PU BASED FOOTWEARS
[EIRI/EDPR/1395] J.C. 172
INTRODUCTION
Polyurethane is widely defined as a polymer material containing a huge amount of urethane group. Despite the chemical reaction between the NCO group and the hydroxyl compound that was originally found in the 19th century, the basic addition polymerization reaction of diisocyanate with alcohols to produce polymers, which is a polyurethane reaction, was not discovered and established until 1937 by Dr. Otto Bayer and co-worker in the laboratories of I. G. Farben Industrie. Chemical Co. in Germany. Between 1945 and 1947, millable elastomers, coatings and adhesives, the first commercial applications of polyurethane polymers, were developed. This was followed by the flexible polyurethane foams in 1953 and rigid polyurethane in 1957.
Polyurethanes can be manufactured in an extremely wide range of density and stiffness and have a broad range of applications. The densities of polyurethanes range from 6 to 1,220 kg/m3 and polymer stiffness of polyurethanes range from elastomers to flexible, rigid and hard plastics. The global polyurethanes consumption has been growing at an average rate of over 7% annually for the last 15 years. Thus, it is not surprising that polyurethanes are all around us, from shoes to sofas, insulation panels to automobiles, playing an important role in many ways in our daily life.
In the past, polyurethanes were usually made with petroleum polyols. With the dwindling and non-renewable petroleum resource, some novel polyols made from vegetable and seed oil have been investigated for their potential of replacing the petroleum polyols. of particular interest is a group of polyols derived from soybean oil.
These new polyols, however, have some major disadvantages limiting its applications when compared with petroleum polyols:
1. The alcohol groups in the petroleum polyols are primary which are 3.3 times more reactive with isocyanates than the secondary ones in the new polyols.
2. The saturated fatty acid in these new polyols is not reactive and adversely impacts the properties of polyurethane foams.
3. Most of these new polyols are not cost competitive against the petroleum polyols due to multiple steps involved and/or solvent consumption.
COST ESTIMATION
Plant Capacity 1000 Pairs/Day
Land & Building (10,000 sq.mt.) Rs. 11.25 Cr
Plant & Machinery Rs. 1.40 Cr
Working Capital for 2 Months Rs. 2.43 Cr
Total Capital Investment Rs. 15.77 Cr
Rate of Return 15%
Break Even Point 64%
CONTENTS
INTRODUCTION
SUPPLEMENTARY ACTIVITIES
GENERAL FUNCTIONAL REQUIREMENTS FOR SHOE SOLES
GENERAL MANUFACTURING PROCESS
THE CONSTRUCTION OF SPORTS SHOE SOLES
IMPORTANCE OF POLYURETHANE IN SHOE INDUSTRY AND ITS PROPERTIES
PHOTODEGRADATION IS REALLY TWO DISTINCT PROCESSES
GLOBAL PU FOOTWEAR INDUSTRY
SHOE MAKING- HOW SHOES ARE MADE
PROCESS OF MANUFACTURE
PROCESS DESCRIPTION:
ADDRESSES OF SUPPLIERS/MANUFACTURERS OF COMPLETE SHOE MAKING MACHINES
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)