Detailed Project Report (DPR) on SBR Rubber Sheets, Shoe Sole & Footwear Manufacturing

SBR RUBBER SHEETS, SHOE SOLE & FOOTWEAR MANUFACTURING

[EIRI/DFR/1203] (J.C. 9853)

INTRODUCTION

INDIAN RUBBER INDUSTRY

Indian rubber industry is nearly five decades old. There are  over  1,400  rubber  manufacturing  units  spread  over  the country. The total production of rubber goods is estimated at  Rs 340/- crores.

In a span of over 50 years the Indian rubber  Industry has  grown  from strength to strength. Nearly a  decade  ago  the industry  was  entirely dependent on imports for  its  basic  raw materials. But now the industry is almost self sufficient except for  a  very small range of specialty products.  The industry's steady progress can be evident from the following facts.

Consistent increase in consumption of new rubber  which has  jumped  from 22, 790, tonnes in 1951 is 1,38,200  tonnes  in 1972.

Considerable increase in number of rubber factories.

Steady increase in exports of rubber products crossing the figure of Rs 11.5 crores.

The natural rubber production in the country at the end of current year 1973 would be 1.25 lakh times, synthetic  rubber 35,000 tonnes and reclaimed 30,000 tonnes.

The industry  manufactures  almost  every  conceivable rubber product, from tiny toy balloons to giant tractor and aero tyres,  needed for internal consumption as well as  for  exports. The rubber goods industry manufacturers a wide range of  products such  as  automobiles tyres and tubes, bi-cycle tyres  and  tubes, rubber  and  canvas  foot wear, various types  of  rubber  hoses, railway  fitting, and automobiles rubber components. The  largest single  items  of  manufacture is the automobile  tyres  and  tubes accounting for fifty percent of consumption of rubber. The rubber foot  wear industry is next in importance and accounts for  about 12% of the total rubber consumption. The Indian tyre industry  is very  much  the  development  of the GOS,  and  product  of  post independent India.

It has made a great progress in a short span of period. Eight units are engaged in the manufacture of  automobile  tyres and  tubes  with a production capacity of over 5  million  tyres. Over 50 units manufactured foot wear, about 12 units from  rubber and  the  rest are engaged in the manufacture of  Various  rubber products  including belling, hose pipes, sheets and shelling  and innumerable mechanical, industrial and agricultural components.

The rapid growth of the rubber industry has brought about the production of several essential raw materials needed by the industry.  During a brief period (about 10 to  12  yrs)  the country saw the birth of all synthetic rubber manufacturing  unit, two  carbon black units, two rubber chemical units,  three  rayon card  units  and one nylon card unit and a number of  units  for manufacturing  and components like stearic acid, zinc  oxide  tube valves, bed wire etc.

Where as the rubber industry has been,   steadily progressing, it is not without problems. The  progress  in  the directing  of research and development in the rubber industry  is almost  negligible.  However industry has made a beginning by setting up Indian Rubber manufactures Research Association.  The Government  proposed  to  take up during the fifth  plan  60  new research  projects  under a scheme for the  expansion  of  rubber research.  As it looks, the rubber industry has in store a bright future, but much depends on the trend of economic, social & political conditions  in the country. The all India Rubber Industries  Associates.  The only representative body of the country's rubber industry can also contribute for  the  further development of the industry in the country.

Plantation of rubber is of comparatively recent origin. The output amounted to 10.000 tonnes in 1931 & 12,000 tonnes in 1940  the  area under rubber in 1940-41 was 1.38 lakh  acres.  In 1960, the  area amounted to 1.44 lakhs acres and  production  to 14.45 thousand tonnes. The area planted with rubber at the end of 1976-70 was 1,96,713 hectares. The production of natural in 1969-70 was 61.953 thousand tonnes.

The rubber board introduced a replanting subsidy scheme in 1957, it granted a subsidy of Rs 5.55 crore, up to the end of march  1971, and an area of 27, 733 hectares was replanted  under the  scheme  upto  January  synthetic  rubber.  Synthetic rubber production in  1969-70 was 28, 689 tonnes.  The  consumption  of rubber been increasing.

COST ESTIMATION

Plant Capacity            2500 Shoe Pairs/Day

Land & Building (4000 sq.mt.)    Rs. 1.03 Cr

Plant & Machinery                    Rs. 97.13 Lac

Working Capital for 2 Months    Rs. 2.58 Cr

Total Capital Investment          Rs. 4.68 Cr

Rate of Return                          44%

Break Even Point                      43%

CONTENTS

INTRODUCTION

INDIAN RUBBER INDUSTRY

PRODUCT DESCRIPTION

SYNTHETIC RUBBER

STYRENE-BUTADIENE RUBBER (SBR)

STYRENE - BUTADIENE RUBBER (SBR)

SBR RUBBER

AVAILABLE IN BLACK OR RED COLORS

SBR RED RUBBER

CHARACTERISTICS:

TYPES OF SBR

EMULSION POLYMERISATION

SOLUTION POLYMERISATION

INTRODUCTION

RUBBER AS A MATERIAL

TYPES OF RUBBER

NATURAL RUBBER

RUBBER AS A MATERIAL

TYPES OF RUBBER

NATURAL RUBBER

CHEMISTRY AND PRODUCTION:

TYPICAL RECIPE FOR SBR EMULSION POLYMERIZATION

PROPERTIES OF E-SBR:

MECHANICAL PROPERTIES

ELECTRICAL PROPERTIES

CURE PROPERTIES

TYPES OF SBR:

USES OF SBR:

TYPICAL APPLICATIONS FOR E-SBR POLYMERS

RUBBER COMPOUNDING

SEQUENCE OF ADDITIVES USED DURING COMPOUNDING

VULCANIZATION

MACHINERY USED FOR RUBBER COMPOUNDING

BANBURY MIXER

TWO ROLL MILL

BANBURY MIXER

PROCESS DESCRIPTION OF RUBBER SHEET MANUFACTURING

FLOW SHEET OF RUBBER COMPOUNDING

LAB TESTING

VERTICAL INJECTION MOLDING OF RUBBER

VERTICAL INJECTION MOLDING MACHINE

EVA AS MATERIAL

COMPOUNDING SEQUENCE

MACHINERY USED

KNEADERS

CALENDARING DEVICE

FLOW SHEET OF EVA SHEET MANUFACTURING

PROCESS DESCRIPTION OF EVA SHEET MANUFACTURING

TWO ROLL MILL CALENDARING DEVICE KNEADERS

PRESSING SECTION

CRITERIA OF A COMPOUND TO BE SOLE

MACHINERIES USED:

MANUAL C. M. MACHINES:

AUTOMATIC COMPRESSION MOLDING MACHINES:

COLD FLOW MOLDING:

LAB TESTING

BATCH CLEANING PROCESS FOR MOLDS

POLYVINYL CHLORIDE AS A MATERIAL

PHYSICAL PROPERTIES

SIGNIFICANCE OF K VALUE

INJECTION MOLDING

MACHINE DESCRIPTION

PROCESS DESCRIPTION

MACHINE DESCRIPTION

PROCESS DESCRIPTION

POLYURETHANE AS A MATERIAL

THE RIM PROCESS

RIM VARIANTS FOR PU SYSTEMS FOR SHOE SOLES

MOLDS

MOLDING PROCESS

STYRENE BUTADIENE RUBBER MANUFACTURER

ADDRESS OF MACHINE MANUFACTURER

ABOUT AND SHOE MANUFACTURING PROCESS

SHOES AND SHOE MAKING

PARTS OF A SHOE

SHOE MAKING PROCESS

SHOE MANUFACTURING PROCESS

CLICKING OR CUTTING DEPARTMENT

CLOSING OR MACHINING DEPARTMENT

LASTING & MAKING DEPARTMENT

FINISHING DEPARTMENT AND THE SHOE ROOM

USES & APPLICATIONS

B.I.S. SPECIFICATION

MARKET SURVEY

SCOPE OF RUBBER SHEETS

USES & SCOPE

SCOPE OF RUBBER SOLES

MARKET-POSITION

PRODUCTION AND CONSUMPTION FIGURE

CONSUMPTION OF RUBBERS

IMPORT OF NEW RUBBERS

CONSUMPTION OF RUBBERS

GRADE WISE PRODUCTION OF SYNTHETIC RUBBER

STATE WISE CONSUMPTION OF SYNTHETIC RUBBER

MANUFACTURES OF RUBBER SHEETS FOR SHOES SOLES

FORMULATION-II RUBBER SHEET (FOR EVA SOLE) :-

MANUFACTURING PROCESS OF EVA RUBBER SHEET FOR SHOE SOLES

MIXING MILL:-

CALENDERING:-

TALC SPRAYING:-

VULCANIZATION:-

PROCESS FLOW DIAGRAM FOR EVA RUBBER SHEET FOR SHOE SOLE

OTHER METHOD FOR THE MANUFACTURE OF EVA RUBBER SHEET

PROCESS FLOW DIAGRAM OF EVA SHEET

MICROCELLULAR SOLING PROCESS (MANUFACTURING PROCESS FOR MICROCELLULAR SHEETS)

COMPOUNDS:-

METHOD OF COMPOUNDING:-

THE IMPORTANCE OF COMPOUNDING:-

METHOD OF MILLING:-

VULCANIZATION:-

HOT VULCANISATION:-

GOLD VALCANIZATION:-

ACCELERATORS:-

SOLVENTS FOR RUBBER:-

VULCANIZING AGENTS:-

GENERAL PLANT LAYOUT

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

POWER

IMPLEMENTATION SCHEDULE

EFFLUENT TREATMENT AND DISPOSAL

THE WASTE FROM THE FOOD PROCESSING OPERATIONS MAY BE CLASSIFIED ON THE BASIS OF:

STANDARD

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

SECONDARY

TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

MANPOWER

GENERAL

BASIS OF ESTIMATION

SUPPLIERS OF PLANT & MACHINERY

RUBBER MIXING MILL

RUBBER COMPRESSION MOULD

RUBBER VULCANIZER

BOILER

RUBBER MACHINES (KNEADERS, EXTRUDERS AND HYDRAULIC PRESS)

CALENDERING MACHINERY

DOUBLE SHAFT PADDLE MIXER

WATER STORAGE TANKS

D.G. SET

SUPPLIERS OF RAW MATERIALS

PRECIPITATED SILICA

NATURAL RUBBER

SYNTHETIC RUBBER

ZINC OXIDE

STEARIC ACID

SYNTHETIC RUBBER MANUFACTURER

ADDRESSES OF MACHINERY AND EQUIPMENT SUPPLIERS

SANDAL LAST

RAW MATERIAL SUPPLIERS

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

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)