Step Media Final DPR Project With Cover
Step Media Final DPR Project With Cover
Step Media Final DPR Project With Cover
Profile
DPR
of
PVC PANAFLEX
An Initiative of
Step Media Ltd.
CORPORATE HEAD OFFICE
HOUSE- 07, ROAD -
23/B, (LEVEL-3)
GULSHAN-1, DHAKA-1212
TABLE OF CONTENTS
SYNOPSIS OF THE PROJECT.........................................................4
EXECUTIVE SUMMARY........................................................................5
PROJECT COST DETAILS...............................................................7
CHAPTHER ONE
ALL ABOUT STEP MEDIA LIMITED......................8
OUR VISION.......................................................................................9
OUR MISSION..................................................................................10
BUSINESS POLICY............................................................................11
CORE VALUES REGARDING QUALITY...............................................12
LEADERSHIP.......................................................................14
OWNERSHIP STRUCTURE.................................................................16
AUDIT COMMITTEE..........................................................................20
TRANSPARENCY AND PROACTIVE RISK CONTROL..........................20
CODE OF CONDUCT...........................................21
EMPLOYMENT...................................................21
SERVICES & TRAINING..............................................23
SAFETY & SECURITY................................................23
HEALTH & MEDICATION..................................................25
QUALITY CONTROL & INSPECTIONS....................................25
PERSONAL NET WORTH OF THE DIRECTORS.........26
AREAS OF ACTIVITIES OF MEDIA LIMITED................33
DIGITAL PRINTING........................................................33
CREATIVE DESIGN...................................................35
EVENT & ACTIVATION....................................................37
BRANDING...............................................38
LOGISTICS &SERVICES..............................................39
ii
CHAPTER TWO
ALL ABOUT PVC PANAFLEX, FOAM BOARD AND PVC
PLASTIC WOOD........................................................40
HISTORY OF PVC.........................................................41
HOW IS PVC MADE?................................................43
HOW IS PVC USED?.............................................45
PVC IS A MORE ECONOMIC MATERIAL................................45
PVC UNDERPINS SAFETY...........................................46
PVC ENHANCES OUR LIVES........................................46
WHAT MAKES PVC IMPORTANT?.......................................46
KEY PROPERTIES:........................................................47
SUSTAINABILITY................................................54
WHAT IS PVC BANNER FLEX?......................................56
WHY IS PVC THE MOST PREFERRED MATERIAL?.....................61
CHAPTER THREE
MARKETING STARTAGY...............................................66
THREE MOTIFS..........................................66
THREE KEYS.........................................67
CHAPTER FOUR
FINANCIAL PART OF THE PROJECT........................70
LIST OF MACHINERY.....................................................72
CHAPTER FIVE
CONCLUDING REMARKS............................................104
RISK & MITIGATION.....................................................105
OUR CLIENTS............................................................107
SYNOPSIS OF THE PROJECT
Location: Gazipur
4
EXECUTIVE SUMMARY
This Detailed Project Report is prepared to determine the overall viability of implementing the
project of sett ing up of a PVC Panaflex Industrial Unit at Gazipur, Dhaka. The Report
has been prepared to assess the financial viability and market demand of the product and its
rationale for setting up of the same. As Bangladesh is a very big market for the products
of this kind which is growing more than 25% every year and as there is no single unit of industry
who manufacture this products, Bangladesh fully depend on importation, Step Media has
thought of coming in to manufacture the high quality product in Bangladesh with a view to
meeting the inland demand and then exporting the same to the neighboring countries as there
is a huge scope and thus our foreign currency will be saved and our demand will be fulfilled
and the Company will earn super normal profit and would be able to adjust the bank liabilities
in time.
Mr. Mostafa Towhid Khan, the leading promoter of this project has a vast market knowledge
and has been doing business in this country for a period of more than two decades with
reputation and commitment. He has a current market and customer set up which he
can utilize fully for getting in the business of this kind as he can utilize his expertise and
connection to make his dream come true. PVC Panaflex project is a dream project of Mr.
