Detailed Project Report on Cast Polypropylene Films (CPP Film)

CAST POLYPROPYLENE FILMS (CPP FILM)

[EIRI/EDPR/1646] J.C.452

INTRODUCTION

The term CPP is used in the plastics industry to describe polypropylene-based films produced by a cast extrusion process (Cast Polypropylene). Although there are some CPP films used for hygiene applications and synthetic paper (usually involving fillers and other additives), the term CPP is usually used to refer to high clarity films targeting lamination, metallization and packaging applications. The rapid quench achieved with chill rolls results in excellent film clarity and gloss.

These types of films differ from BOPP (Biaxially-Oriented Polypropylene) because they are not oriented. Orientation is a process that increases the tensile strength of film in a specific direction by stretching or rolling. Strictly speaking, CPP films experience a small amount of orientation, but only in the Machine Direction (MD), due to the nature of the process.

The cast film extrusion process is gaining increased popularity and enjoying sustained growth worldwide. New lines are being installed in a significant number and the market segments penetrated by this technology are on the rise. This article identifies the main components of a cast extrusion line and presents the fundamental aspects that require consideration when approaching cast film technology.

Cast films are used for food and textiles packaging, flower wrapping, as photo album page protectors, as coating substrates in extrusion coating processes or laminated to other materials in the formation of more complex films, among others. Typically, the cast film process involves the use of coextrusion, which is a simultaneous extrusion of two or more materials from a single die to form a multi-layered film. This is because in many cases the final application of the plastic film demands a performance that cannot be achieved if the film is composed of only one material. For example, in many instances food packaging applications require the use of films with oxygen barrier capabilities. To meet the requirement a high oxygen barrier material like EVOH is combined with polyolefin materials in a multi-layered structure. Coextruded films typically contain up to seven layers; however, the use of more layers is becoming more common. The number of layers, their position in the coextrudate and their individual thickness are all variables that change depending on the particular application of the film.

COST ESTIMATION

Plant Capacity            16.667 MT/Day

Land & Building (4000 sq.mt.)    Rs. 2.45 Cr

Plant & Machinery                    Rs. 2.80 Cr

Working Capital for 2 Months    Rs. 9.36 Cr

Total Capital Investment          Rs. 14.92 Cr

Rate of Return                          43%

Break Even Point                      38%

CONTENTS

INTRODUCTION

PROPERTIES AND CHARACTERISTICS OF CAST POLYPROPYLENE FILM

RAW MATERIALS AND FILM PROPERTIES

SES AND APPLICATION OF CPP FILM

TYPES AND GRADE OF CPP FILM

BENEFITS/LAMINATION OF CAST EXTRUSION

MARKET SURVEY

SCOPE OF PACKAGING INDUSTRY IN INDIA

PRODUCTION OF CPP FILM IN INDIA IN (ORGANIZED AND UNORGANIZED SECTOR)

IMPORT & EXPORT OF CPP FILM

APPARENT CONSUMPTION OF CPP FILM IN INDIA

GLOBAL MARKET OF CPP FILM

EUROPEAN CPP FILM MARKET TRENDS

SEGMENT WISE MARKET OF CPP FILM IN INDIA

PRESENT MANUFACTURERS OF CPP FILMS (INDIA & ABROAD)

DESCRIPTION OF CPP FILMS

TECHNICAL DETAILS OF CPP FILMS

DETAILS OF EQUIPMENTS AND PROCESSING TRENDS IN CPP FILM

TRENDS IN CPP FILMS

COMPARISON OF CPP FILM WITH OTHER’S PLASTIC FILM

TYPICAL PROPERTIES (1.0 MIL FILM)

MANUFACTURING PROCESS OF CPP FILM (CAST POLYPROPYLENE FILM)

PROCESS IN DETAILS

FORMULATION OF CPP FILM

PROCESS FLOW DIAGRAM

TECHNICALITIES IN CPP FILM EXTRUSION

CAST POLYPROPYLENE FILM LINES ALPHA CPP – CAST POLYPROPYLENE FILM LINES

QUALITY CONTROL AND TEST METHOD OF CPP FILM

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)

SUPPLIERS OF PLANT AND MACHINERIES

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)