Detailed Project Report on plastic water storage tanks (hdpe) (sintex type)

PLASTIC WATER STORAGE TANKS

[EIRI/EDPR/1487] J.C. 271

INTRODUCTION

The term Plastics usually refers to a large and varied group of  synthetic materials which are solid in finished form  but  at some  stage in their processing are fluid enough to be shaped  by application  of  heat  and  pressure.  The  use  of  plastics  in building has grown rapidly in the last few years.  Plastics  were first used for decorative and non structural purposes but because of  increased knowledge of the long term properties  of  plastics particularly  resistance to creep and environmental effects  some plastics  are  now available that maintain long  term  structural integrity,  such as piping, doors and windows, water  tanks  that can contain moderate pressures for a long period of time.  During the last decade Plastic (conversion) Industry has progressed at a fast rate. New fields of application of plastics are continually being   developed. Tile sometime ago drums, barrels were conventionally manufactured out of M.S. Sheets.  Today we can get the drum and barrel made out of Plastics. Blow moulding has been the most widely used method of the manufacture of hollow-ware out of thermoplastics. The choice of plastic types and formulations now run in thousands and  this  diversity  indeed   appears formidable.

It  is  easier to cope with this diversity if plastics are considered to be a category of materials like  metals  embracing different  distinct  families in which each family,  in  turn  is composed  of many individual types.  Inspite of the diversity  of plastics  being  great,  in  practice  the  choice  for  a  given application  will normally lie between a narrow band  of  plastic spectrum. Within this band there may be several plastics  which approximate the desired requirements. Selection of the best one out  of these, requires weighing and comparing the properties  of each.  Among  thermo  plastic, L.D.P.E., L.L.D.P.E.,  H.D.P.E, P.V.C., Polyethylenes, Polypropylenes etc have  entered  market with  large number of articles of multifarious uses. Big sizes tanks of plastics are manufactured by various methods  patronized under molding. Plastic tanks are storage tanks defined as a container for storing liquids and gases.  A tank may be made  of capacity  much  bigger than barrel drum and may be of  sizes  100 litres to 25,000 litres.  The tank may be made of metal,  alloys, wood, plastic i.e. H.D.P.E., LLDPE and others depending upon use.  Large  size  water tanks sintex type are being  made  of  plastic material  by  a unique process known as  Rotational  molding  for making  hollow  parts especially applicable for making  large  or complex  shapes  usually from polyethelene. Plastic tanks are becoming very popular and are finding  wider  acceptability  in every homes as well as industry.

COST ESTIMATION

Plant Capacity            30 Nos./Day  

Land & Building (4000 sq.mt.)    Rs. 30.00 Lac    

Plant & Machinery                    Rs. 1.14 Cr 

Working Capital for 3 Months    Rs. 68.91 Lac 

Total Capital Investment          Rs. 2.22 Cr 

Rate of Return                          40%

Break Even Point                      46%

CONTENTS

INTRODUCTION

PROPERTIES OF PLASTIC TANKS

PROPERTIES OF HDPE WATER TANKS

PLASTICS USED FOR TANK CASTING WITH SPECIFIC PROPERTIES

PHYSICAL PROPERTIES OF PLASTICS

ADVANTAGES OF LLDPE ARE:-

DETAILS OF RAW MATERIALS

B.I.S. SPECIFICATION AND REQUIREMENT

TESTING OF PLASTICS

USES AND APPLICATIONS

MARKET SURVEY

PLASTIC WATER STORAGE TANKS MANUFACTURER/EXPORTERS

SELECTION AND DESCRIPTION OF PROCESS

MANUFACTURING PROCESS OF PLASTIC WATER STORAGE TANK

OVER VIEW OF ROTATIONAL MOULDING PROCESS

PRODUCTION PROCESS

PROCESS FLOW DIAGRAM

HISTORY

EQUIPMENT AND TOOLING

STANDARD SETUP AND EQUIPMENT FOR ROTATIONAL MOLDING

ROTATIONAL MOLDING MACHINES

RECENT IMPROVEMENTS IN ROTATIONAL MOULDING

RECENT IMPROVEMENTS

LIMITATIONS

MATERIAL REQUIREMENTS

MOULD RELEASE AGENTS AND MATERIALS FOR ROTATIONAL MOULDING

MOLD RELEASE AGENTS

MATERIALS

DESIGN CONSIDERATION FOR ROTATIONAL MOULDING

PRODUCT DESIGN

DESIGNING FOR ROTATIONAL MOLDING

MATERIAL LIMITATIONS AND CONSIDERATIONS

WALL THICKNESS

LIST OF PRODUCT, MADE USING THE SAME PRODUCTION UNIT

ADVANTAGES AND LIMINATION OF ROTATIONAL MOULDING

MATERIAL TESTING AND PREPARATION OF POLYMER

DETAILS OF EQUIPMENT, USED IN THE PROCESS

DETAILS OF MOULDS & MOULDING

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERY

COMPLETE PLANT AND MACHINERY SUPPLIER

PLANT LAYOUT

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)