Khan as he has control over this market, the product has a high market demand and nobody is now
doing this manufacturing business in Bangladesh now and he will be pioneer in this business
and would be able to take over the market in full in terms of competitive advantage and market
penetration.
Moreover, Step Media Ltd is consuming 100 ton per month being 1200 tons per year which can play
a pivotal role in proceeding with the endeavor. The project cost is assessed at Tk. 239.96 Crore and it
is estimated that by 5 years of operation the total investment will be brought back easily and a good
number of employments will be generated.
5
Step Media thinks that it’s time to go for this project as it’s an uncultivated area and Step Media
can be the pioneer and take the benefit of.
The Project will install the most sophisticated machinery from Germany who prepare the most
modern and high- t e c h machinery with state- o f - t h e - a r t technology. As such the
product quality will be unique and market will be in favor of the product and it will be easier to
replace the imported low-quality goods. It is noticeable that the demand of the PVC
Flex is growing more than 25% in a year. Bangladesh imported 4503 tons in 2015-16
which went to 9547 ton in 2017-18 which is around double. Our home demand is
growing at a very rapid scale but it is unfortunate that we don’t have any
manufacturing unit in Bangladesh and so we are totally dependent on import resulting huge
flight of foreign currency every year to meet up the importing needs.
Besides we have own consumption as we are involved in this line of printing business for the last
two decades. Our monthly consumption is around 100 ton having a yearly demand of 1200 ton
which we currently procure the same from home and abroad. Setting up of factory will ensure our
consumption at a lower cost resulting increase of profitability. It is to be noted that in our country there
are around 6000-7000 printing units who are in continuous operation having a huge demand.
Setting up the industrial unit here we can have the competitive advantage. The business is dealt in
cash, no credit at all. We would be able to take order and money first and then prepare and
give supply to our vast clients. So our market receivables in the beginning will be very less
which is very rare in case of dealing other business in Bangladesh.
It is mentionable that because of the China America business war we can get an advantage of
exporting it as our price would be far lower than that of the Chinese counterpart. So, there is
an ample scope of exporting the goods to other neighboring countries in a bulk amount.
6
PROJECT COST DETAILS
4 Others 36,400,000.00
7
CHAPTHER ONE
ALL ABOUT STEP MEDIA LIMITED
Step Media Limited is market leader in print production and one of the most integrated
Printing, Publishing, Signage and Display solution companies in Bangladesh. Our aim is
to give our customers value added solutions that meet the most demanding aspect of their
business needs. We have been supplying quality products for the country over two decades
and have vast industry experience to deal with any requirements as regard to signage
production, publishing, printing of quality products & services our customers may require.
Step Media Limited was formed in June 1998 and incorporated as a Private Limited Company
with the registrar of Joint Stock Companies of Bangladesh under the Companies Act 1994.
Initially we started as a Media Development Center, along with a Market Research and
Development wing having computerized digital image printing facility. Then
software development, Event Management & other related functions were added to its flow to
complement the operations. Along with computerized digital image printing facility, we can
provide the most innovative planning, designing & the latest tools in organizing Event
Management Programs and events for locally and internationally.
We believe that we are best demanded company in service and product quality, delivery,
customer service and commitment. Our technology is the best in the industry which enables
Step Media Limited to stay ahead of the competition and guarantee the finest end result.
We provide in printing, digital printing large format, house design, pre-press services and post
press services & A to Z Solutions to the Signage related works.
Step Media Limited is the only ISO certified company in digital printing company in
Bangladesh. Through providing integrated digital printing, Publishing, Interior and Display
solution services it has become market leader in this sector. The company with adequate
industrial set up has been supplying quality products and services to the most MNCs and
large corporate houses and arranging the National and International events (like ICC T20
World Cup in 2016) as per their needs in the last 20 years.
Step Media Limited, a name of glory a name of trust; welcomes the customers in the digital
world; making the virtual dreams material. Our goal is to meet and exceed the expectations
of every client by offering outstanding customer service, increase flexibility, and greater
value thus, optimizing system functionality and improving operational efficiency. Our
associates are distinguished by their functional and technical expertise combined with their
hands-on experience, thereby ensuring that our customers receive the most effective products
and professional services and comfort working with us.
