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    Detailed Project Report on aerosol-pesticides

    Detailed Project Report on aerosol-pesticides
    Detailed Project Report on aerosol-pesticides
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      AEROSOL – PESTICIDES
      [CODE NO. 3348]  


      Aerosols are dispersions of liquid droplets or small solid particles in gases. Gaseous dispersions can  be produced from atomizers,  nebulizers, or insufflators. Pressurized containers utilizing various propellent gases for delivering chemical products through appropriately designed valve systems and actuator  devices have been available. These propellent include liquefied gases or gas mixturers. Non-liquefied compressed gases are  also used.  The products can be produced in the form of suspensions, emulsion, gel, solutions, foam depending on the formulation,  valve  system, dip-tube, propellant,  actuator  and container.

      The word "aerosol" was first employed in the field of colloid chemistry to describe a suspension of small particles  in air or gas in which radius of the particles was  less  than  50 micron. The suspended particles could be either solid or  liquid. Dust,  smoke and fog are examples of this class of  aerosol. The particles  in dusts may have diameter  as small as 0.1 micron  or less. The suspensions produce haze smoke is an aerosol consisting of solid particles, usually carbon, in air.  Carbon smoke is composed  of small particles with a radius of about 0.01  micron. The particle sizes in fogs are longer and range from about  4-50 micron in  diameter. The first aerosol of any commercial significance,  the aerosol insecticide, was defined in 1949 as  a system of particles suspended in air where 80 % of the  particles were  less  than  30 microns in diameter and  no  particles  were larger than 50 micron.

      According to a recent CSMA glossary of terms, aerosol packaging  is  defined as " pressurizing sealed  containers  with liquefied  or  compressed  gases so that  the  product  is  self-dispensing".

      The present aerosol industry is generally considered to have received its stimulus  from the development of  the aerosol insecticide used in world war II. The need for a  portable insecticide dispenser became imperative because of the disease caused among overseas troops by insects.

      Packaging  technology plays an important role  for  aerosols containers  which  are usually made of metal, such  as  tinplate. (Sheet  metal  plated  with tin) or aluminium  generally  with  a protective  coat of lacquer on the inside. The  other  components are valve & spring nozzle. The selection of nozzle is crucial for the tublence and particle size of spray.
       
      To  ensure  stability  metal containers  may  be  internally coated.  These  coatings must be acceptable in term of  safety  & product  compatibility. The type of valve used depends  upon  the product  use. It can be designed to deliver metered doses  or  to control  the  size  of the delivered  liquid  droplets  or  solid particles. Various actuators or adaptor units can be attached for different purposes. (eg.  to obtain different spray pattern).

      The aerosol insecticides were packaged in 1-lb heavy steel containers. The  containers were made of two  shells,  drawn  of 0.044  in  steel and welded together. The cylinders were  fitted with  an  oil-burner-type  valve  with  a  swirl  chambers. The containers were filled with a mixture of 90 wt % freon 12 and  10 wt  % of a pyrethrin and sesame oil concentrate. A  4-inch  metal dip  tube,  0.017 inch in diameter, was attached to  the  valve, inside  the container. The pressure in the aerosols was about  70 psig at 70 oF, and the blow-off release was set at 300 psig. The aerosol  insecticides were  named  "big  bombs"  by westing house employees  because  of  their resemblance to a small bomb.  The insecticides  were  sold at 80 locations, including department stores, groceries, supermarkets, hardware  stores  and  filling stations.

      COST ESTIMATION

      Plant  Capacity                                                     :     10000.00 Cans/day
      land & Building (1000 Sq.Mtr)                            :    Rs.  83.00 Lacs
      Plant & Machinery                                                 :    Rs.  1.1   Cr
      Working Capital for 1 Month                               :    Rs.  1.7   Cr
      Total Capital Investment                                      :    Rs.  3.05  Cr
      Rate of Return                                                       :    48%
      Break Even Point                                                  :    44%


