EPDM RUBBER PROFILES (WEATHER STRIPS, INDUSTRIAL MONO STRIPS ETC)
[EIRI/EDPR/1492] J.C. 277
INTRODUCTION
Ethylene - propylene Rubber (EPM and EPDM)
Ethylene Propylene Diene Monomer Rubber, also named as EPDM in short, is the polymer of ethylene and propylene. Large scale commercial production began in 1963 and the current overall global consumption of EFPM are 800,000 tons per year. EPDM is polyolefine - categorized and has excellent performance of vulcanization and its gravity is the lowest among all rubbers.
These are radon copolymers of the two hydrocarbons ethylene and propylene with the ethylene varying from 40 to 70% by weight. This produces a saturated rubber, EPM, which has to be vulcanized with peroxide systems. Small quantities of a third monomer are, therefore added to produce ethylene-propylene terpolymers (EPDM) which can be vulcanized with sulphur in the usual way. Both types have outstanding resistance to sunlight, ozone and all forms of aging and weathering; together with a capacity to accept large loadings of extender oil and fillers without undue loss of physical properties. So far, their use in tyres has been limited mainly due to processing difficulties, although blends with up to 20% of EPDM have been successfully adopted by some manufacturers, particularly for sidewalls. Recent developments indicate more extensive use of EPDM in tyres. Non-tyre applications for EPDM include automobile components, roller coverings, acid hose, general building applications, reservoir linings and roofing sheet. Another important application for EPM and EPDM is in electric cable insulation.
EPDM (Ethylene Propylene Diene Monomer) Rubber has outstanding resistance to aging, weathering, ozone, oxygen and many chemicals. It offers excellent high and low temperature stability, plus steam and water resistance. In general, EPDM has dynamic and mechanical properties between natural rubber and SBR.
COST ESTIMATION
Land & Building (3000 Sq.Mtr) Rs 3.96 Cr
Plant & Machinery Rs.2.00 Cr
W.C. for 3 Months Rs.4.49 Cr
Total Capital Investment Rs. 8.60 Cr
Rate of Return 36%
Break Even Point 43%
CONTENTS
INTRODUCTION
ETHYLENE - PROPYLENE RUBBER (EPM AND EPDM)
PROPERTIES OF EPDM RUBBER
EPDM RUBBER MATERIAL PROPERTIES
THE MAJOR PROPERTIES OF EPDM GRANULES ARE AS FOLLOWS:
1. EXCELLENT CHEMICAL STABILITY:
2. GOOD ELASTICITY:
3. VIVID COLOR:
4. MADE FROM EPDM RUBBER:
5. EPDM CONTENT:
6. CONTAINING NO HAZARDOUS MATERIAL, NON-TOXIC AND ODORLESS AND SAFE.
7. LOW HEAT ABSORBENCY FOR BAREFOOT WALKING.
8. ECONOMIC AND EASY MAINTENANCE:
SPECIFICATION: 7
TABLE 1. - PROPERTIES OF ETHYLENE-PROPYLENE ELASTOMERS
APPLICATION OF EPDM RUBBER
FEATURE OF EPDM ELASTOMERS
MAJOR PRODUCERS OF EPDM
CHEMISTRY AND MANUFACTURING PROCESSES
TABLE II – CURE-SITE DIENE TERMONOMERS IN ETHYLENE-PROPYLENE ELASTOMERS
EPDM PROFILES:
EPDM RUBBER PROFILE
SPECIALIZATION:
MARKET SURVEY
INDUSTRY OVERVIEW IN 2011
GLOBAL THE EPDM MARKET CAPITALIZATION WILL REACH $ 6.5 BILLION BY 2017
