HDPE PIPE MANUFACTURING UNIT
[CODE NO.4389]
High-density polyethylene (HDPE) is a polyethylene thermoplastic made from petroleum. It is known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97g/cm3 or 970Kg/m3. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand much higher temperatures (120°C for short periods, 110°C continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally required autoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions.
HDPE pipes are important plastic products which have wide range of applications. These have more tensile strength in comparison to other plastic pipes. These are being used for Sprinkler Irrigation System, potable water supply and sewerage purpose. Their low cost, easily installation and better durability make them ideal for the purpose. They also offer very good resistance to most of the chemicals and have excellent electrical insulation properties. These pipes are also used for circulation of acids in various chemical industries due to their acid resistant quality.
The demands of HDPE Pipes are likely to increase due to their wide use in various sectors in India. Apart from its regular uses, such as for irrigation system, water supply, sewerage, it is being used by Department of Telecommunication for conduit for optical fiber cables. Looking to its increased demand, it appears to be good scope for setting up new small scale industries. Hence the product has good market potential.
CLASSIFICATION
(A) Pipes shall be classified according to the grade of materials as MRS; Polyethylene pipes and classified by the raw materials used in the production of attachments. A MRS material strength value of 20°C is also shown by the internal pressure for 50 years.
Raw material class MRS(MPa) value
PE 63 6.3
PE 80 8.0
PE 100 10
(B) Pipes by pressure rating (PN) corresponding to the maximum shall be classified permissible working pressure at 3WC, as follows:
The pressure grades available according to European standards are:
• PN 2.5 - max pressure 2.5 bar
• PN 4 - max pressure 4 bar
• PN 6 - max pressure 6 bar
• PN 10 - max pressure 10 bar
• PN 16 - max pressure 16 bar
Color codes used to indicate the pressure grades on the pipes are:
Color Code PE Pressure Grade
Yellow PN 4
Red PN 6
Blue PN 10
Green PN 1
HDPE Pipes for following grades/sizes/pressure rating
PE 63 PN 2.5 DN 63 to 110
PE 63 PN 4 DN 40 to 110
PE 63 PN 6 DN 32 to 110
PE 63 PN 8 DN 32 to 110
PE 63 PN 10 DN 32 to 110
PE 63 PN 12.5 DN 32 to 110
PE 63 PN 16 DN 32 to 110
PE 80 PN 2.5 DN 90 to 110
PE 80 PN 4 DN 50 to 110
PE 80 PN 6 DN 40 to 110
PE 80 PN 8 DN 32 to 110
PE 80 PN 10 DN 32 to 110
PE 80 PN 12.5 DN 32 to 110
PE 80 PN 16 DN 32 to 110
PE 100 PN 6 DN 50 to 110
PE 100 PN 8 DN 40 to 110
PE 100 PN 10 DN 32 to 110
PE 100 PN 12.5 DN 32 to 110
PE 100 PN 16 DN 32 to 110
COST ESTIMATION
Plant Capacity 116 Ton/Day
Land & Building (20,000 sq.mt.) Rs. 15.00 Cr
Plant & Machinery Rs. 7.49 Cr
Working Capital for 1 Month Rs. 29.80 Cr
Total Capital Investment Rs. 53.03 Cr
Rate of Return 32%
Break Even Point 41%
- INTRODUCTION
- CLASSIFICATION
- COLOR CODES USED TO INDICATE THE PRESSURE GRADES ON THE PIPES ARE:
- HDPE PIPES FOR FOLLOWING GRADES/SIZES/PRESSURE RATING
- CHARACTERISTICS
- USES AND APPLICATION
- INDUSTRIES
- SPECIAL SERVICES
- APPLICATIONS
- SUBMARINE PIPELINES
- LAYING ON THE WATERBED:
- LAYING IN DREDGED CHANNELS:
- LAYING BY THE FLUSHING-IN METHOD:
- RELINING - NEW PIPES IN OLD
- SEWER PIPES
