Detailed Project Report on pvc compounding plant for cable grades

PVC COMPOUNDING PLANT FOR CABLE GRADES
[CODE NO.3367]  


Indian plastics industry is one of the largest in the Asian Region. It had a modest beginning in the late twenties when articles like combs, soap boxes, ash trays etc. began to be manufactured in the country from imported raw materials. Three are about fifty materials identified as plastics and the list is being extended continuously. Plastics are classified as thermoplastics and thermo sets on the basic of the polymerization method adopted to produce the basic plastic material as on the basic of the primary raw materials source. Polyvinyl chloride comes under thermoplastics. Polyvinyl chloride (PVC) polymers or resins are the most important constituents of PVC compounds and are classified into bulic or mass polymers, emulsion polymers, suspension polymers and paste-forming polymers. There is a fifth type known as solution polymers which is used for coating applications.

Compounding of PVC resin is done in three steps, namely

1.    Premixing

2.    Fusion or gelation

3.    Pelletizing or granulation. Mixing of the ingredients to a high degree of homogenization is called (premixing). The premixed material is homogenized during Fusion or Gelation. In the third step namely pelletization or granulation the homogenous mass is produced in a suitable form for smooth processing. Hence it is possible to avoid one or more of the steps with the help of modern processing equipment.

Although plastic industry in India experienced many ups and downs in the 70's it has made considerable progress not only in the output and range of plastics raw materials produced and consumed but also in learning and absorbing better processing technology as well as the manufacture of more and better machine.

COST ESTIMATION

Plant  Capacity                                          :    5.00 MT/day               
land & Building (600 sq.Mt)                    :    Rs. 90.00 Lacs
Plant & Machinery                                     :    Rs. 25.00 Lacs
Working Capital for 2 Months                 :    Rs. 2.5  Cr
Total Capital Investment                          :    Rs. 3.29 Cr
Rate of Return                                           :    40%
Break Even Point                                      :    45%

INTRODUCTION    
DEVELOPMENT IN PVC COMPOUND    
WHAT IS THE INTENDED APPLICATION?    
HOW WILL THE MATERIAL BE PROCESSED?    
BASE MATERIAL    
ADDITIVES    
MATERIAL DEVELOPMENTS    
PVC PERFORMANCE    
SOFT PVC (A PLASTICIZED PVC)    
PIGMENTS    
RIGID (OR UNPLASTICIZED) PVC    
PVC COMPOUNDING ESSENTIAL INGREDIENTS    
PVC RESIN    
SUSPENSION GRADE PVCH    
EMULSION GRADE PVC    
BULK POLYMERISED PVC    
COPOLYMER PVC    
K VALUE    
PRIMARY PLASTICIZERS    
SECONDARY PLASTICIZERS    
STABILIZERS    
HEAT STABILIZERS    
LIGHT STABILIZERS    
LUBRICANTS    
FILLERS    
GROUND CALCIUM CARBONATE    
PRECIPITATED CALCIUM CARBONATE    
PIGMENTS    
MASTERBATCHES    
SPECIAL ADDITIVES    
FLOW PROMOTERS    
IMPACT MODIFIERS    
FIRE RETARDANTS AND SMOKE SUPPRESSANTS    
FOAMING AGENTS    
FUNGICIDES AND BIOCIDES    
USES AND APPLICATION    
BUREAU OF INDIAN STANDARDS SPECIFICATION    
OVERVIEW OF WIRE & CABLES    
TWO INDIES    
POWER PLAYERS    
BETTER CABLES MEAN BETTER RELIABILITY    
IMPROVING TRANSMISSION FOR A BRIGHT FUTURE    
MARKET TRENDS    
END USERS DEMAND LONG-TERM PERFORMANCE    
GOVERNMENT REFORM IS CHANGING THE ELECTRICITY MARKET    
PE STRONG IN POWER CABLE INSULATION AND TELECOMMUNICATION CABLES    
NEW TECHNOLOGIES    
STANDARDS    
INNOVATIVE WIRE & CABLE SOLUTIONS FOR INDIA    
POWER CABLE MATERIALS    
TELECOMMUNICATIONS CABLE MATERIALS    
SPECIALTY WIRE AND CABLE PRODUCTS    
ELASTOMERS FOR WIRE AND CABLES    
MARKET SURVEY    
U.S. PLASTIC COMPOUNDING MARKET REVENUE BY PRODUCT
2014 - 2026 (USD MILLION)    
GLOBAL DEMAND OF PVC    
THE PROCESSING SECTOR    
PRESENT MANUFACTURERS OF PVC COMPOUND    
RENEWABLE PVC COMPOUNDING AND ITS DETAILS    
RENEWABLE PLASTICIZERS    
RENEWABLE PVC COMPOUND    
ENVIRONMENTAL IMPACT AND TOXICOLOGY    
THE CALCULATION IS SUMMARIZED BELOW    
FORMULATION OF PVC COMPOUND (CABLE GRADE)    
FORMULATION FOR DIFFERENT GRADES OR P.V.C.    
PROCESS OUTLINE OF PVC COMPOUNDING    
PROCESS OF MANUFACTURE    
TRANSFORMATION OF THE RAW MATERIALS COMPOUND CONSISTS
OF THE FOLLOWING    
RAW MATERIAL QUALITY ASSURANCE, EVERY STEP OF THE WAY    
RELIABLE, PROVEN PVC COMPOUNDING CAPABILITY.    
PROCESS FLOW DIAGRAM    
DETAILS OF PVC COMPOUNDING    
DRY BLENDING    
MELT COMPOUNDING    
MELT COMPOUNDING OF ELVALOY/PVC BLENDS USING
A HIGH-SHEAR, CO-ROTATING, TWIN SCREW EXTRUDER    
TABLE 1. TYPICAL SCREW DESIGN (53 MM W&P)    
TABLE 1. FORMULAS    
PVC COMPOUNDING EXTRUDER    
PVC COMPOUNDING MACHINES    
SUPPLIERS OF RAW MATERIALS    
POLYMERS POLYVINYL CHLORIDE (PVC)/RESINS    
STABILIZERS    
PLASTICIZERS    
CALCIUM STEARATE    
C.P.W    
CALCIUM CARBONATE    
HDPE WOVEN BAGS   
SUPPLIERS OF PLANT AND MACHINERY    
GRANULES EXTRUSION MACHINES    
HIGH SPEED MIXER    
AIR COMPRESSOR    
PLASTIC SCRAP GRINDER MACHINE    
LABORATORY EQUIPMENTS    
D.G. SETS    


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