PROJECT PROFILE

PRODUCT

P V C COMPOUND

NIC PRODUCT CODE

316204005

QUALITY STANDARD

AS PER CUSTOMERS SPECIFICATION

PRODUCTION CAPACITY :

(i) QUANTITY - 360 MT (ii) VALUE - Rs.2,91,60,000/-

MONTH & YEAR OF PREPARATION

JANUARY, 2011

PREPARED BY -

MSME- DEVELOPMENT INSTITUTE MINISTRY OF MICRO, SMALL AND MEDIUM ENTERPRISES 22 GODOWN INDUSTRIAL ESTATE, JAIPUR 302006 (RAJ.) Phone: (0141)2212098, 2213099, 2215847 Telefax: (0141)2210553 E-mail: dcdi-jaipur.dcmsme@gov.in Website: www.msmedijapiur.gov.in

PROJECT PROFILE ON P.V.C. COMPOUND

I.

INTRODUCTION : PVC is undoubtedly a very versatile thermoplastic material commercially available in a variety of compounded form to cover a wide range of flexibility and hardness for host of applications. Its physical strength and resistance to water and most of chemicals makes its popular plastic for wide variety of products. In general, PVC material is difficult to ignite and self extinguishing (when flame removed) property/ characteristic make it important thermoplastic. Thermal degradation, an inherent property, makes it difficult to process and makes proper compounding essential, which needs incorporation of thermal stabilizers, internal and external lubricants, plasticizers (when softness is required), opacifier, anti UV agents (for outdoor use) etc. Compounding of PVC is critical as economy and better quality are critical factors to control, uniform dispersion of additives is necessary to make good compound. The conventional type of machinery & equipment used for compounding are high speed mixer, ribbon blenders and extruders. PVC Compounds, in general, may be divided into two groups i.e. Granulated Compound where mix is fused and extruded in pellets form and Dry Blend where resultant compound is often in free flowing powder form.

2.0

MARKET POTENTIAL : PVC Compounds are used extensively both in pellet and dry blend forms for wide variety of products ranging from flexible to rigid, plasticised to unplasticised for the manufacture of items like pipes, conduits, tubings, cables, shoes, footwear, films, sheating, moulded products etc. With the increasing demand of above products, the consumption of PVC Compound is also rising proportionately. Construction activity is growing at fast pace so the demand for PVC Compounds is also increasing.

Contd 2.

-23.0 BASIS & PRESUMPTIONS : (i) The project is based production capacity on single shift basis at 70% efficiency and 300 working days in a year. The cost of machinery & equipment and raw materials as indicated refers to a particular make and prices are approximate and are those obtained prevailing at the time of preparation of this profile. The rate of interest on investment is taken at 15% on an average and BEP in the profile has been calculated on full capacity. Where as some names of manufacturers/ suppliers of Machinery & Equipment, Raw materials etc. are indicated at the end of the profile, these are by no means exclusive or exhaustive.

(ii)

(iii)

(iv)

3.0

IMPLEMENTATION SCHEDULE : The following steps involved in the implementation of the project. i) ii) iii) iv) v) vi) vii) viii) ix) Selection of Site Preparation of Detailed Project Report Filing of EM Procurement of Machinery Construction of Building Power Connection Arranging Finance Appointment of Staff & Labour Trial Run 1 month 2 weeks 1 week 3 months 3 months 1 month 2 months 1 month 1 week

4.0 4.1

TECHNICAL ASPECTS : Process Outline :

4.1.1. Dry Blends: PVC Resin is added to high speed mixer and stirred for few minutes to remove volatile impurities and moisture. Measured qualities of plasticizer, heat stabilizer, pigments, filler, opacifiers etc, are added as per formulation and mixer run for few minutes. High speed and increase in temperature due to rotation helps to disperse the additives uniformly. Lubricants are added at the end and mixer is run for a few more minutes.

Blended mixer is discharged to cooler mixer is to allow the dry blends to cool down to room temperature. Final dry blend is packed in sacks for dispatch. 4.1.2 Granulated Compound : The process of mixing the PVC compounding ingredient in the form of a powder compound is described as above. This powder compound is then fed to extrusion unit and extruded in the form of solid chords which are then cut in the form of pellets. 4.1.3 Typical Formulations Certain typical formulations for PVC Compound required for some general purpose applications are as appended below. However, the actual formulations would depend on the performance requirements of the end product for which the compounds are formulated and also the cost considerations. 4.1.3.1 Unplasticised Rigid PVC Pipes Parts by weight (i) (ii) (iii) (iv) (v) (vi) PVC resin Heat Stabilisers (non toxic) Internal lubricants External lubricants Fillers Pigments & Colourants 100 56 3 4 35 0.5

