Detailed Project Report on o-pvc pipe plant

 

 

 

 

The technology used to produce PVC‐O pipe has come a long way since the first process was developed for commercial production by Yorkshire Imperial Plastics in the 1970’s. Australia was an early adopter of this process, with Vinidex commencing manufacture of PVC‐O pipes back in 1984.

 

This process involved orientating the pipes off‐line in a separate orientation chamber, inflating the pipes using pressurised hot water. The process was slow and cumbersome and production was very limited

 

Come the 1990’s, a number of companies including Vinidex began to develop processes that would significantly increase the output of PVC‐O pipe. Out of this work came the in‐line orientation process, where a feedstock pipe from the extruder is stretched over a mandrel or plug under tightly controlled conditions to produce a bioriented PVC pipe. This concept subsequently became the standard process for production of PVC‐O pipes around the world. In Australia, Iplex installed Wavin Apollo PVC‐O lines, whilst Vinidex installed their patented Cornet process, both in NSW.

 

In 2006, Molecor was formed in Spain by former employees of the Spanish pipe producer Uralita. The company was formed to develop and market a new PVC‐O manufacturing method utilising an off‐line orientation technique, based on pressurised hot air to inflate feedstock pipes. This method on the surface appears to a variant of the Yorkshire process using air instead of water. However, by utilising a preheating oven to bring the feedstock pipes up to the required temperature for orientation, the Molecor process matches the output rates of the in‐line processes.

 

 

 

Plant Capacity            66.66667 MT/ Day  

Land & Building (15000 Sq.Mtr)  Rs 8.97 Cr    

Plant & Machinery               Rs 6.59 Cr 

Working Capital for 2 Month    Rs 26.48 Cr 

Total Capital Investment        Rs.42.80 Cr 

Rate of Return                  22%

Break Even Point                57%

 

 

INTRODUCTION

HISTORY OF O-PVC PIPE

ORIENTED POLYVINYL CHLORIDE (OPVC)

DIFFERENT TYPES OF ADDITIVES AND THEIR FUNCTIONS

TYPES OF ADDITIVES

FUNCTIONS OF ADDITIVES

1. PLASTICIZERS

2. STABILIZERS

3. LUBRICANTS

4. IMPACT MODIFIER

5. PIGMENTS

6. PROCESS AIDS

7. REINFORCEMENT

8. FLAME RETARDANT

9. FILLERS

10. COMPATIBILIZERS

THE RAW MATERIALS OF POLYVINYL CHLORIDE (PVC)

CHARACTERISTICS OF POLYVINYL CHLORIDE (PVC) AS A MATERIAL

1. VERSATILITY

2. FIRE RETARDING PROPERTIES

3. DURABILITY

4. CHEMICALS RESISTANT

5. MECHANICAL STABILITY

6. PROCESSABILITY AND MOULDABILITY

TECHNICAL SPECIFICATION OF O-PVC PIPE

FEATURES OF PVC-O CLASS 500 PIPES

ADVANTAGES OF PVC-O PIPE

USES AND APPLICATION

B.I.S. SPECIFICATION

PROCESS FLOW CHART

MANUFACTURING PROCESS OF O-PVC PIPE

1. RAW MATERIALS

2. MANUFACTURING PROCESS

3. CONTROL POINTS

4. ENVIRONMENTAL AND HYGIENIC CONDITIONS

EXTRUSION PROCESS

WORKING PRINCIPLE

EXTRUSION PROCESS PARAMETERS

ADVANTAGES:

DISADVANTAGES:

DESCRIPTION OF MANUFACTURING PROCESS:

INCOMING RAW MATERIAL INSPECTION

RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE

RESIN STORAGE AND CONVEYANCE

RESIN FEEDING

2. SIZING:

3. TRACTION:

4. CUTTING:

QUALITY CONTROL

GENERAL REQUIREMENTS OF PIPES

1. VISUAL APPEARANCE

2. COLOUR

3. OPACITY

INSPECTION AND TESTING

1. LOT AND CONTROL UNIT

2. TESTS ON RAW MATERIAL

3. TESTS ON PIPES

TESTING

(A) TYPE TEST

(B) ACCEPTANCE TEST

(C) MARKING

MARKET POSITION

INDIA PVC PIPES MARKET IS STUDIED BY VARIOUS SEGMENTS:

INDIA PVC PIPES MARKET WAS VALUED AT US$ 3,539.0 MN IN 2018 & IS

  PROJECTED TO BE WORTH US$ 5,209.4 MN BY 2027; IT IS EXPECTED TO

  GROW AT A CAGR OF 4.5% DURING THE FORECAST PERIOD 2019 - 2027

MARKET INSIGHTS

MARKET GROWTH

KEY FINDINGS OF THE INDIA PVC PIPE MARKET:

PLANT LAYOUT

SUPPLIERS OF O-PVC PIPE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PVC RESIN GRANULE

SUPPLIERS OF PLASTISIZERS

SUPPLIERS OF PVC STABLISERS

SUPPLIERS OF CALCIUM STERATE

SUPPLIERS OF STEARIC ACID

SUPPLIERS OF CHINA CLAY

SUPPLIERS OF PIGMENTS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF COMPELETE PVC PIPE PLANT

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

 

 

 

 1.   COST OF PLANT ECONOMICS  

 2.   LAND & BUILDING                                  

 3.   PLANT AND MACHINERY                              

 4.   FIXED CAPITAL INVESTMENT                         

 5.   RAW MATERIAL                                     

 6.   SALARY AND WAGES                                 

 7.   UTILITIES AND OVERHEADS                          

 8.   TOTAL WORKING CAPITAL                            

 9.   COST OF PRODUCTION                               

10.   PROFITABILITY ANALYSIS                           

11.   BREAK EVEN POINT                                 

12.   RESOURCES OF FINANCE                       

13.   INTEREST CHART                                   

14.   DEPRECIATION CHART                               

15.   CASH FLOW STATEMENT                               

16.   PROJECTED BALANCE SHEET