uPVC PROFILES (DOORS & WINDOWS)
[EIRI/EDPR/1303] J.C. 9965, 874
INTRODUCTION
PVC was produced for the first time in 1935 and has been industrially manufactured in large quantities for over 50 years. It has been developed into a material that can offer a wider range of properties and therefore has many different applications. Total PVC productions can be split approximately into the following applications:
• 55% Construction Industry
• 16% Packaging History
• 4% Furniture
• 4% Cars
• 2% Electricity Industry
• 19% Others (including Medical and Horticultural)
The production process starts with sodium chloride, (common salt) from which chlorine gas is obtained by electrolysis. Petroleum or natural gas is used to produce ethylene, one of many products of the process known as cracking. Bringing together chlorine and ethylene, liquid vinyl chloride (VC) is produced which is immediately changed in the process by polymerisation into polyvinyl chloride.
Vinyl chloride is toxic and therefore a closed production process is used producing PVC as a white power that is chemically stable.
Polyvinyl Choride (PVC) is a chemical compound of chlorine, carbon and hydrogen. The components of PVC originate from the naturally occurring raw materials of petroleum or natural gas and common salt. The ‘u’ stands for unplasticised and means that the material has not been softened by the addition of chemicals known as plasticizers.
uPVC FOR DOORS
The basic material properties of uPVC make it ideal for door application. These properties include:
• Does not rot or biologically decompose
• Is resistant to weathering with low maintenance requirements
• Is tough on impact
• It retains its shape within normal climatic temperatures
• It can be reshaped at high temperature and can therefore be recycled
COST ESTIMATION
Plant Capacity 4 MT/Day
Land & Building (10,000 sq.ft.) Rs. 2.14 Cr
Plant & Machinery Rs. 2.15 Cr
Working Capital for 2 Months Rs. 1.66 Cr
Total Capital Investment Rs. 6.11 Cr
Rate of Return 60%
Break Even Point 35%
CONTENTS
INTRODUCTION
RAW MATERIAL SECTION
TYPICAL PROPERTIES OF RIGID PVC
MARKET SURVEY
MARKET POSITION
BLOCK DIAGRAM OF THE PRODUCTION
SPECIFICATION OF RAW MATERIAL
TECHNICAL KNOW-HOW AVAILABLE AT FOLLOWING ADDRESS
HOW TO MEASURE WINDOWS & DOORS
MANUFACTURING SIZES
LOCATION OF SITE
PROCESS OF MANUFACTURE
PROCESS FLOW SHEET
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
UPVC WINDOWS WORKING VIEW
IMPLEMENTATION SCHEDULE
PRESENT MANUFACTURERS OF UPVC DOORS AND WINDOWS (PROFILES)
SUPPLIERS PLANT AND MACHINERY
RAW MATERIAL SUPPLIERS
MANUFACTURERS/SUPPLIERS OF UPVC DOORS AND WINDOWS MAKING MACHINE
ANNEXURE – A TEST METHODS FOR UPVC PROFILES
ANNEXURE B MATERIAL CHARACTERISTICS- SAMPLE PREPARATION AND REQUIREMENTS
ANNEXURE C COLOR RANGE & PERMISSIBLE TOLERANCE
ANNEXURE D THE RADIATION DOSE AND EXPOSURE TIME TO BE USED FOR ARTIFICIAL WEATHERING
ANNEXURE E RESISTANCE TO IMPACT OF MAIN PROFILES BY FALLING MASS
ANNEXURE F HEAT AGING BEHAVIOR AT 150°C
ANNEXURE G DETERMINATION OF THE STRENGTH OF WELDED CORNERS AND T JOINTS
ANNEXURE H METHOD FOR CALCULATION OF FAILURE STRESS
ANNEXURE I HEAT REVERSION TEST
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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