SBR RUBBER SHEETS, SHOE SOLE & FOOTWEAR MANUFACTURING
[EIRI/DFR/1203] (J.C. 9853)
INTRODUCTION
INDIAN RUBBER INDUSTRY
Indian rubber industry is nearly five decades old. There are over 1,400 rubber manufacturing units spread over the country. The total production of rubber goods is estimated at Rs 340/- crores.
In a span of over 50 years the Indian rubber Industry has grown from strength to strength. Nearly a decade ago the industry was entirely dependent on imports for its basic raw materials. But now the industry is almost self sufficient except for a very small range of specialty products. The industry's steady progress can be evident from the following facts.
Consistent increase in consumption of new rubber which has jumped from 22, 790, tonnes in 1951 is 1,38,200 tonnes in 1972.
Considerable increase in number of rubber factories.
Steady increase in exports of rubber products crossing the figure of Rs 11.5 crores.
The natural rubber production in the country at the end of current year 1973 would be 1.25 lakh times, synthetic rubber 35,000 tonnes and reclaimed 30,000 tonnes.
The industry manufactures almost every conceivable rubber product, from tiny toy balloons to giant tractor and aero tyres, needed for internal consumption as well as for exports. The rubber goods industry manufacturers a wide range of products such as automobiles tyres and tubes, bi-cycle tyres and tubes, rubber and canvas foot wear, various types of rubber hoses, railway fitting, and automobiles rubber components. The largest single items of manufacture is the automobile tyres and tubes accounting for fifty percent of consumption of rubber. The rubber foot wear industry is next in importance and accounts for about 12% of the total rubber consumption. The Indian tyre industry is very much the development of the GOS, and product of post independent India.
It has made a great progress in a short span of period. Eight units are engaged in the manufacture of automobile tyres and tubes with a production capacity of over 5 million tyres. Over 50 units manufactured foot wear, about 12 units from rubber and the rest are engaged in the manufacture of Various rubber products including belling, hose pipes, sheets and shelling and innumerable mechanical, industrial and agricultural components.
The rapid growth of the rubber industry has brought about the production of several essential raw materials needed by the industry. During a brief period (about 10 to 12 yrs) the country saw the birth of all synthetic rubber manufacturing unit, two carbon black units, two rubber chemical units, three rayon card units and one nylon card unit and a number of units for manufacturing and components like stearic acid, zinc oxide tube valves, bed wire etc.
Where as the rubber industry has been, steadily progressing, it is not without problems. The progress in the directing of research and development in the rubber industry is almost negligible. However industry has made a beginning by setting up Indian Rubber manufactures Research Association. The Government proposed to take up during the fifth plan 60 new research projects under a scheme for the expansion of rubber research. As it looks, the rubber industry has in store a bright future, but much depends on the trend of economic, social & political conditions in the country. The all India Rubber Industries Associates. The only representative body of the country's rubber industry can also contribute for the further development of the industry in the country.
Plantation of rubber is of comparatively recent origin. The output amounted to 10.000 tonnes in 1931 & 12,000 tonnes in 1940 the area under rubber in 1940-41 was 1.38 lakh acres. In 1960, the area amounted to 1.44 lakhs acres and production to 14.45 thousand tonnes. The area planted with rubber at the end of 1976-70 was 1,96,713 hectares. The production of natural in 1969-70 was 61.953 thousand tonnes.
The rubber board introduced a replanting subsidy scheme in 1957, it granted a subsidy of Rs 5.55 crore, up to the end of march 1971, and an area of 27, 733 hectares was replanted under the scheme upto January synthetic rubber. Synthetic rubber production in 1969-70 was 28, 689 tonnes. The consumption of rubber been increasing.
