Detailed Project Report (DPR) on Plastic mats production from polypropylene

PLASTIC MATS PRODUCTION FROM POLYPROPYLENE
 [CODE NO.3310]


Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications including packaging and labeling, textiles (e.g., ropes, thermal underwear and carpets).
 
Polypropylene has a relatively slippery "low energy surface" that means that many common glues will not form adequate joints. Joining of polypropylene is often done using welding processes.

In 2013, the global market for polypropylene was about 55 million tones. Polypropylene is the world's second-most widely produced synthetic plastic, after polyethylene.

Polypropylene is in many aspects similar to polyethylene, especially in solution behaviour and electrical properties. The additionally present methyl group improves mechanical properties and thermal resistance, while the chemical resistance decreases.: The properties of polypropylene depend on the molecular weight and molecular weight distribution, crystallinity, type and proportion of comonomer (if used) and the isotacticity. In isotactic polypropylene, for example, the CH3 groups are oriented on one side of the carbon backbone. This creates a greater degree of crystallinity and results in a stiffer material that is more resistant to creep than both atactic polypropylene and polyethylene.

     Mat and matting industry is well established in India. Previously it was made from vegetable origin like coconut fibers, jute and cotton fibers etc. Woven fabrics were among the earliest bases used for laminating. They provide a  stronger  and  more impact resistant product. In woven fabrics the fibrous  structure is stronger because the individual fibers are longer by virtue of spinning into yarn. Continuous filament yarns of plastics are much tougher than conventional yarns of vegetable origin. The continuous filament fabrics produce tough  structure  that  are often  difficult  to  bond because the surface  of  the  extruded filament  is  smooth, the individual filaments  are in maximum geometrical  close  packing,  and  there are no ends to the filaments to provide mechanical anchoring.

     After the availability of PP and HDPE as commercial plastic raw materials, the  plastic mats have been replacing the conventional mats. Plastic mats are made in a large variety of patterns and designs to provide attractive and damp-proof floor covering. These are preferred over jute or coir mats due to cheap, light, durable and attractive designs.

     Now - a - days plastic mats are woven with PP/HDPE yarn  or strapping’s.  The  warp yarns are held in two frames which alternately go up and down and a weft is passed between the  warp every  time  they  move. The matting is dove plain or  stripped according  as the warp is of one colour or of different  colours. It may be woven in various attractive designs.

     The weaving pattern of the fabric controls the physical nature of the laminate. A very common weave is a square pattern in which each warp yarn passes above and below each alternate fill yarn during weaving. This gives a structure with  maximum crimp.  In drills and twills each yarn still has considerable crimp as it passes from one side of the fabric to the other. Such weaves exhibit uniform properties in the crosswise and lengthwise directions but are relatively weak owing to the great  crimp  in each yarn.

COST ESTIMATION

Plant  Capacity                                               :       600.00 NOS/day
land & Building (700 Sq.Mtrs)                     :       Rs. 1.1   Cr
Plant & Machinery                                          :       Rs. 50.00 Lacs
Working Capital for 1 Month                        :       Rs. 23.17 Lacs
Total Capital Investment                              :        Rs. 1.80  Cr
Rate of Return                                               :        25%
Break Even Point                                           :       6435%

•    INTRODUCTION                                        
•    PROPERTIES OF POLYPROPYLENE                            
•    USES & APPLICATIONS                                    
•    QUALITY & BIS SPECIFICATION                            
•    MARKET SURVEY                                        
•    EXPORT DATA OF POLYPROPYLENE MAT                        
•    OVERVIEW AND FUTURE OF TECHNICAL TEXTILE                
•    RAW MATERIALS                                        
•    MANUFACTURERS/SUPPLIERS/EXPORTERS OF PLASTIC MATS        
•    CONSULTANT FOR PLASTIC MAT UNIT                        
•    MANUFACTURING PROCESS OF PLASTIC MAT (PP MAT) FROM RECYCLABLE PLASTIC AND PP GRANULES                    
•    PROCESS IN DETAILS                                    
•    PROCESS FLOW CHART                                
•    PP MAT MANUFACTURING DIAGRAM    
•    PLANT LAYOUT                                        
•    TECHNICAL SPECIFICATION OF MAT WEAVING MACHINE            
•    PRINCIPLES OF PLANT LAYOUT                            
•    PLANT LOCATION FACTORS                                
•    EXPLANATION OF TERMS USED IN THE PROJECT REPORT            
•    PROJECT IMPLEMENTATION SCHEDULES                    
•    SUPPLIERS OF RAW MATERIAL                            
•    SUPPLIERS OF PLANT AND MACHINERIES                    
       
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