8
OUR VISION
Step Media Limited wants to have the global reach as a leading company of the country.
Our Vision is to offer the valuable customers reliable and best quality products & services. Step
Media Limited is connected to a vast network of great companies ensuring illustrious feedback to its
valued clients in the field of Digital Signage & Services, interior-exterior designs & constructions,
technology- based solutions and enterprise communications, organizing events, publication of
Newspaper Supplement, City decoration, Creative Media Solution, Producing TV program,
organizing campaign program etc.
9
OUR MISSION
Step Media dedicates its workforce to achieve optimal return on its assets, achieve
leadership in the marketplace and build a stable and profitable enterprise for the future &
improve healthy management system for the betterment of the company staffs.
Our national economy is expanding in the context of growth and strength. Local businesses
now have an opportunity to perform in an international platform. Bangladesh has the most
opportunity to expand business to a large scale to meet the domestic demand and proceed
beyond the boundary.
To achieve the goal, it has some specific objectives which are as follows:
10
BUSINESS POLICY
11
CORE VALUES REGARDING QUALITY
12
Key messages: Describe the key messages that will elevate services in the target
customers’ eyes. If there is sample collateral or graphical images of some messages, include
them.
Marketing activities: Which of the following promotion options provide the company the best
chance of product recognition, qualified leads, store traffic, or appointments?
Step Media views corporate governance as the manner in which members of the Board of
Directors, Shareholders, Management and Employees of the company are organized and run-
in practice. The company good corporate governance involves keeping business practice above
reproach and thus retaining the trust and confidence of all the stakeholders who enable Step
Media to operate, thrive and prosper.
13
LEADERSHIP
Step Media Limited is working with a good number of MNCs and local companies in
Bangladesh. We are practicing corporate culture and values to synchronize with our customers
to speak the same language. We are led by best people and technology and so we are the most
respected, reputed and trusted company in Bangladesh.
Step Media Limited provides a complete outsource of technology, infrastructure and customer
support to enable the enterprise to mass-deploy these solutions to its Business Partners as an
affordable service. Company has pioneered a range of innovations setting new standards of
service, which its competitors have subsequently sought to follow. Despite Step Media
Limited's growth, the service still remains customer driven with an emphasis on value for
money, quality, reliability and innovation. Step Media Limited has 12 branch offices and now
employs more than 1000 permanent workforce & a good many numbers of outsourcing staffs
are associated with us. jbb
In the year 1998 Step Media Limited acquired state of the art digital printing machine HP
Scitex XL Jet to deliver premium quality image visibility to satisfy its customers in Bangladesh.
Bangladesh has only one unit of HP Scitex XL Jet(5m) Printers, HP Scitex XL Jet Printer
machine, which is with Step Media Limited and we should be proud of it.
14
Company Details:
Name Green
Step Media Limited
of Communication
the Ltd.
Company
Printing, Publishing,
Business Types Signage and Display Communication
solution
15
Step Media Limited is operated by a team of top management. That is regarded as Board of
Directors. This Board of Directors plays a pivotal role in company’s daily operation. The Board
formulates company’s policies and provides guideline to continue business operations
that assist in leading the company towards growth and development.
Under the Articles of Association of STEP MEDIA LIMITED, the Board of Directors consists
of four enthusiastic professionals by a Managing Director in leading role and the number
Apart from the Board, the Managing Director functions as the Chief Executive of the company
to take charge of the business affairs and other logistic supports. The Board of Directors is
ultimately accountable and responsible for the strategy and business performance of the
company and its subsidiaries.
16
The specific responsibilities of the Board of Directors are as follows:
Ensures that financial statements accurately disclose Step’s financial position; Monitors
the implementation of strategy by management;
Detects management performance and determines whether to approve
recommendations for the remuneration of senior management;
Convenes and prepares the agenda for shareholders’ meeting;
Observes conflict of interest and prevents abusive party transactions;
Assures equitable treatment of shareholders, including ordinary shareholders.