4.1.3.2 Wires & Cables (Electrical)

(i) (ii) (iii) (iv) (v) (vi) (vii)

PVC resin Stabiliser Primary Stabiliser Secondary Plasticiser Lubricant Filler Pigment & Colourants

100 3 3.0 25 1 40 50 As per requirements

4.1.3.3 Rigid PVC Sheet

(i) (ii) (iii) (iv)

PVC resin Stabiliser Organic Chelater Lubricants

100 3 1 0.5

4.1.3.4 ClearTubings (i) (ii) (iii) (iv) (v) (vi) (vii) 4.2 PVC resin Stabilizer Primary Stabilizer Internal Lubricant External Lubricant Organic Chelater Blue Pigment 100 3 3 0.5 0.5 0.75 1.0 As per requirements

QUALITY CONTROL & STANDARDS : No specific Standards have been laid down for PVC Compound. However, quality of the compound shall depend upon the performance requirement of the product for which a compound is formulated. Hence, PVC compounds are normall6y manufactured as per Customers Specifications.

4.3

PRODUCTION CAPACITY (ANNUAL) : Quantity Value : : 360 M.T. Rs.2,91,60,000/-

4.4

MOTIVE POWER : The unit would need approximate 7,500 KW Electric Motive Power per month.

4.5

POLLUTION CONTROL :

Although the manufacturing of PVC Compound is not a pollution prone manufacturing activity, however, it is advisable that NOC must be obtained from State Pollution Control Board (SPCB) before commencement of commercial activity. Proper utilization / recycling of water used in cooler mixer and cooling bath should be optimized and effluent should be discharged only after ascertaining the parameters in accordance with PCB Rules & Regulations. 4.6 ENERGY CONSERVATION : For conservation of energy shunt capacity for electric motors, thermal insulation for chill water line and heaters are suggested besides maintaining power factor.

5.0 5.1 5.1.1

FINANCIAL ASPECTS : Fixed Capital Land & Building Land Built up Area Working Shed, Laboratory, Office, Godown. 400 Sq. Meter 325 Sq. Meter 4,00,000 12,00,000 -------------16,00,000 --------------

5.1.2

Machinery & Equipment :

1.

Nos. Mixing Unit High Speed Mixer, Capacity 50 Kg. Batch 2 size for construction material S.S. with Air tight lid with opening and closing device mounted on steel frame and 25 HP motor with cooling trays fitted with all accessories.

Rs. 14,00,000

-62. Extrusion Unit Extruder 65mm, twin screw with AC drive, 2 Nos. Reduction Gear fitted with 10 H.P. Motor with die head, control panel for heating control, starter, switches, thermocouples etc. with pettetising unit and water cooling trough fitted with guides. 3. 4. 5. 6. 7. 8. Scrap Grinder with 3 H.P. Motor Maintenance tools & Equipments Testing & Quality Control Equipments Electrification and installation charges @ 10% of cost of machinery & equipment Dies and other fixtures Office Equipment & Computer, Printer etc. Furniture with Total 5.1.3 Total Fixed Capital (i) (ii) (iii) 5.2 5.2.1 Land & Building Plant & Machinery Pre Operative Expenses 16,00,000 39,53,500 21,500 55,75,000 1 No. L.S. L.S. 18,00,000

1,50,000 25,000 60,000 3,43,500 75,000 1,00,000 -----------39,53,500 ------------

Working Capital (Per Month) : Staff & Labour (Per Monh) Production Engineer Accountant Peon / Chowkidar Technical Staff : Skilled Worker Unskilled Worker 4 6 4,000 2,200 16,000 13,200 42,900 6,435 ---------------49,335 49,500 1 1 1 7,500 4,000 2,200 7,500 4,000 2,200

Add 15% perquisites

Say

-75.2.2 Raw Materials (Per Month) Qty. PVC Resin DOP CPW 40% Fillers Stabilizer Epoxy Pigments Other additives and Packaging Materials 20 M.T. 5 M.T. 1 M.T 3.2 M.T. 600 Kg. 200 Kg. L.S. Rate/Kg 61/104/45/9/125/75/Cost (Rs.) 12,20,000/5,20,000/45,000/28,800/75,000/15,000/15,000/------------19,18,800/------------5.2.3. Utilities (Per Month) (i) (ii) Electricity Water 7500 KW @ 5.50 per kwh. L.S. Total : 5.2.4 Other Contingent Expenses (Per Month) (i) (ii) (iii) (iv) (v) (vi) (v) Postage & Stationery Telephone Repair & Maintenance Transport Advertisement & Publicity Insurance Packaging 1,000/500/1,000/5,000/2,500/1,800/8,000/19,800/-------------41,250/1,000/---------------42,250/---------------