      INTRODUCTION    
      DETAILS OF AEROSOL (PESTICIDES/INSECTICIDES)    
      AEROSOL CONTAINER    
      STRENGTH OF CONTAINERS    
      AEROSOL VALVE    
      DIP TUBE    
      HOUSING    
      VALVE SPRING    
      VALVE STEM    
      VALVE INNER GASKET    
      VALVE CUP    
      ACTUATOR (BUTTON)    
      INSECTICIDES APPROVED CONTROL HOUSEHOLD PEST    
      INSECTICIDE    
      FORMULATION    
      INSECTICIDE    
      FORMULATION    
      HABITAT    
      ANOPHELES LARVAE    
      10 LIT IN 500 LTR WATER/HA    
      CULEX LARVAE    
      5 LIT IN 500 LTR WATER/HA    
      AEDES LARVAE    
      10 LIT IN 500 LTR WATER/HA    
      HABITAT    
      ADULT    
      LARVAE    
      USES AND APPLICATION    
      B.I.S. SPECIFICATION    
      SPECIFICATION FOR PROPOXUR EMULSIFIABLE CONCENTRATES
      (IS - 9665 - 1981)    
      PACKING AND MARKING    
      SAMPLING:    
      TESTS:    
      SPECIFICATION FOR PROPOXUR TECHNICAL    
      (IS: 8496 - 1977)    
      DETERMINATION OF PROPOXUR CONTENT    
      GENERAL:-    
      ULTRA VIOLET SPECTROPHOTOMETRIC METHOD:-    
      PRINCIPLE:-    
      APPARATUS:-    
      REAGENTS:-    
      PREPARATION OF STANDARD AND SAMPLE SOLUTIONS:-    
      PREPARATION OF STANDARD SOLUTION:-    
      PREPARATION OF SAMPLE SOLUTIONS:-    
      PROCEDURE:-    
      CALCULATION:-    
      SAPONIFICATION METHOD:-    
      PRINCIPLE:-    
      REAGENTS:-    
      NITROGEN:-    
      PROCEDURE:-    
      ALLETHRIN, TECHNICAL SPECIFICATION    
      STRUCTURAL FORMULA    
      REFERENCES:-    
      REQUIREMENTS:-    
      DESCRIPTION:-    
      PACKING:-    
      MARKING:-    
      SAMPLING:-    
      TESTS:-    
      QUALITY OF REAGENTS:-    
      NOTE:-    
      DERMINATION OF D-ALLETHRIN CONTENT    
      COLUMN:-    
      REAGENTS:-    
      PROCEDURE:-    
      PREPARATION OF INTERNAL STANDARD SOLUTION:-    
      PREPARATION OF STANDARD SOLUTION:-    
      PREPARATION OF SAMPLE SOLUTION:-    
      ESTIMATION:-    
      CALCULATION:-    
      WHERE,    
      CHEMICAL COMPONENTS AND FORMULATIONS    
      SPRAY CHARACTERISTICS AND PRODUCT VARIABLES    
      ACTIVE INGREDIENTS    
      FLYING INSECT KILLER    
      CRAWLING INSECT KILLER    
      MULTI-PURPOSE    
      OPTIMISED FORMULATION    
      THE FORMULATION MAY BE OPTIMISED SUCH THAT:    
      THEY CAN BE DESCRIBED AS FOLLOWS:    
      SOLVENTS, CO-SOLVENTS AND PROPELLANTS    
      SOLVENTS    
      PROPELLANTS    
      EXAMPLES ARE:    
      CFCS    
      CS    
      HCFS    
      HFCS    
      DIMETHYL ETHER (DME)    
      COMPRESSED GAS PROPELLANTS    
      OIL-BASED AEROSOLS AND WATER-BASED AEROSOLS    
      OIL-BASED AEROSOLS    
      WATER-BASED AEROSOLS    
      MARKET SURVEY    
      DRIVERS AND TRENDS    
      DETAILED EXPORT DATA OF AEROSOL    
      PRESENT MANUFACTURERS/SUPPLIERS    
      MANUFACTURE OF AEROSOLS    
      MANUFACTURING OF AEROSOLS ARE DONE AT TWO STAGES.    
      PRESSURE FILLING METHOD:    
