Detailed Project Report on pvc pipe manufacturing, pvc pipe fitting and hdpe pipe manufacturing

PVC PIPE MANUFACTURING, PVC PIPE FITTING AND HDPE PIPE MANUFACTURING
[CODE NO.3424]  


PVC is a thermosetting plastic. In other words, it can only be softened and molded into form once. If it is softened and remolded a second time it will lose some of it's favorable characteristics. Recently, 'Fuseable PVC' has come to market to compete with the fuseable properties of HDPE Pipe.

PVC also has a high chemical resistance. While it will react with some chemicals, there are a large number of chemicals it will not react with, making it an excellent product for industrial applications.

Because PVC is mostly a 'rigid' pipe product, PVC pipe is an excellent pipe choice for just about any application that does not require a 'flexible' solution. The most common uses for PVC are:

Water Distribution
Underground Fire Main Distribution
Gravity Sanitary Sewer Collection
Forcemain Sewerage Transmission
Irrigation Mains
Reclaimed Water Distribution
Electrical & Communications Conduit
Numerous Industrial Applications

PVC Pipe fittings are integral and essential part of PVC piping systems. These are required where ever PVC pipes are used.

The efficiency of various PVC piping systems depend largely upon the quality of the fittings used in pipe assembly. The most commonly used PVC pipe fittings are Sockets, Tees elbows, Bends, Joints etc.

PVC pipes are fast replacing the conventional metallic pipes in many applications such as electrical conduits, irrigation, sanitary fittings, portable water etc. They are also used in tube wells and due to their chemical resistance properties they find applications in chemical plants too.

Over 70% of India's rural population does not have access to safe drinking water. Villagers have to trek for miles to get water.  It is estimated that at least 24 million people  are living at risk in about 34,000 cholera, endemic villages, and small towns. The magnitude of the problem is so enormous that it is essential to have a high performance     and  low  cost  scheme to convey extensively  the  water now available to as many villages as possible. Such as system is now possible with PVC pipe lines. PVC can replace     conventional materials like steel, cast iron and asbestos cement and in advanced countries it has already done so.

HDPE pipe market has been witnessing steady rise for the past decade owing to its rise in application in its relevant industry. The product is being activity used across the globe resulting in the quantitative increase in demand which is in turn pushed the revenue generation year on year. In term of types the global HDPE pipe market is segmented into PE80, PE100 pipe. The HDPE pipe market segmented by region include US. Canada, Mexico, Germany, France, UK, Italy, Russia, China, Japan, India, Korea, Australia, Brazil, Middle East and Africa.


COST ESTIMATION

Plant  Capacity                                     :       PVC PIPE, FITTING
                                                                        & HDPE PIPE MFG.
                                          
land & Building (12000 Sq.mtr)       :    Rs.  3.25 Cr
Plant & Machinery                              :    Rs.  2.20 Cr
Working Capital for 2 Months          :    Rs.  2.76 Cr
Total Capital Investment                  :    Rs.  9.16 Cr
Rate of Return                                   :    25%
Break Even Point                              :    59%

