Detailed Project Report on Expanded Polyethylene Flexible Foam

EXPANDED POLYETHYLENE FLEXIBLE FOAM

[EIRI/EDPR/8261] J.C.: 6172XL

INTRODUCTION

Polyolefin (PO) foams are manufactured by many producers in a variety of processes and are classified as low density (25-250 kg/m3) or high density (250-700 kg/m3). The market has expanded relative to other foamed plastics, especially in japan.

Most polyolefin foams are made from low density polyethylene [9002-88-43] (LDPE). Copolymers such as the more flexible ethylene vinyl acetate [24937-78-8] (EVA) and more rarely, highdensity polyethylene [9002-88-4] (HDPE) are also found, finally, foams may be produced from linear low-density polyethylene (LLDPE), copolymer of ethylene and other olefins (1-butene to 1-octene) which is synthesized with a Ziegler catalyst. Polpropylene [9003-07-0] (PP) awhich is more resistant to heat deformation, stiffer and tougher than polyethylene, was first processed into foamed sheets in the 1960s. Today, a polypropylene copolymer with a few percent ethylene is also utilized.

Among foaming plastics, cellular polyethylene is a light plastic mateirals produced by the extrusion of a polyethylene compound containing an intimately dispersed chemical blowing agent. Extrusion can be accomplished with conventional equipment. A recent innovation in plastics materials, cellular polyethylene has demonstrated a number of interesting distinct properties. Which have suited it for. wire and cable coating because the excellent basic properties of solid polyethylene flexibility, tonghness, low moisture absorption, abrasion and chemical resistance and low electrical loss characteristics are retained with a significant reduction in specific gravity.

This material is composed essentially of unconnected hollow cells. During extrusion polyethylene compound exponds 100% resulting in a composition which is 50% inert gas. Becouse of this certain properties are improved.

COST ESTIMATION

Plant Capacity            910.64 Meters/Day

Land & Building (600 sq.mt.)    Rs. 48.60 Lac

Plant & Machinery                    Rs. 1.35 Cr

Working Capital for 1 Month    Rs. 18.81 Lac

Total Capital Investment          Rs. 2.07 Cr

Rate of Return                          17%

Break Even Point                      76%

CONTENTS

INTRODUCTION

USES & APPLICATIONS OF POLYOLEFIN FOAMS

PROPERTIES & CHARACTERISTICS OF POLYOLEFIN FOAMS

FIRE BEHAVIOUR OF POLYOLEFIN FOAMS

PROPERTIES & CHARACTERISTICS OF RAW MATERIALS POLYETHYLENE

LOW DENSITY POLYETHYLENS (BRANCHED CHAIN)

BLAVING AGENT AZODICARBONAMIDE

B.I.S. SPECIFICATION

MARKET SURVEY

TRADE NAMES OF COAMED AND FOAMABLE PLASTICS

MANUFACTURING PROCESS FOR EXPANDED POLYETHYLENE FLEXIBLE FOAM (LOW DENSITY FOAM) (25-250 KG/M3)

CROSS-LINKED FOAMS

BATCH PROCESS FOR MOULDED CROSS-LINKED FOAM

MANUFACTURING PROCESS FOR EXPANDED POLYETHYLENE FLEXIBLE FOAM USING BLOWING AGENT AND CROSSLINING AGENT

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE EXPANDED POLYETHYLENE FLEXIBLE FOAM

MANUFACTURING PROCESS OF EXPANDED POLYETHYLENE FLEXIBLE FOAM ANOTHER PROCESS FOR CROSS-LINKED SHEETS (IRRADIATION PROCESS)

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CROSS-LINKED SHEETS OF POLYETHYLENE FLEXIBLE FOAM

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

EXTRUDERS

BOILER

TUNNEL HEATING

SUPPLIERS OF RAW MATERIALS

BLOWING AGENT (AZODICAR BONAMIDE)

DICUMYL PEROXIDE

RAW MATERIALS CALCULATIONS

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

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:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF STATE INDUSTRIAL DEVELOPMENT CORPORATIONS

ADDRESSES OF FINANCIAL INSTITUTIONS

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

SUGGESTED STEPS

ECONOMIC ADVANTAGE IN SETTING UP THE PROJECT IN INDIA

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)