GLOBAL DEMAND FOR EPDM (ETHYLENE PROPYLENE DIENE MONOMER) IS SET TO INCREASE BY 1.5 MILLION TONS BY 2020
SUPPLY SCENARIO -PERIOD 2012
FUTURE INSTALLED CAPACITY AND PRODUCTION ESTIMATES FROM 2011 TO 2020 (IN METRIC TONNES)
DEMAND DRIVERS AND GROWTH TILL 2020
PATTERN OF APPLICATION SECTOR WISE DEMAND
EPDM DEMAND SET TO INCREASE BY 1.5 MILLION METRIC TONS BY THE YEAR 2020
PROJECTED DEMAND SUPPLY SCENARIO – PERIOD 2020
EPDM RUBBER USED SHRED GRAPH AREA WISE
MARKET SURVEY OF EPDM RUBBER PRODUCTS INCLUDING PROFILES IN INDIA FROM 2006 TO 2013
APPARENT CONSUMPTION OF EPDM PRODUCTS INCLUDING PROFILES FROM 2006 TO 2013
ESTIMATED DEMAND OF EPDM PRODUCTS FROM 2014 TO 2020
DEMAND SUPPLY GAP TILL 2019-20
RAW MATERIALS REQUIRED
PROCESS FLOW SHEET OF MANUFACTURE
FORMULATION AND PROCESSES OF EXTRUDED EPDM PROFILE
NR/EDPDM BLENDS FOR EXTRUDED PROFILE WEATHER-STRIP
TABLE-1 FORMULATIONS OF NR/MODIFIED –EPDM BLENDS FOR INITIAL EXTRUSION TRIALS
SMALL SCALE EXTRUSION TRIALS
TABLE-2 RHEOMETER CHARACTERISTICS OF COMPOUNDS FOR INITIAL EXTRUSION TRIALS
A MONSANTO MDR 2000E AT 180OC
NR / EPDM BLENDS FOR EXTRUDED PROFILE WEATHERSTRIP
TABLE-3 NR AND EPDM MASTERBATCH FORMULATIONS FOR LARGE SCALE MIXING AND EXTRUSION TRIALS OF SOFT AND MEDIUM SOFT BLEND COMPOUNDS
FORMULATION DEVELOPMENT AND PROCESSING
TABLE-4 EXTRUSION RATINGS OF LARGE SCALE MIXING TRIAL COMPOUNDS
TABLE-5 PHYSICAL PROPERTIES OF LARGE-SCALE MIXING TRIAL COMPOUNDS
TABLE-6 RESISTANCE OF LARGE SCALE MIXING TRIAL
COMPOUNDS TO AGEING IN AIR FOR 7 DAYS/70OC
FORMULATION DEVELOPMENT AND PROCESSING
TABLE-7 FORMULATIONS OF NR AND EPDM MASTERBATCHES FOR IMPROVED COMPRESSION SET PROFILES.
TABLE 8 EFFECT OF CURE SYSTEM ON COMPRESSION
SET OF NR/MODIFIED-EPDM BLENDS
COMPOUND FORMULATION OF EPDM WEATHER STRIP
COMPOUND FORMULATIN OF INDUSTRIAL MONO STRIP
RAW MATERIAL CALCULATION
FOR INDUSTRIAL MONO STRIP
FORMULATION
EPDM TEST FORMULATION-1
EPDM TEST FORMULATION-2
EPDM PROFILE MAKING MACHINE
SCHEMATIC FIGURE OF EPDM PROFILES PRODUCTION LINE
DIFFERENT TYPES OF EPDM PROFILE MANUFACTURE WITH SAME MACHINERY
DETAILS OF MACHINERY AND EQUIPMENT'S
RUBBER EXTRUSION
PRODUCTION LINE FOR RUBBER PROFILES PRODUCTION
SCHEMATIC FIGURE OF PROFILES PRODUCTION LINE
TYPES OF EXTRUDERS
SINGLE SCREW EXTRUDER:
TWIN SCREW EXTRUDER:
DIE FLOWS
A TYPICAL PROFILE EXTRUSION DIE
RUBBER PROFILE PRODUCTION LINE MODELS
RUBBER PROFILE PRODUCTION LINE
BLOCK DIAGRAM OF THE PRODUCTION
BLOCK DIAGRAM OF THE PRODUCTION PROCESS
VACUUM CALIBRATING STAND
HAUL-OFF
CUTTING MACHINE
TILT STACKER
RAW MATERIAL
TECHNICAL KNOW-HOW AVAILABLE AT FOLLOWING ADDRESS
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
IMPLEMENTATION SCHEDULE
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
LIST OF EPDM BASED PRODUCTS MANUFACTURER IN INDIA
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MATERIAL/EPDM/SYNTHETIC RUBBER
CARBON BLACK
INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER
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)