The duty of the Board of Directors is required for material matters, including the business plan
and budget for each fiscal year, capital raising, capital markets and other financing
transactions of the company. The management team consists of several sections and function
as operational team of the company.
The overall supervision and control of the business and affairs of the Company shall be
managed by the Managing Director who will exercise all his powers as mentioned in the
memorandum together with such powers which may from Time to be delegated to him by
board of Directors. The Managing Director is the Chief Executive to look after the business
affairs and other logistic support of the company. The Managing Director will be assisted by
the Directors as well as by the managerial and technical staffs at different levels.
OWNERSHIP STRUCTURE
The production of the soft drinks Bangladesh is franchise or license basis. The soft drinks market in
Bangladesh consists mainly of seven local companies associated with global brands, as shown in the
following table:
The Board of Directors of Step Media has formed an Audit Committee lead by a director.
The Audit Committee is responsible for the oversight of Step internal audit, external audit,
risk management and compliance functions.
External auditor, the head of the Internal Audit department, the head of Compliance, and the
head of the Risk Management department report to the Audit Committee.
The members of the Audit Committee are appointed by the Board of Directors, and is required
to meet at least four times each fiscal year.
Transparency at STEP MEDIA involves the open and proactive discussion of issues and
problems with all stakeholders. The role and nature of the Board of Directors and its
committees and SML’s management structure are vital elements of framework for mitigating
risks, allocating resources and making decisions with full accountability based on all relevant
information.
CODE OF CONDUCT
Employment
I. Legal Acts:
The Organization complies with the legal framework of Bangladesh, Namely the factories Act,
Personal files of worker have a signed copy of Service Contract, which clearly Mention the Job
Title, Employment Terms, Probation Period, Maternity Benefits & Termination Clause.
Workers are screened by doctors within the three days of joining and are given Age
Certificates.
III. Wages & Overtime:
Overtime records for past three months are made available in the factories at all times and are
controlled as per the local legislative requirement .One day rest is mandatory in one week /
seven days .Overtime records indicate the overtime hours and overtime premium .It is being
paid as per local legislative requirements .Copy of payroll is available at all times and this
includes Basic Salary, House Rent, Medical Allowance, other Benefits and deductions.
of labor, industrial safety and environmental protection is available in the factory at all times
for ready reference.
V. Disciplinary Actions:
There is no provision for monetary or financial penalties to be exercised in the factory. All
records for grievance and actions taken are made available in the factory. Disciplinary
procedures are documented in personal file and are signed by workers and management
Disciplinary actions are communicated to the workers.
Grievance Procedures are documented .A “suggestion box “is readily available to all workers in
the factory and actions taken if any
A worker welfare committee has been formed for better transparency between the workers
and management.
Services & Training
I. Training Center:
As per Step Media Policy training center has been established to enhance and upgrade
workers to multi task and to develop operator skills.
I. Fire Fighting:
The factories are fully compliant of fire safety standard and have trained in-house fire fighting
Team. In case of fire, smoke detectors, fire alarm and emergency light will activate in every
floor.
The factories do not use any pins and staples in production. Factory has sealed containers in all
sections for metal disposal. An inventory of tools boxes in all sections. Sharp tools inventory
control chart for all department is readily available. All trimmers, points, scissors are secured
to the working table .No hazardous instruments are being used in the work place.
To safe guard workers from any accidents / job related injuries, plant equipment such as
electric generator, machine guard, gas boiler, electrical fitting and etc. Are checked
periodically, Emergency lights are tested weekly and records maintained. All boiler operators
are trained by the local bureau and have certificates of training as well as Boiler Operator’s
License.
Machine operators are always wearing gloves for protection. No dangerous chemical or fire
hazardous substance is kept in the Factory. Moreover, personal protective equipment such as
gloves goggles, facemask, etc. are also provided to undertake any aspect of the work safety. All
rotating or movable parts of sewing machines are pulleys have guards. Management has
ensured such machinery / equipment’s are properly guarded & pictorial signage is posted.
