POLYURETHANE FOAM (PRODUCTION RATE – 360 TPA)
[EIRI/EDPR/4586] J.C.: 2803XL
INTRODUCTION
Polyurethane foams are materials with a low weight-to-strength ratio, desirable insulating properties and a strong tendency for energy absorption. Broadly, foams come in three types – polyurethane (PU), memory foam and latex rubber foam. PU foam and Memory foam both are polyurethanes but memory foam has additional chemical composition to provide the contraction and retention. So, it is important to understand Polyurethane Foams in detail and the cost structure. At its core, manufacturing polyurethane foam is similar to making a cake. You have a batter and then you bake it (causing it to expand) and you get a fluffy cake. Similarly, you have a chemical mix which when exposed to a blowing agent and a catalyst causes the mix to expand and cool down to become foam.
Polyurethane foams are prepared by the reaction of a polyisocyanate with a polyol in the presence of a blowing agent, a surfactant, and a catalyst without external heating of the foaming system. The principle of preparation of urethane foams is based on the simultaneous occurrence of two reactions, i.e., polyurethane formation and gas generation in the presence of catalyst and surfactant, as shown below. While polyurethane polymers are used for a vast array of applications, their production method can be broken into three distinct phases. First, the bulk polymer product is made. Next, the polymer is exposed to various processing steps. Finally, the polymer is transformed into its final product and shipped.
PU Foams come in two types – flexible and rigid PU foams. In flexible polyurethane foams, the major blowing agent is water and, at the same time, auxiliary blowing agents, i.e., low–boiling–point inert solvents such as CFC–11, methylene chloride, can be used. But in the case of rigid polyurethane foams, the major blowing agent has been CFC–11, which vaporizes due to the exothermic reaction of polyurethane formation.
The foams that are generally used in the mattresses that have already found their way into your homes are largely adulterated. They contain calcium carbonate as an inexpensive filler, to make up the ‘mass’ of the mattress. The higher the adulteration, the slower the foam comes back into shape.
Fundamentally, foam quality is measured by its ability to come back into shape after usage (compression). IFD Test is one of the tests to clearly understand the quality of any foam
COST ESTIMATION
Plant Capacity 1.2 MT/Day
Land & Building (1730 sq.mt.) Rs. 1.55 Cr
Plant & Machinery Rs. 1.59 Cr
Working Capital for 4 Months Rs. 2.26 Cr
Total Capital Investment Rs. 5.71 Cr
Rate of Return 23%
Break Even Point 60%
CONTENTS
INTRODUCTION
PROPERTIES
RESILIENCE
SOLVENT RESISTANCE
ANTIBACTERIAL PROTECTION
YELLOWING AND DISCOLORATION
LOW FIRE RETARDANCY
USAGE AND APPLICATION
ADVANTAGES
MARKET OVERVIEW
MARKET DYNAMICS
COVID-19 IMPACT
SEGMENTS INSIGHT
PRODUCT INSIGHTS
APPLICATION INSIGHTS
REGIONAL INSIGHTS:
THE KEY PLAYERS OPERATING IN THE POLYURETHANE FOAM MARKET ARE:
BIS SPECIFICATION
FOAMING PROCESS
FOAM CURING
QUALITY CONTROL
MANUFACTURING PROCESS
PROCESS FLOW
ENGINEERING DESIGN CONSIDERATIONS
PLANT & MACHINERY
REQUIRED MACHINE FEATURES
SUPPLIER OF PU FOAM
SUPPLIER OF RAW MATERIALS
SUPPLIER OF CHEMICALS
SUPPLIER OF PLANT AND MACHINERY
SUPPLIER OF PRODUCTION LINE
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EXHAUST FAN
SUPPLIERS OF TESTING EQUIPMENTS
ETP FACILITY
GREEN BELT
SEWAGE AND WASTE TREATMENT FACILITY
PRELIMINARY LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROJECT IMPLEMENTATION MANAGEMENT
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS
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)