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    Detailed Project Report on wpc (plastic composite) board line manufacturing

    Detailed Project Report on wpc (plastic composite) board line manufacturing
    Detailed Project Report on wpc (plastic composite) board line manufacturing
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      WPC (PLASTIC COMPOSITE) BOARD
      LINE MANUFACTURING
      [CODE NO.3386]


      Wood–plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220 °C; thus, general-purpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood–plastic composites are boards or lumber used in outdoor decking applications. Although early WPC products were mainly extruded for profiled sections, nowadays, many injected parts made of WPC are being introduced for various industries, including electrical casings, packaging, daily living supplies, and civil engineering applications. Mold and mildew and color fading of WPCs tend to be the durability issues of prime importance for WPCs. Most recent research on WPC durability focuses on studies to better understand the mechanisms contributing to various degradation issues as well as methods to improve durability. Most WPC products in the USA are utilized in building materials with few exceptions for residential and commercial building applications, which means that building codes are the most important national rules for the WPC manufacturers. New developments are being made especially in
      the area of nano additives for WPCs including nanocellulose. Recently, the trend of patent registrations for WPCs has shifted to new products or applications instead of the materials itself.


      COST ESTIMATION

      Plant  Capacity                             :    8400.00 KGS/day
      land & Building (4000 Sq.Mtr)   :    Rs. 2.00  Cr
      Plant & Machinery                        :    Rs. 1.25  Cr
      Working Capital for 2 Months    :    Rs. 3.50  Cr
      Total Capital Investment             :    Rs. 6.89  Cr
      Rate of Return                              :    37%
      Break Even Point                         :    44%


      INTRODUCTION    
      USES & APPLICATIONS    
      OURDOOR APPLICATION OF WPC    
      RAW MATERIALS    
      POLYMERS    
      ADDITIVES    
      ADVANTAGE AND DISADVANTAGE OF WPC    
      ADVANCE MATERIALS FOR WPC    
      WOOD MODIFICATION    
      ADDITIVES    
      PROFILES    
      ASPECT OF WPC DURABILITY    
      WEATHERING STUDIES    
      FORMULATION OF WPC    
      FIGURE  POLYETHYLENE (PE) – BASED COMPOSITE    
      DIFFERENT PROCESSES FOR PLASTIC COMPOSITES    
      EXTRUSION PROCESSING    
      SINGLE-SCREW EXTRUDER    
      COUNTER-ROTATING TWIN-SCREW EXTRUSION    
      COMPOSITE SYSTEM    
      MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS    
      PLASTIC COMPOSITE MANUFACTURING TECHNIQUES    
      WPC NEW MANUFACTURING TECHNOLOGY    
      EXPERIMENTAL STAGES    
      PILOT EXPERIMENTATIONS    
      PREREQUISITE STAGE    
      STAGE 1    
      STAGE 2    
      PROCESSES EXPERIMENTAL SETTINGS    
      MARKET SURVEY    
      NEW MARKET- WPC    
      FENCING FUTURE    
      THREAT FROM THE EAST?    
      FEWER, BIGGER PLAYERS    
      ADDITIVES CREATE RECIPE FOR GROWTH    
      EXPORT OF WPC FROM INDIA    
      GLOBAL TREND IN WOOD PLASTIC COMPOSITES    
      GLOBAL PRODUCTION OF WPC, AND THE FORECAST    
      PRESENT MANUFACTURERS OF    
      WOOD PLASTIC COMPOSITE BOARDS LINE    
      PROCESS FLOW DIAGRAM FOR PLASTIC COMPOSITE BOARD    
      THE WPC (PLASTIC COMPOSITE) MANUFACTURING PROCESS WITH EXTRUSION FORMING    
      TECHNICAL DETAILS OF PVC WPC FOAM BOARD LINE    
      TECHNICAL/TURNKEY CONSULTANT    
      FOR SETTINGUP WPC PLANT    
      SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)    
      SUPPLIERS OF PLANT & MACHINERIES (INDIAN)    
      BOILER    75
      GENERATOR SET (D.G. SET)    
      MANUFACTURERS/SUPLIERS OF PLANT & MACHINERY    
      EXTRUDERS    
      PRESSING MACHINE    
      COOLING TOWERS    
      BOILER    
      GENERATOR SET (D.G. SET)    
      MANUFACTURERS/SUPPLIERS OF RAW MATERIALS    
      PLASTIC POLYMERS    
      COUPLING AGENT    
      ADDITIVES    
      RAW MATERIALS CALCULATION    


      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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