Health & Medication
I. Health Attendants:
Factory has a full time Doctor and Nurse. A proper First Air Team is being trained by Doctor.
Qualification of the Doctor, Nurse & First Aid Team are readily available in the factory.
Furthermore, a registered physician provides health screening, age certification and counseling
on hygiene to all the workers on a routine basis.
First Aid box is available in all departments and usage records are kept. Selected workers and
line supervisors have been trained to the factory workers.
workers are taken to the hospitals. Any injury/accident of the workers that take place in the
factory are properly documented in a register with their name, section, date and cause of the
injury/accident and preventive measures are taken and recorded as well.
The management of Step Media Limited believes in transparency and integrity. As such we are
open to the bank and thus, we are providing our personal net worth with the documents so
that the bank can get to know the ins and out of all the directors.
In order to availing and maintaining credit facilities from time to time in any from whatsoever
with NBL, the understanding submit (s) the following Personal Net Worth Statement which is
true and accurate.
Total 73,00,000/-
● Real State (Unencumbered):
Schedule - B
Area of Land & Market Price
Location Building With Mortgage
detailed with Lan Building Total
Description d
Diakhali, Goran,
16.24 Decimal,
Ashulia, Savar, 1,62,40,000/-
Development Land
Dhaka
Total 4,79,90,000/-
Total 3,07,50,000/-
Liabilities Assets
In order to availing and maintaining credit facilities from time to time in any from whatsoever with NBL,
the understanding submit (s) the following Personal Net Worth Statement which is true and accurate.
Mercantile Bank
Limited SOD 14,00,00 04.10.09 13,80,000/- DPS
Bijoynagar Branch,
0/
Dhaka
-
NRB Commercial
Bank Ltd, Banani SOD 50,00,00 31.03.15 47.82,000/-
Branch
0/
-
Total 61,62,000
Total 2,05,,00,000/-
Liabilitis Assets
Payable to the Bank/ Financial
a. a. Cash in Hand Tk. 5,00,000/-
Institutions ( Schedule-A)
In order to availing and maintaining credit facilities from time to time in any from whatsoever with NBL,
the understanding submit (s) the following Personal Net Worth Statement which is true and accurate.
Mercantile Bank
Limited SOD 11,74,000/ 25.01.12 01.04.14 10,00,000/- DPS
Bijoynagar Branch,
-
Dhaka
Total 15,56,000/-
Total 1,55,,00,000/-
Liabilities Assets
a. Payable to the Bank/ Financial a Cash in Hand Tk. 1,00,000/-
Institutions ( Schedule-A) .
Secure TK15,56,000/- b Cash with MBL ( Mercantile TK. 2,00,000/-
. Bank Ltd.)
In-secure TK. c Cash with other Bank TK.
.
Sub-Total TK.15,56,000 d Sub-Total TK.3,00,000/-
/- .
b. Other Creditors TK. e FDR/Financial obligation TK.10,00,000/-
.
c. Unpaid Tax TK. f. Investment MBL DPS TK.9,00,000/-
Govt. Security TK.
Shares, Debentures, Bond, etc. TK. 2,00,000/-
Digital Printing
SOLVENT BASED
Speed and Efficiency: Solvent printers are generally faster than water based at producing.
Usually 25-50% more efficient than water based. Solvent printing is geared more for
production and is an industrial type machine. They also have wider in diameter and higher in
weight media capacity. Cost of Ownership and Consumables: Solvent printing technology is
designed every day, long-term high volume production runs. They are built to last, total
workhorses! Solvent inks cost LESS than water-based inks; this is a substantial savings
considering it's the most expensive consumable you purchase! Inkjet media like canvas and
paper is one more cost savings component. This varies of course with the quality of the
substrate, and if there's an inkjet coating layer applied to the base. Solvent ink does not require
an inkjet receptive coating, but it will indefinitely improve the output.
