POWDER MANUFACTURING UNIT
FOR PUREPOLYESTER & EPOXY
[CODE NO. 2063]
The success of powder coatings from its earliest beginnings in 1960’s is unmistakable. More than twenty years after they first entered the market powder coatings in the 80s has now become a commercial and technical success.
Powder can be described as solid paint. It is applied through special gun which electrically charges the particles and deposits them on to an earthed article. The charge allows the particles to remain adherent to the substrate and when baked the particles fuse together and cross link the polymers to form hard abrasion resistant coating.
There is an liner increasing variety of powder coatings to choose from and the final selection will depend on the end use and requirement of coated substrate.
The thermo setting system the polymer is a low molecular weight species which melts and flows decreasing fusion and undergoes to a thermoset cured condition. Once this condition has been achieved it can no longer be remelted to plastic condition.
The iron linking reaction occurs in thermosetting powders between the reactive group of resins like epoxy, polyester etc. and those of curing agents. To achieve a smooth film the polymers must flow out to a continuous and even film before cure is initiated.
Powder is in variably a composite, balancing the softening temperature with the melt viscosity or fusion characteristic and the speed of cross linking . The components required for manufacture of thermosetting powders are as follows :-
1. Polymers
2. Hardeners, Catalyst, Curing agents
3. Pigments, extenders
4. Flow control additives.
Resins having a softening point between 700C to 1100C are usually employed. Resins of lower melting point have tendency to 'Cake" in the powder form on storage and furthermore have very poor 'edge coverage'.
Alternatively those of higher melting point will give better 'edge coverage' but have very poor flow and 'Orange peel defect.
The applications curing and properties required in the coating influence the choice of curing agent to be used with the particular type of polymer to be used in the formulation.
The hardener should be unreactive at room temperature remaining latent at upto 100oC and should react fully below 1800C. The reaction should not be so rapid as to prevent complete flow out of the fused resins as this would lead to very poor flow of the powder.
COST ESTIMATION
Plant Capacity 4.00 Ton./day
Land & Building (3000 Sq.Mtr) Rs. 2.67 Cr
Plant & Machinery Rs.1.50 Cr
W.C. for 2 Months Rs. 4.90 Cr
Total Capital Investment Rs.9.27 Cr
Rate of Return 26%
Break Even Point 52%
• INTRODUCTION
• PROPERTIES
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• MARKET POSITION
• CMEMISTRY OF POWDER COATINGS POLYMERS
• PRESENT MANUFACTURERS
• FORMULATION OF POWDER COATINGS
• MANUFACTURING PROCESS
• PROCESS FLOW SHEET FOR POWDER COATING MANUFACTURING
• APPLICATION TECHNIQUES
• ELECTROSTATIC FLUIDIZED BED
• PRINCIPLES OF PLANT LAYOUT
• PLANT LOCATION FACTORS
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• PROJECT IMPLEMENTATION SCHEDULES
• PLANT LAYOUT
• SUPPLIERS of RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
APPENDIX – A :
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