- SLURRY TRANSPORTATION
- IRRIGATION
- DOMESTIC GAS DISTRIBUTION
- CHEMICAL PROCESS PIPING
- B.I.S. SPECIFICATION
- SEQUENCES IN HDPE PIPES
- MANUFACTURING PROCESS OF HDPE PIPES
- MECHANICAL INSPECTION
- OTHER QC TESTS CAN INCLUDE:
- PROCESSING DETAILS OF HDPE PIPES
- EXTRUDER
- FEED HOPPER
- BARREL
- SCREW
- DIE
- WATER COOLING TUB
- PROCESS FLOW CHART
- EXTRUSION PROCESSING LINE FOR HDPE PIPES
- RAW MATERIALS HANDLING
- EXTRUSION BASICS
- FIGURE: TYPICAL SINGLE STAGE, SINGLE SCREW EXTRUDER (RESIN FLOW FROM RIGHT TO LEFT)
- FIGURE: TYPICAL EXTRUSION SCREW
- FIGURE: TYPICAL RESIN MIXING DEVICES
- FIGURE: MIXING PINS
- FIGURE: FLUTED MIXER
- FIGURE: HELICAL MIXER
- EXTRUDERS
- BREAKER PLATE/SCREEN PACK
- DIE DESIGN
- FIGURE: TYPICAL PIPE DIES
- FIGURE: PIPE DIE WITH SPIDER DESIGN
- FIGURE: PIPE DIE WITH BASKET DESIGN
- PIPE SIZING
- FIGURE: EXTERNAL SIZING SYSTEMS
- FIGURE: VACUUM TANK SIZING
- FIGURE: INTERNAL (PRESSURE) SIZING FOR SMALL AND MEDIUM PIPE DIAMETERS
- FIGURE: TYPICAL PE PROFILE WALL PIPE FROM ASTM STANDARD F894
- FIGURE: TYPICAL PROFILE WALL SECTION SHOWING BELL END (RIGHT) AND SPIGOT ENG (LEFT)
- COOLING
- PULLERS
- TAKE-OFF EQUIPMENT
- SAW EQUIPMENT AND BUNDLING
- SEQUENCES IN HDPE PIPE FITTING MANUFACTURE
- MANUFACTURING PROCESS OF HDPE PIPE FITTING
- INJECTION MOLDED FITTINGS
- FIGURE: TYPICAL PE PIPE FITTINGS
- FIGURE: SOCKET TEE
- FIGURE: BUTT TEE
- FIGURE: SOCKET ELBOW
- FIGURE: 90° BUTT ELBOW
- FIGURE: SADDLE FUSION FITTINGS
- FIGURE: BUTT FLANGE ADAPTER/STUB END
- FIGURE: CONSTRUCTION AND MODE OF OPERATION OF A RECIPROCATING SCREW INJECTION UNIT (COURTESY OF HOECHST CELANESE CORPORATION)
- FABRICATED FITTINGS
- THERMOFORMED FITTINGS
- ELECTROFUSION COUPLINGS
- INJECTION MOLDED COUPLINGS
- FIGURE: TYPICAL FABRICATED FITTINGS
- QUALITY CONTROL/QUALITY ASSURANCE TESTING
- WORKMANSHIP, FINISH AND APPEARANCE
- DIMENSIONS
- RAW MATERIALS
- A. HDPE GRANULES
- B. BLACK MASTER BATCH
- C. ANTI-OXIDANT
- QUALITY CONTROL OF HDPE PIPES
- VISUAL INSPECTIONS
- MECHANICAL INSPECTION
- OTHER QC TESTS CAN INCLUDE:
- TECHNICAL DETAILS OF HDPE PIPE MANUFACTURE
- 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
- OVERVIEW OF HDPE PIPES
- MICRO DUCTS IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
- TELECOM IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
- MARKET POSITION OF INDIAN HDPE PIPES
- OPPORTUNITIES OF HDPE PIPES
- MARKET BY APPLICATION
- MARKET BY GRADE TYPE
- MARKET BY DIAMETER TYPE
- MARKET BY PRESSURE RATING
- GLOBAL MARKET POSITION OF HDPE PIPES
- INDIAN PLASTIC PIPES MARKET
- TYPES OF PLASTIC PIPES APPLICATION
- MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
- INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
- BARGAINING POWER OF SUPPLIERS
- BARGAINING POWER OF BUYERS
- INTERNAL RIVALRY
- ENTRY
- THREAT OF SUBSTITUTES
- GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
- OTHER MEASURES
- SWOT ANALYSIS
- STRENGTHS
- WEAKNESSES
- OPPORTUNITIES
- THREATS
- SEWER RINGFIT PIPES AND SEWER SELFIT PIPES
- DOMESTIC USE
- INDUSTRIAL
- OTHER
- HDPE PIPES DIMENSION
- MANUFACTURERS/SUPPLIERS OF HDPE PIPE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF HDPE GRANULES
- SUPPLIERS OF BLACK MASTER BATCH
- SUPPLIERS OF ANTIOXIDANT
- SUPPLIERS OF COMPLETE HDPE PIPE PLANT
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSOR
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- TORNOVER (FIRST YEAR) ON MONTHLY BASES
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)