5.2.5

Working Capital (Per Month) (i) (ii) (iii) (iv) Staff & Labour Raw Materials Utilities Other Expenses Total: 49,500/19,18,800/42,250/19,800/-------------20,30,350/-

6.0

WORKING CAPITAL FOR 3 MONTHS : 20,30, 350 x 3 = 60,91,050/-

7.0

TOTAL INVESTMENT : (i) (ii) Fixed Capital Working Capital (for 3 months) Total : Say 55,75,000/60,91,050 ------------1,16,66,050/--------------1,16,66,000/-

8.0 8.1.

FINANCIAL ANALYSIS : Cost of Production (Per Annum) :

(i) (ii) (iii)

Total Recurring Expenses Depreciation on Building @ 5% Depreciation on Plant & Machinery @ 10% of cost.

2,43,64,200/60,000/3,85,350/-

(iv) (v)

Depreciation on Office & Furniture Interest on Investment @ 15% Total

20,000/17,49,900/------------------2,65,79,450/-------------------

8.1

Turn Over (Annual) : By sale of 360 M.T. of PVC Granules @81,000 per M.T. 2,91,60,000/-

8.3 8.3.1 8.3.2

PROFITABILITY (PER ANNUM) : Total Profit (Before Tax) Net Profit Ratio 25,80,550/8.8% 22.1%

8.3.3. Rate of Return on Investment

8.3.4

Break Even Point (BEP): (A) Fixed Cost (FC): (i) (ii) (iii) (iv) (v) Depreciation 40% of Salary 40% of Other Expenses Interest on Investment Insurance 4,65,350/2,37,600/86,400/17,49,900/21,600/25,60,850/------------------------

(B) Profit (P) : FC x 100 FC + P =

25,80,550/2560850 x 100 2560850 + 2580550 = 49.8%

9.0

NAMES & ADDRESSES OF MACHINERY & EQUIPMENT SUPPLIERS

1)

M/s Kabra Extrusion Technik Ltd., 402, Lalita Complex, Opp. HDFC, Navrangpura, Ahmedabad 380009. Phone: 079-26564828, Fax: 079-26427281 M/s M.N. Panchal & Co., Plot No. 23-24/A, Gopal Indl. Estate, Behind Harshad Chambers, Opp. Vallabh Nagar High School, Odhav, Ahmedabad. Phone: 22879204, Fax: 079-22870204. M/s Pioneer Engineering Corporation, E-14, Ansa Indl. Estate, Saki Vihar Road, Sakinaka, Andheri (E), Mumbai 400072. Phone: 022-28473143 Fax: 022-28473787 M/s Jogendra Engineering Works Pvt. Ltd., B-6, 70 Ram Road, New Delhi 110 015. Phone: 011-25442112 Fax:011-25453836

2)

3)

4)

5)

M/s V.K. Engineering Works, 2 Heera Bari (Near S.K. Industries), Jhotwara Indl. Area, Jaipur 302012. Phone: 0141-2346878. M/s Shree Radhakrishna Extrusion Pvt. Ltd., Plot No.C-1-4 509, Phase-IV, Behind Techno Industries Ltd., Vatva, GIDC, Ahmedabad 382 445 Phone: 07925842509, 2584-1785.

6)

10.0

NAMES & ADDRESSES OF RAW MATERIAL MANUFACTURERS/ SUPPLIERS : PVC Resin 1) M/s Reliance Industries, Maker Chambers-IV, 222, Nariman Point, Mumbai 400 021. Phone: 022-22785000 M/s Shriram Vinyl & Chemical Industries, Kirti Mahal, 19, Rajendra Place, New Delhi 110129. Phone: 011-25713442, 25714006

10.1

2)

10.2

Lubricants, Pigments & other additives 1) M/s Calchem Industries (India) Ltd., 61-62, MIDC Industrial Area, Village- Dhatav, Rodha, Distt. Raigad 402116 (MS) Phone: 0219-2363734, 263833. M/s Shri Ram Sons Wax Pvt. Ltd., 181, Tilak Bazar, New Delhi 110 006. Phone: 011-23927312 Fax: 011-23927312 M/s Viraver Chemicals, 12, Mills Officers Colony, Opp. Times of India, Ashram, Ahmedabad. Phone: 26582199, 26581780.

2)

3)

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