OF RAW MATERIALS
POLYMERS: POLYVINYL CHLORIDE (PVC)/RESINS
STABILIZERS
PLASTICIZERS’
CALCIUM STEARATE
C.P.W
SUPPLIERS OF PLANT AND MACHINERY
GRANULES EXTRUSION MACHINES
HIGH SPEED MIXER
AIR COMPRESSOR
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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