Detailed Project Report on pvc and cpvc pipe and fittings manufacturing plant

PVC AND CPVC PIPE AND FITTINGS MANUFACTURING PLANT [3527]

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes. PVC Pipes and fittings a often used in the following circumstances: • For drinking water pipe distribution systems, both main and supply lines. • Sewer and discharge pipe systems. Due to its non-metallic nature, the material used is totally resistant to all forms of metallic corrosion. Aggressive water resulting from high sulphate soils and low hardness water will not attack PVC pipes. Our pipes are therefore resistant to a wide range of industrial waters and chemicals and offer an advantage in long-term systems life and manufacture costs. For more information on the resistance of PVC for specific chemical(s), do not hesitate to let Interplast know. We inform you of the suitable pipe solution necessary. Being made of a tasteless and odorless material, PVC pipes remain neutral to all transported fluids. PVC is completely inert and is widely used for transporting liquids made for human consumption. Because of their mirror-smooth inside surface, PVC pipes have minimum flow head loss. There is also no buildup of inside deposits, a particular advantage in the construction of sewerage systems. The physical properties of PVC pipes are not affected by neither direct sunshine, nor wind or rain. However, to avoid surface browning due to long exposure to direct sunlight, it is recommended that the pipes are kept protected from direct sunlight. Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to travel on PVC pipes. They therefore offer added safety when used for electrical installations, both domestic and industrial. PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel pipes. This cuts down transportation costs and facilitates installation when in difficult and remote places. Installation is quick and easy with a complete line of fittings either with the solvent glue weld sockets or the rubber seal socket joints. In either case, a leak-proof joint is assured. Subsequent maintenance work is also carried out with a minimum of complication and cost. PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when plasticized or softened with other chemicals has some rubber-like properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC socket or threaded fittings (schedule 80). PVC Pipe and Fittings have got tremendous demand in India as well as in abroad. To manufacture this, all the machinery and raw materials are available indigenously. A polyvinyl chloride (PVC) pipe is made from a plastic and vinyl  combination  material.  The pipes  are  durable,  hard  to damage, and long lasting. A PVC pipe does not rust, rot, or  wear over  time. For that reason, PVC piping is most commonly used  in water systems, underground wiring, and sewer lines. PVC was first developed in 1925 when a BF Goodrich employee, Dr.  Waldo Semon, attempted to invent a method for bonding metal and rubber. After blending materials together to create a strong and flexible material, Semon discovered PVC. Nonetheless, the product remained virtually useless for another decade. In the late 1930's, PVC  was  found  to  have  great  shock  absorbing abilities. This discovery led to the creation of long lasting PVC tire treads, which were created with flexible forms of PVC. Two decades later, PVC pipe was invented. By heating the PVC material,  a special machine called an extruder could be used  to push the PVC into hollow pipes. This PVC pipe was extremely solid and  virtually  indestructible. Using PVC  pipes  for  irrigation systems  proved  to  be  effective. PVC pipe has since been considered an affordable and reliable means for water piping. Due to the ability of PVC pipe to withstand extreme movement and  bending,  it is also increasingly used in  earthquake  prone areas.  PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of  the  PVC pipe  is  also resistant to bacterial contamination, such  as  E. coli.  Therefore, many water companies rely on PVC pipe in  their systems in order to keep them free of contamination. Unfortunately,  the material used in PVC pipe appears to be detrimental to a person's health and safety. Reported cases of PVC  pipe  shattering when used with high-pressured gases have increased drastically. The Federal Government has issued safety warnings, which strongly recommend using alternative piping material. In addition, the heavy metals used to create PVC pipe can leach out when heated. The vapors emitted from the heated PVC pipe are now being linked to certain forms of cancer,  especially lung cancer. CPVC Pipes and Fittings are manufactured from compound, CPVC- Chlorinated polyvinyl chloride is a thermoplastic used for hot and cold water lines. Chlorinated polyvinyl chloride (CPVC) is a thermoplastic produced by chlorination of polyvinyl chloride (PVC) resin used for hot and cold water lines. CPVC is the first choice of material for potable water supply across the world and is in use across the world for more than 50 years.

