Detailed Project Report (DPR) on P.V.C. Leather Cloth (Rexine)

P.V.C. LEATHER CLOTH (REXINE)

[EIRI/EDPR/1091] J.C.9735

INTRODUCTION

For many years a range of leather like materials has been in use for sockings, linkings and uppers. They are all based of fabrics, usually woven and mainly of cotton. These base cloths should be carefully selected to give the requisite physical properties for shoe uppers and they may be coated with oil or PVC or rubber compound, Cellulose derivatives or synthetic resin (plastics). The surface may be smooth with high polish or matt effect, or embossed with designs, many of which simulate leather or fabrics. All these coated materials are totally impermeable to air and water, ventilation must therefore achieved by suitable shoe design. The earliest type of leather cloth was American Cloth, the coating being of linseed oil. This was followed by nitrocellulose coating. Both are practically obsolete for uppers, being superseded by plastic coatings, but they are used for sockings.

Plastic sheetings are also used for uppers of cheaper qualities of shoes. For shoe uppers the unsupported sheeting has proved unsatisfactory in making and the more usual upper materials consist of a specially woven fabric coated with a plastic film, nearly always plasticized PVC. Since this synthetic resin the most freely available in all country. The many constructional difficulties are gradually being overcome and owing to the impenetrable nature of a plastic film, the more general finishes can not be used. PVC upper materials may be cleaned with petroleum cleaners without determinant to the luster of the surface and additional polish may be given by means of wax creams or light polishing on the rotary brush. PVC leather cloth is the most useful plastic. It has two grades, flexible or rigid which give by means of wax creams or light polishing on the rotary brush. PVC leather cloth is the most useful plastic. It has two grades, flexible or rigid which give it considerable scope. The flexible leather sheet is  used for articles of clothing such as boot and shoe, sales, heels and uppers etc. In fact the range of products is so wide that it is impossible to state all of them.

PVC leather cloth is also known in other words as Artificial leather which is becoming increasingly popular all over the world because of shortage of actual leather and high cost of the same. Artificial leather is specially suitable for upholstery, shoe upper, attachicases, brief cases and all kinds of bags. It is water repellent and is chemically inert. It is much cleaner both in production and in use beside being competitive in price. Present inductions show that artificial leather goods have good export potential.

How it is possible to manufacture artificial leather in the small scale sector because of the introduction of automatic machines by the world renowned manufacturers of Japan, Akatsuki machinery works Ltd., who have exported already about 2,000 such plants to South East Asia and Middle East countries. The plant designed by them is continuous one line system, ensuring uniform quality of production of artificial leather as well as less labour costs. With the embossing device one can have plain as well as engraved designs manufactured. Colour of coatings would be according to your choice.

Now, the machineries for PVC leather cloth are being manufactured in India by a India renowned manufacturers. A list of such manufacturers is given at the end of this report.

PVC leather cloth is manufactured by applying a coating of PVC paste on cotton cloth. The cloth has a coating with a glossy surfaced and smoothness to tough. It is used in air-proof and water-proof packing and also for decoration. It is extensively used in such applications which require a water proof media and strength. It is comparatively a new technique and has widely growth prospects. In India the manufacture of PVC leather cloth is very limited and there exists lot of scope for new industries in this field.

PVC leather cloth do not get affected by Heat or water. It is a substitute of natural leather cloth.

PVC leather cloth industry cloth industry has now become very common and the manufacturing technique is very simple.

COST ESTIMATION

Plant Capacity            5000 Mtr./Day

Land & Building (600 sq.mt.)    Rs. 72.50 Lac

Plant & Machinery                    Rs. 63.00 Lac

Working Capital for 1 Month Rs. 1.60 Cr

Total Capital Investment          Rs. 3.12 Cr

Rate of Return                          60%

Break Even Point                      44%

CONTENTS

INTRODUCTION

POLYVINYL CHLORIDE (P V C)

USES AND APPLICATIONS

DETAILS OF RAW MATERIALS

MARKET SURVEY

REXINE INDUSTRY IN FARIDABAD GROWING BY 30 TO 40 PER CENT

REXINE IMPORTS DATA & IMPORT STATISTICS IN INDIA.

LEATHER CLOTH

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS

MANUFACTURING PROCESS

PIGMENT TITANIUM DIOXIDE

OTHER COMMERCIAL METHODS

ARTIFICIAL LEATHER

PRODUCTION OF POLYURETHANES

EXAMPLES 4-6

PRODUCTION OF POLYURETHANES

COMPARATIVE POLYMERIZATION EXAMPLES 1-3

EXAMPLES 1-6 AND COMPARATIVE EXAMPLES 1-7

EXAMPLES 7-14

STRUCTURE OF SYNTHETIC LEATHER

LAMINATED ARTIFICAL LEATHER

METHOD FOR FORMING LAMINATED SYNTHETIC LEATHER

FEW IMPORTANT DETAILS DURING PROCESSING        

SPECIFICATION OF FINISHED PRODUCT                           

PLANT LAYOUT                           

SUPPLIERS OF RAW MATERIAL                                    

SUPPLIERS OF PLANT AND MACHINERY                 

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)