COST ESTIMATION
Plant Capacity 2500 Shoe Pairs/Day
Land & Building (4000 sq.mt.) Rs. 1.03 Cr
Plant & Machinery Rs. 97.13 Lac
Working Capital for 2 Months Rs. 2.58 Cr
Total Capital Investment Rs. 4.68 Cr
Rate of Return 44%
Break Even Point 43%
CONTENTS
INTRODUCTION
INDIAN RUBBER INDUSTRY
PRODUCT DESCRIPTION
SYNTHETIC RUBBER
STYRENE-BUTADIENE RUBBER (SBR)
STYRENE - BUTADIENE RUBBER (SBR)
SBR RUBBER
AVAILABLE IN BLACK OR RED COLORS
SBR RED RUBBER
CHARACTERISTICS:
TYPES OF SBR
EMULSION POLYMERISATION
SOLUTION POLYMERISATION
INTRODUCTION
RUBBER AS A MATERIAL
TYPES OF RUBBER
NATURAL RUBBER
RUBBER AS A MATERIAL
TYPES OF RUBBER
NATURAL RUBBER
CHEMISTRY AND PRODUCTION:
TYPICAL RECIPE FOR SBR EMULSION POLYMERIZATION
PROPERTIES OF E-SBR:
MECHANICAL PROPERTIES
ELECTRICAL PROPERTIES
CURE PROPERTIES
TYPES OF SBR:
USES OF SBR:
TYPICAL APPLICATIONS FOR E-SBR POLYMERS
RUBBER COMPOUNDING
SEQUENCE OF ADDITIVES USED DURING COMPOUNDING
VULCANIZATION
MACHINERY USED FOR RUBBER COMPOUNDING
BANBURY MIXER
TWO ROLL MILL
BANBURY MIXER
PROCESS DESCRIPTION OF RUBBER SHEET MANUFACTURING
FLOW SHEET OF RUBBER COMPOUNDING
LAB TESTING
VERTICAL INJECTION MOLDING OF RUBBER
VERTICAL INJECTION MOLDING MACHINE
EVA AS MATERIAL
COMPOUNDING SEQUENCE
MACHINERY USED
KNEADERS
CALENDARING DEVICE
FLOW SHEET OF EVA SHEET MANUFACTURING
PROCESS DESCRIPTION OF EVA SHEET MANUFACTURING
TWO ROLL MILL CALENDARING DEVICE KNEADERS
PRESSING SECTION
CRITERIA OF A COMPOUND TO BE SOLE
MACHINERIES USED:
MANUAL C. M. MACHINES:
AUTOMATIC COMPRESSION MOLDING MACHINES:
COLD FLOW MOLDING:
LAB TESTING
BATCH CLEANING PROCESS FOR MOLDS
POLYVINYL CHLORIDE AS A MATERIAL
PHYSICAL PROPERTIES
SIGNIFICANCE OF K VALUE
INJECTION MOLDING
MACHINE DESCRIPTION
PROCESS DESCRIPTION
MACHINE DESCRIPTION
PROCESS DESCRIPTION
POLYURETHANE AS A MATERIAL
THE RIM PROCESS
RIM VARIANTS FOR PU SYSTEMS FOR SHOE SOLES
MOLDS
MOLDING PROCESS
STYRENE BUTADIENE RUBBER MANUFACTURER
ADDRESS OF MACHINE MANUFACTURER
ABOUT AND SHOE MANUFACTURING PROCESS
SHOES AND SHOE MAKING
PARTS OF A SHOE
SHOE MAKING PROCESS
SHOE MANUFACTURING PROCESS
CLICKING OR CUTTING DEPARTMENT
CLOSING OR MACHINING DEPARTMENT
LASTING & MAKING DEPARTMENT
FINISHING DEPARTMENT AND THE SHOE ROOM
USES & APPLICATIONS
B.I.S. SPECIFICATION
MARKET SURVEY
SCOPE OF RUBBER SHEETS
USES & SCOPE
SCOPE OF RUBBER SOLES
MARKET-POSITION
PRODUCTION AND CONSUMPTION FIGURE
CONSUMPTION OF RUBBERS
IMPORT OF NEW RUBBERS
CONSUMPTION OF RUBBERS
GRADE WISE PRODUCTION OF SYNTHETIC RUBBER
STATE WISE CONSUMPTION OF SYNTHETIC RUBBER
MANUFACTURES OF RUBBER SHEETS FOR SHOES SOLES
FORMULATION-II RUBBER SHEET (FOR EVA SOLE) :-
MANUFACTURING PROCESS OF EVA RUBBER SHEET FOR SHOE SOLES
MIXING MILL:-
CALENDERING:-
TALC SPRAYING:-
VULCANIZATION:-
PROCESS FLOW DIAGRAM FOR EVA RUBBER SHEET FOR SHOE SOLE
OTHER METHOD FOR THE MANUFACTURE OF EVA RUBBER SHEET
PROCESS FLOW DIAGRAM OF EVA SHEET
MICROCELLULAR SOLING PROCESS (MANUFACTURING PROCESS FOR MICROCELLULAR SHEETS)
COMPOUNDS:-
METHOD OF COMPOUNDING:-
THE IMPORTANCE OF COMPOUNDING:-
METHOD OF MILLING:-
VULCANIZATION:-
HOT VULCANISATION:-
GOLD VALCANIZATION:-
ACCELERATORS:-
SOLVENTS FOR RUBBER:-
VULCANIZING AGENTS:-
GENERAL PLANT LAYOUT
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
POWER
IMPLEMENTATION SCHEDULE
EFFLUENT TREATMENT AND DISPOSAL
THE WASTE FROM THE FOOD PROCESSING OPERATIONS MAY BE CLASSIFIED ON THE BASIS OF:
STANDARD
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
ANAEROBIC TREATMENT
SECONDARY
TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
MANPOWER
GENERAL
BASIS OF ESTIMATION
SUPPLIERS OF PLANT & MACHINERY
RUBBER MIXING MILL
RUBBER COMPRESSION MOULD
RUBBER VULCANIZER
BOILER
RUBBER MACHINES (KNEADERS, EXTRUDERS AND HYDRAULIC PRESS)
CALENDERING MACHINERY
DOUBLE SHAFT PADDLE MIXER
WATER STORAGE TANKS
D.G. SET
SUPPLIERS OF RAW MATERIALS
PRECIPITATED SILICA
NATURAL RUBBER
SYNTHETIC RUBBER
ZINC OXIDE
STEARIC ACID
SYNTHETIC RUBBER MANUFACTURER
ADDRESSES OF MACHINERY AND EQUIPMENT SUPPLIERS
SANDAL LAST
RAW MATERIAL SUPPLIERS
PRINCIPLES OF PLANT LAYOUT
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:
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. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
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)