COST ESTIMATION

Plant Capacity                                           13 MT/Day  
Land & Building (8000 sq.mt)                Rs. 3.20 Cr
Plant & Machinery                                    Rs. 3.48 Cr
Working Capital for 3 Months                Rs. 12.94 Cr
Total Capital Investment                         Rs. 20 Cr
Rate of Return                                          26%
Break Even Point                                      52%



INTRODUCTION    
PROPERTIES OF PVC PIPES & FITTINGS    
CHLORINATED POLYVINYL CHLORIDE (CPVC)    
ADVANTAGES & LIMITATIONS    
HANDLING & STORAGE:-    
WIDE RANGE OF APPLICATIONS OF CPVC PIPE    
IMPORTANT CPVC RELATED STANDARDS    
STANDARD    
TOPIC    
ANSI/NSF STANDARD     
CPVC PIPES-POTABLE WATER SUPPLY THIS IS A CRITICAL CERTIFICATION WITHOUT
    WHICH CPVC PIPES CANNOT BE USED FOR CARRYING POTABLE WATER    
ASTM D2840    
CPVC HOT COLD WATER DISTRIBUTION SYSTEMS    
ASTM F439    
CPVC SCHEDULE 80 CPVC FITTINGS    
ASTM F441    
CPVC SCHEDULE 40 & 80 PIPES    
DIN-8079    
CPVC PIPES DIMENSION    
DIN-8080    
CPVC PIPES GENERAL QUALITY REQUIREMENTS AND TESTING    
BS 7291/4    
CPVC PIPES AND FITTINGS FOR HOT AND COLD WATER DISTRIBUTION    
NFT 54-014-1/2    
CPVC PIPES AND FITTINGS FOR HOT AND COLD WATER DISTRIBUTION    
EN-ISO 15877:2003    
PLASTICS PIPING SYSTEMS FOR HOT AND COLD WATER INSTALLATIONS –
    CHLORINATED POLY VINYL CHLORIDE (PVC - C)    
BUREAU OF INDIAN STANDARDS SPECIFICATIONS    
PLASTIC PIPES & FITTINGS    
PRESSURE PIPES FOR WATER SUPPLY & IRRIGATION    
(TABLE OF DIMENSIONS OF PIPES TO IS : 4985-1968)    
PLUMBING PIPES    
APPLICATIONS OF PVC PIPES & FITTINGS    
ADVANTAGES OF USING PVC PIPES    
1.   IT IS ECONOMICAL:    
2.   IT RESISTS CORROSION:    
3.   NON-ENRUSTATION:    
4.   LIGHT WEIGHT:    
5.   EASE OF INSTALLATION:    
MARKET SURVEY    
IMPACT OF GST, DEMONETISATION, RERA ON PIPES AND FITTINGS INDUSTRY    
OPPORTUNITIES FOR THE PIPES AND FITTINGS SEGMENT FROM BUDGET 2018    
IMPORTED OR INDIGENOUS PIPES    
NEW VENTURE IN PIPES AND FITTING SEGMENT    
PRODUCTION OF PVC AND CPVC PIPES FROM 2007 TO 2017    
APPLICATION BREAK UP OF PVC IN INDIA    
GLOBAL APPLICATION OF PVC    
PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES    
PVC PIPES OFFERS THE FOLLOWING ADVANTAGES:-    
TREND IN INCREASE IN DEMAND    
TREND GROWTH RATE IN INCREASE OF DEMAND = 15%    
ENHANCED RECYCLING PROPERTIES FOR PVC PIPES    
OVERVIEW OF PVC    
GLOBAL SCENARIO    
GLOBAL PVC CAPACITY BREAK-UP (%)    
PER CAPITA CONSUMPTION OF SUSPENSION PVC    
GLOBAL PVC DEMAND BREAK-UP    
INDIAN SCENARIO    
FIGURE: PVC PRODUCTION AND IMPORTS IN INDIA    
FIGURE: PVC DEMAND IN INDIA - HISTORY    
FIGURE: APPLICATION BREAK-UP OF PVC – INDIA    
FIGURE: APPLICATION BREAK-UP OF PVC – GLOBAL    
FIGURE: PVC CONSUMPTION IN INDIA (2001-2015)    
FIGURE: DOMESTIC MANUFACTURERS AND CAPACITIES (KT)    
MANUFACTURERS/EXPORTERS    57
PVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION    
PVC RESIN:    
DIMENSION OF PVC PIPE    
PVC PIPE & FITTINGS DIMENSIONS (SCH 40 / SCH 80)    
FORMULATION FOR PVC RIGID PIPES    
PVC FLEXIBLE PIPES    
PROCESS OF MANUFACTURE    
PLUMBING PIPES    
USES & APPLICABILITY OF PVC COMPOUNDS    
BUILDING AND CONSTRUCTION:    
PACKAGING:    
MISCELLANEOUS:-    
MANUFACTURING PROCESS OF PVC PIPES    
PROCESS OF MANUFACTURE OF RIGID PIPES    
TWIN SCREW EXTRUDERS    
EXTRUSION DIES    
EXTRUSION LINES:-    
PVC PIPE FITTINGS:-    
PLASTICIZER OF PVC    
FILLERS OF PVC    
STABILIZERS    
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES    
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS    
MANUFACTURING PROCESS OF PVC & CPVC PIPE FITTING    
DETAILS OF PLASTIC EXTRUSION PROCESS    
EXTRUDER HEATER    
BLOCK DIAGRAM OF THE PLASTIC EXTRUSION PLANT    
TEMPERATURE SECTION OF PVC PLANT    
HEATER SPECIFICATION OF PLASTIC EXTRUSION SYSTEM    
PLASTIC EXTRUSION SCREW    
DETAILS OF INJECTION MOLDING FOR PIPE FITTINGS    
PROCESS CYCLE    
EQUIPMENT    
INJECTION UNIT    
INJECTION MOLDING MACHINE - INJECTION UNIT    
CLAMPING UNIT    
INJECTION MOLDING MACHINE - CLAMPING UNIT    
MACHINE SPECIFICATIONS    
INJECTION MOLDING MACHINE    
TOOLING    
MOLD OVERVIEW    
MOLD BASE    
MOLD BASE    
MOLD CHANNELS    
MOLD DESIGN    
MOLD - CLOSED    
MOLD - EXPLODED VIEW    
THE NEW GENERATION OF PVC-O PIPES    
MOLECULAR ORIENTATION, A REVOLUTION IN PVC TECHNOLOGY    
A PLASTIC WITH UNBEATABLE PROPERTIES    
CUTTING-EDGE TECHNOLOGY FOR WATER    
MAXIMUM RELIABILITY AND SECURITY    
HIGH SHORT AND LONG TERM HYDROSTATIC RESISTANCE    
EXCELLENT RESPONSE TO WATER HAMMER    
INCREASE HYDRAULIC CAPACITY    
MAXIMUM FLEXIBILITY    
COMPLETE CORROSION RESISTANCE    
TOTAL WATER QUALITY    
COMPLETELY WATER TIGHT    
LOWER COST AND EASIER INSTALLATION    
THE MOST ECO-FRIENDLY PIPES ON THE MARKET    
ENERGY EFFICIENT    
OPTIMAL USE OF WATER RESOURCES    
100% RECYCLABLE    
THE BEST MECHANICAL PROPERTIES    
TENSILE RESISTANCE    
LONG TERM HYDROSTATIC RESISTANCE    
PIPING AND MATERIAL MECHANICAL PROPERTIES    
OTHER MATERIAL CHARACTERISTICS    
UNBEATABLE HYDRAULIC PROPERTIES    
HYDRAULIC CAPACITY    
WATER HAMMER    
A RANGE FOR ALL KINDS OF APPLICATIONS    
DIMENTIONS    
PACKAGING    
JOINTS AND WATER TIGHT SEALS    
FITTINGS    
TAPPING SADDLES    
FLANGE WITH ANTI-TRACTION SYSTEM    
FITTINGS WITH PLUGS EURO TYPE    
APPLICATIONS    
OTHER APPLICATIONS    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
MOULDS FOR PIPE FITTINGS    
HIGH SPEED MIXER    
EXTRUDER    
PLASTIC SCRAP GRINDER MACHINE    
PLASTIC INJECTION MOULDING MACHINE    
GENERATOR SET    
SUPPLIERS OF RAW MATERIALS    
PVC RESIN    
CALCIUM STEARATE    
LEAD STEARATE    
PRECIPITATED CALCIUM CARBONATE    
PIGMENT DYE    

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)