      A. METHOD-1    
      B. METHOD-2    
      COMPRESSED GASES FILLING:    
      TESTING THE FILLED CONTAINERS:    
      PACKAGING, LABELING AND STORAGE    
      AEROSOL COMPONENTS    
      PROPELLANTS:-    
      GENERAL PROPERTIES:-    
      BOILING POINT AND VAPOR PRESSURE:-    
      COST:-    
      FLAMMABILITY:-    
      ODOR:-    
      PURITY:-    
      STABILITY:-    
      TOXICITY:-    
      SOLVENTS:-    
      ACTIVE INGREDIENTS:-    
      OPERATION OF AN AEROSOL:-    
      THIS OPERATION IS ILLUSTRATED IN FIGURE SHOWN BELOW.    
      RAW MATERIALS    
      SOLVENTS    
      PETROLEUM SOLVENTS    
      ALCOHOLS    
      ESTERS    
      KETONES    
      ETHERS    
      VEGETABLE OILS    
      FOLLOWING DESIRABLE PROPERTIES OF THE SOLVENT.    
      FINITROTHOIN    
      CAUTION  
      FORMULATION AND FILLING EQUIPMENT    
      LIQUID    
      FIRE/EXPLOSION PRECAUTIONS    
      INDUSTRIAL HYGIENES PRECAUTIONS    
      CARBAMATES    
      INSECTICIDAL AEROSOLS    
      SIZE OF LIQUID PARTICLES IN AN AEROSOL    
      SPRAY EMULSION    
      AEROSOL INSECTICIDE/PESTICIDES FORMULATIONS    
      (FOR COSTING - I)    
      (FORMULATION APPROVED BY THE GOVT.)    
      OTHER AEROSOL INSECTICIDE FORMULATION    
      OTHER FORMULATIONS OF HOUSE HOLD AEROSOLS    
      DETAILED MANUFACTURING PROCESS    
      PROCESS FLOW DIAGRAM FOR AEROSOL INSECTICIDE SPRAY (BAYOR TYPE)
      PROCESS FLOW DIAGRAM FOR AEROSOL INSECTICIDE SPRAY    
      (HIT TYPE FOR MOSQUITOES & FLIES)    
      PROCESS FLOW DIAGRAM FOR AEROSOL INSECTICIDE SPRAY    
      PROCESS FLOW DIAGRAM FOR AEROSOL INSECTICIDE SPRAY    
      PROCESS FLOW DIAGRAM FOR AEROSOL INSECTICIDE SPRAY    
      GENERAL PROCESS DIAGRAM   
      FILLING OF AEROSOLS CONTAINERS WITH LIQUEFIED    
      GAS PROPELLANTS (LPG)    
      METHOD OF FILLING OF CANS    
      (I)  PRESSURE FILLING:-    
      STEP 1 :-    
      STEP 2 :-    
      STEP 3 :-    
      STEP 4 :-    
      STEP 5 :-    
      STEP 6 :-    
      STEP 7 :-    
      STEP 8 :-    
      STEP 9 :-    
      STEP 10 :-    
      STEP 11 :-    
      STEP 12 :-    
      PROCESS FLOWSHEET FOR AEROSOL INSECTICIDE/PESTICIDES    
      METHOD:-2    
      UNDERCAP FILLING METHOD:-    
      PESTICIDE FORMULATION & PROCESS    
      A PESTICIDE FORMULATION MAY CONSIST OF:    
      AEROSOLS (A)    
      READY-TO-USE AEROSOLS    
      ADVANTAGES:    
      DISADVANTAGES:    
      PLANT LAYOUT    
      SUPPLIERS OF RAW MATERIALS    
      SUPPLIERS OF PLANT AND MACHINERY    
      STAINLESS STEEL MIXER    
      STORAGE VESSEL (STORAGE TANKS)    
      LABORATORY EQUIPMENTS    
      INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
      FIRE FIGHTING EQUIPMENTS    
      D.G. SETS    
      RAW MATERIALS CALCULATION    
      BASIS: 1 MONTH    
      COSTING - I    
      PLANT ECONOMICS   

      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      

       

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