PVC PIPES AND FITTINGS (PRODUCTION CAPACITY – 10 TPD)
[EIRI/EDPR/4550] J.C.: 2767XL
INTRODUCTION
PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes.
PVC Pipes and fittings are often used in the following circumstances:
For drinking water pipe distribution systems, both main and supply lines
Sewer and discharge pipe systems
Due to its non-metallic nature, the material used is totally resistant to all forms of metallic corrosion.
Aggressive water resulting from high sulphate soils and low hardness water will not attack PVC pipes.
Our pipes are therefore resistant to a wide range of industrial waters and chemicals and offer an advantage in long-term systems life and manufacture costs.
Being made of a tasteless and odorless material, PVC pipes remain neutral to all transported fluids.
PVC is completely inert and is widely used for transporting liquids made for human consumption.
Because of their mirror-smooth inside surface, PVC pipes have minimum flow head loss. There is also no buildup of inside deposits, a particular advantage in the construction of sewerage systems.
The physical properties of PVC pipes are not affected by neither direct sunshine, nor wind or rain. However, to avoid surface browning due to long exposure to direct sunlight, it is recommended that the pipes are kept protected from direct sunlight.
Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to travel on PVC pipes. They therefore offer added safety when used for electrical installations, both domestic and industrial.
PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel pipes. This cuts down transportation costs and facilitates installation when in difficult and remote places. Installation is quick and easy with a complete line of fittings either with the solvent glue weld sockets or the rubber seal socket joints. In either case, a leak-proof joint is assured. Subsequent maintenance work is also carried out with a minimum of complication and cost.
PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when plasticized or softened with other chemicals has some rubber-like properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC socket or threaded fittings (schedule 80).
PVC Pipe and Fittings have got tremendous demand in India as well as in abroad. To manufacture this, all the machinery and raw materials are available indigenously.
A polyvinyl chloride (PVC) pipe is made from a plastic and vinyl combination material. The pipes are durable, hard to damage, and long lasting. A PVC pipe does not rust, rot, or wear over time. For that reason, PVC piping is most commonly used in water systems, underground wiring, and sewer lines.
Due to the ability of PVC pipe to withstand extreme movement and bending, it is also increasingly used in earthquake prone areas. PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of the PVC pipe is also resistant to bacterial contamination, such as E. coli. Therefore, many water companies rely on PVC pipe in their systems in order to keep them free of contamination.
It is intended to prepare a Feasibility Report to install PVC Pipes and Fitting facility with an installed capacity of 10 TPD as a Green Field Project.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (4575 sq.mt.) Rs. 5.49 Cr
Plant & Machinery Rs. 3.45 Cr
Working Capital for 0.5 Months Rs. 1.24 Cr
Total Capital Investment Rs. 10.54 Cr
Rate of Return 43%
Break Even Point 48%
CONTENTS
INTRODUCTION
PVC PIPES AND FITTINGS ARE OFTEN USED IN THE FOLLOWING CIRCUMSTANCES:
PROPERTIES OF PVC PIPES & FITTINGS
ADVANTAGES & LIMITATIONS
HANDLING & STORAGE
BIS SPECIFICATIONS
PIPES & FITTINGS
PLUMBING PIPES
APPLICATIONS OF PVC PIPES & FITTINGS
FOR TRANSPORTATION OF WATER:
TUBE WELLS
CHEMICAL PROCESSING PLANT
DUCTING FOR POWER AND COMMUNICATION CABLES:
FOR TRANSPORTATION OF PULVERIZED MATERIALS
ADVANTAGES OF USING PVC PIPES
IT IS ECONOMICAL:
IT RESISTS CORROSION:
NON-ENRUSTATION:
LIGHT WEIGHT:
EASE OF INSTALLATION:
MARKET OVERVIEW
INDIAN MARKET
EMERGING TRENDS IN INDIAN PLASTIC PIPE MARKET
LIST OF INDIAN PLASTIC PIPE COMPANIES
GLOBAL MARKET
GROWTH FACTORS
APPLICATION INSIGHTS
END USER INSIGHTS
REGION INSIGHTS
KEY DEVELOPMENTS
SOME OF THE PROMINENT PLAYERS IN THE GLOBAL POLYVINYL CHLORIDE (PVC) PIPES MARKET INCLUDE:
MANUFACTURERS/EXPORTERS
RAW MATERIAL
DIMENSION OF PVC PIPE
PVC PIPE & FITTINGS DIMENSIONS (SCH 40/SCH 80)
PLUMBING PIPES
FORMULATION
FORMULATION-I
PVC FLEXIBLE PIPES (AGRICULTURAL PIPES)
FORMULATIONS
PROCESS OF MANUFACTURE
MANUFACTURING PROCESS
TWIN SCREW EXTRUDERS
EXTRUSION DIES
EXTRUSION LINES
A) EXTRUSION SECTION:
B) MELT FORMING SECTION:
C) CONVERSION INTO THE FINAL PRODUCT:
PVC PIPE FITTINGS
PROCESS FLOW
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS
PLASTIC EXTRUSION PROCESS
EXTRUDER HEATER
BLOCK DIAGRAM OF THE PLASTIC EXTRUSION PLANT
TEMPERATURE SECTION OF PVC PLANT
HEATER SPECIFICATION OF PLASTIC EXTRUSION SYSTEM
PLASTIC EXTRUSION SCREW
PLASTIC EXTRUSION SCREW MODEL
DETAILS OF INJECTION MOLDING FOR PIPE FITTINGS
PROCESS CYCLE
EQUIPMENT
INJECTION UNIT
INJECTION MOLDING MACHINE - INJECTION UNIT
CLAMPING UNIT
INJECTION MOLDING MACHINE - CLAMPING UNIT
MACHINE SPECIFICATIONS
INJECTION MOLDING MACHINE
TOOLING
MOLD OVERVIEW
MOLD BASE
MOLD CHANNELS
MOLD DESIGN
MOLD - CLOSED
MOLD - EXPLODED VIEW
PRELIMINARY LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
MOULDS FOR PIPE FITTINGS
HIGH SPEED MIXER
EXTRUDER
PLASTIC SCRAP GRINDER MACHINE
PLASTIC INJECTION MOULDING MACHINE
GENERATOR SET
SUPPLIERS OF RAW MATERIALS
PVC RESIN
CALCIUM STEARATE
LEAD STEARATE
PRECIPITATED CALCIUM CARBONATE
PIGMENT DYE
SEWAGE AND WASTE WATER EFFLUENT
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:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
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)