CAST POLYPROPYLENE FILMS (CPP FILM)
[EIRI/EDPR/1646] J.C.452
INTRODUCTION
The term CPP is used in the plastics industry to describe polypropylene-based films produced by a cast extrusion process (Cast Polypropylene). Although there are some CPP films used for hygiene applications and synthetic paper (usually involving fillers and other additives), the term CPP is usually used to refer to high clarity films targeting lamination, metallization and packaging applications. The rapid quench achieved with chill rolls results in excellent film clarity and gloss.
These types of films differ from BOPP (Biaxially-Oriented Polypropylene) because they are not oriented. Orientation is a process that increases the tensile strength of film in a specific direction by stretching or rolling. Strictly speaking, CPP films experience a small amount of orientation, but only in the Machine Direction (MD), due to the nature of the process.
The cast film extrusion process is gaining increased popularity and enjoying sustained growth worldwide. New lines are being installed in a significant number and the market segments penetrated by this technology are on the rise. This article identifies the main components of a cast extrusion line and presents the fundamental aspects that require consideration when approaching cast film technology.
Cast films are used for food and textiles packaging, flower wrapping, as photo album page protectors, as coating substrates in extrusion coating processes or laminated to other materials in the formation of more complex films, among others. Typically, the cast film process involves the use of coextrusion, which is a simultaneous extrusion of two or more materials from a single die to form a multi-layered film. This is because in many cases the final application of the plastic film demands a performance that cannot be achieved if the film is composed of only one material. For example, in many instances food packaging applications require the use of films with oxygen barrier capabilities. To meet the requirement a high oxygen barrier material like EVOH is combined with polyolefin materials in a multi-layered structure. Coextruded films typically contain up to seven layers; however, the use of more layers is becoming more common. The number of layers, their position in the coextrudate and their individual thickness are all variables that change depending on the particular application of the film.
COST ESTIMATION
Plant Capacity 16.667 MT/Day
Land & Building (4000 sq.mt.) Rs. 2.45 Cr
Plant & Machinery Rs. 2.80 Cr
Working Capital for 2 Months Rs. 9.36 Cr
Total Capital Investment Rs. 14.92 Cr
Rate of Return 43%
Break Even Point 38%
CONTENTS
INTRODUCTION
PROPERTIES AND CHARACTERISTICS OF CAST POLYPROPYLENE FILM
RAW MATERIALS AND FILM PROPERTIES
SES AND APPLICATION OF CPP FILM
TYPES AND GRADE OF CPP FILM
BENEFITS/LAMINATION OF CAST EXTRUSION
MARKET SURVEY
SCOPE OF PACKAGING INDUSTRY IN INDIA
PRODUCTION OF CPP FILM IN INDIA IN (ORGANIZED AND UNORGANIZED SECTOR)
IMPORT & EXPORT OF CPP FILM
APPARENT CONSUMPTION OF CPP FILM IN INDIA
GLOBAL MARKET OF CPP FILM
EUROPEAN CPP FILM MARKET TRENDS
SEGMENT WISE MARKET OF CPP FILM IN INDIA
PRESENT MANUFACTURERS OF CPP FILMS (INDIA & ABROAD)
DESCRIPTION OF CPP FILMS
TECHNICAL DETAILS OF CPP FILMS
DETAILS OF EQUIPMENTS AND PROCESSING TRENDS IN CPP FILM
TRENDS IN CPP FILMS
COMPARISON OF CPP FILM WITH OTHER’S PLASTIC FILM
TYPICAL PROPERTIES (1.0 MIL FILM)
MANUFACTURING PROCESS OF CPP FILM (CAST POLYPROPYLENE FILM)
PROCESS IN DETAILS
FORMULATION OF CPP FILM
PROCESS FLOW DIAGRAM
TECHNICALITIES IN CPP FILM EXTRUSION
CAST POLYPROPYLENE FILM LINES ALPHA CPP – CAST POLYPROPYLENE FILM LINES
QUALITY CONTROL AND TEST METHOD OF CPP FILM
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
SUPPLIERS OF PLANT AND MACHINERIES
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)