INTRODUCTION    
USES OF PVC PIPES    
SPECIFICATION OF SELECTED PVC AND CPVC PIPE FITTINGS    
INJECTION MOLDED FITTING    
SPECIFICATION & TESTING METHOD OF HDPE PIPES    
SCOPE    
REFERENCES    
DESIGNATION    
COLOUR    
MATERIAL    
DIMENSIONS OF PIPES    
TABLE 2 OUTSIDE DIAMETER, TOLERANCE AND QUALITY OF PIPES    
TABLE 3 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 63    
TABLE 4 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 80    
TABLE 5 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 100    
VISUAL APPEARANCE    
PERFORMANCE REQUIREMENTS    
SAMPLING, FREQUENCY OF TESTS AND CRITERIA FOR CONFORMITY    
TABLE 6 REQUIREMENTS OF PIPES FOR INTERNAL PRESSURE CREEP
  RUPTURE TEST    
MARKING    
EXPLANATORY NOTES    
MASTER BATCH    
TOLERANCE ON OUTSIDE DIAMETER AND MAXIMUM OVALITY    
WALL THICKNESS    
INTERNAL PRESSURE CREEP RUPTURE TEST    
GENERAL    
TEST SPECIMENS    
APPARATUS    
PROCEDURE    
ASSESSMENT OF RESULTS    
LONGITUDINAL REVERSION TEST    
APPARATUS    
PROCEDURE    
EXPRESSION OF RESULTS    
SPECIFICATION OF PVC PIPES AND TESTING METHOD    
UNPLASHCIZED PVC PIPES FOR POTABLE WATER SUPPLIES —
   SPECIFICATION (THIRD REVISION)    
SCOPE    
NORMATIVE REFERENCES    
TERMINOLOGY    
NOTATION    
CLASSIFICATION OF PIPES    
COMPOSITION    
DIMENSIONS    
SEALING RINGS    
PIPE ENDS    
PHYSICAL AND CHEMICAL CHARACTERISTICS    
TABLE 4 INNER DIAMETERS OF SOCKETS FOR USE WITH
    ELASTOMETRIC SEALING RINGS    
MECHANICAL PROPERTIES    
SAMPLING AND CRITERIA FOR CONFORMITY    
MARKING    
QUALITY CONTROL AND TESTING OF PIPES & FITTINGS    
WORKMANSHIP, FINISH, AND APPEARANCE    
DIMENSIONS    
PHYSICAL PROPERTY TESTS    
ASTM TESTS    
GLOBAL MARKET POSITION OF PVC PIPES & FITTING    
ASIA-PACIFIC PVC PIPE MARKET    
GLOBAL MARKET POSITION OF HDPE PIPES    
CHINA, UNITED STATES TO DRIVE GLOBAL DEMAND    
DEVELOPING COUNTRIES TO ALSO SHOW ROBUST GROWTH    
PLASTIC PIPE TO PENETRATE NONTRADITIONAL MARKETS    
PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES    
ADVANTAGES OF PVC    
CHEMICAL RESISTANCE    
STRENGTH    
INTERNAL CORROSION RESISTANCE    
EXTERNAL CORROSION RESISTANCE    
FREEDOM FROM TOXICITY, ODORS, TASTES    
CORROSION FREE    
LOW FRICTION LOSS    
LOW THERMAL CONDUCTIVITY    
EASY INSTALLATION AND LOW INSTALLATION COST    
MAINTENANCE FREE    
STANDARD APPROVED    
PROPERTIES OF PVC PIPES AND FITTINGS    
PIPE DIMENSIONS EIGHT & OPERATING PRESSURE OF PVC & CPVC PIPE    
MANUDFACTURERS/SUPPLIERS OF PVC PIPES FITTINGS AND HDPE PIPES    
PVC FOR PIPING INDUSTRY    100
TABLE GENERAL PROPERTIES OF RIGID PVC    
PVC    
STEPS TO REDUCE THE COST TO PROCESS PLASTIC PIPES INCLUDE    
FORMULATION FOR PVC RIGID PIPES    
PROCESS OF MANUFACTURE PVC PIPE    
PLUMBING PIPES    
MANUFACTURING PROCESS OF PVC PIPES    
ADDITIVES USED FOR MANUFACTURING    
RIGID PVC PIPES    
PROCESS FLOW DIAGRAM FOR PVC PIPES    
PVC COMPOUND FORMULATION    
FORMULATION AND PROCESS OF PVC RIGID PIPES    
FORMULATION FOR PVC RIGID PIPES    
PVC FLEXIBLE PIPES    
PLUMBING PIPES    
PROCESS OF MANUFACTURE OF RIGID PIPES    
TWIN SCREW EXTRUDERS    
EXTRUSION DIES    
EXTRUSION LINES    
PVC PIPE FITTINGS:-    
PLASTICIZER OF PVC    
FILLERS OF PVC    
STABILIZERS    
MANUFACTURING PROCESS OF PVC PIPE FITTINGS    
INJECTION MOULDING :-    
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPE FITTING    
RAW MATERIALS FOR HDPE PIPES    
A. HDPE GRANULES    
B. BLACK MASTER BATCH    
C. ANTI-OXIDANT    
MANUFACTURING PROCESS OF HDPE PIPES    
EXTRUSION PROCESS    
WORKING PRINCIPLE    
EXTRUSION PROCESS PARAMETERS    
ADVANTAGES:    
DISADVANTAGES:    
INCOMING RAW MATERIAL INSPECTION    
RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE    
RESIN STORAGE AND CONVEYANCE    
RESIN FEEDING    
TESTING    
(A) TYPE TEST    
(B) ACCEPTANCE TEST    
(C) LONGLTUDINAL REVERSION PERFORMANCE TEST    
APPRATUS    
1. AIR OVEN    
2. THERMOMETER    
TEST SPECIMENS    
PROCEDURE    
MARKING    
PVC PIPES FITTING MOULDS    
INJECTION MOLD FOR PVC PIPE FITTINGS & CONNECTORS    
TROUBLE SHOOTING GUIDE FOR PIPE EXTRUSION    
PIPE EXTRUSION TROUBLESHOOTING GUIDE    
PROCESSING DETAILS OF PIPE EXTRUSION    
PIPE EXTRUSION    
RAW MATERIALS DESCRIPTION    
EXTRUSION LINE    
RAW MATERIALS HANDLING    
EXTRUSION BASICS    
EXTRUDERS    
BREAKER PLATE/SCREEN PACK    
DIE DESIGN    
PIPE SIZING    
COOLING    
PULLERS    
TAKE-OFF EQUIPMENT    
SAW EQUIPMENT AND BUNDLING    
SUPPLIERS OF PLANT AND MACHINERIES    
COOLING TOWER    
AIR COMPRESSORS    
LABORATORY EQUIPMENTS    
HORIZONTAL INJECTION MOULDING MACHINE    
WATER COOLING UNIT    
SCRAP GRINDER MACHINE    
PRINTING MACHINES    
SUPPLIERS OF RAW MATERIALS    
POLLUTION/ENVIRONMENTAL CONTROL    


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