No Coating Saves Time and Money: there's no top-coating necessary with so is the
most important advantage solvent inks have over water based! You print onto canvas, you
wrap your prints, you ship the canvas prints. There's no post treatment with top-coating
canvas prints. You eliminate a huge step of production, perhaps the longest step if you include
lamination dry time for every print. And of course, the waste incurred on canvas with coating
rejects, or the trial and error with rolling and spraying liquid laminates.
WATER BASED
Extremely Soft Print, Cleaner Prints over Seams, or uneven surfaces Eco-friendly, contains no
harsh chemicals, can be used on Foil applications to add color to the design, Good washable,
long lasting, Creates good distress and vintage effects.
UV BASED
UV inks offer many benefits such as being more environmentally friendly than solvent-based
inks, good opacity, light-fastness, resistance to smearing, sharp contrast, and a nice gloss. The
UV inks, again because of the lack of evaporation agents, will maintain consistency throughout
the whole press run, never getting thick or sticky. Even water-based inks often use chemical
catalyst components that require harsh cleaners to remove, when cleaning the printing
equipment. Cleaning must be done on a regular basis to prevent the plugging of the printing
cells, leading to high costs over time. Thus, UV inks save time, money, and environmental
waste by greatly reducing the need for cleaning.
Information Technology
We use the term information technology or IT to refer to an entire industry. In actuality,
information technology is the use of computers and software to manage information.
In some companies, this is referred to as Management Information Services (or MIS) or simply
as Information Services (or IS). The information technology department of a large company
would be responsible for storing information, protecting information, processing the
information, transmitting the information as necessary, and later retrieving information as
necessary. We customized it for door to door users. Suppose, you have thousands of
signage of hundred products in nationwide, various visuals on it, various size of it; how can
you manage its information? We can provide you customize software, manpower of operate it!
Is it wonder?
Creative Design
INTERIOR DESIGN
Interior design is the process of shaping the experience of interior space, through the
manipulation of spatial volume as well as surface treatment. Interior Design draws on
aspects of environmental psychology, architecture, product design and furniture design in
addition to traditional decoration. We have a team to design your dreamed Interior and also
they can execute it really.
EXTERIOR DESIGN
Outside space do not need to be decorated as inside as it's used by us from time to time.
Nonetheless it may be refurbished because it is where sunlight permeates with no difficulty.
We are able to have parties along with other household function within the space because it
provides natural and enjoyable atmosphere to the valuable visitors. We, the Step Media are
using the term Exterior Design and Decoration in sense of exterior branding. We are the
pioneer of branding you through use of the exterior side of your home.
POP
In the retail world, "POP" is used to refer to point-of-purchase advertising displays. POP
displays can take various forms, including shelf-mounted signs, hanging posters, and more.
Since an estimated 70% of purchase decisions are made within the retail store itself, effective
POP displays can have a dramatic impact on sales for a particular product category or brand.
Recently, static signs have begun to give way to electronic, dynamically updated point-of-
purchase displays that present targeted product information, instant coupons, and more.
Marketing materials or advertising placed next to the merchandise it is promoting. These items
are generally located at the checkout area or other location where the purchase decision is
made. It's Also known as Kiosks, End caps, Point of Sale Display. We provide you the world
class POP display items by using latest technology and machinery of the era.
GRAPHICS SOLUTIONS
We can provide you the following Graphics Solutions as per your needs:
IDENTITY DESIGN
Branding
Logo design
Visual identity
PRINT DESIGN
Annual reports & collateral Book
layout & design
Brochures & postcards
Business cards & stationery
Catalogs & direct mail
Magazine ads & layouts
Marketing kit design & layout
Media packets & Product sheets
Newsletters & Flyers
Package design
Signage & displays Calendar
EVENT DESIGN
Event invitation design
Event promos & marketing
collateral Multimedia presentations
Slideshow presentations
Trade show displays
Website design & build
CONTENT DEVELOPMENT
Copy editing services
Information graphics
Photography & digital imaging
Event & Activation
Audiences gather for all sorts of reasons in today's business world. Whether your team is
managing the event, working with it as a sponsor, or simply attending as a booth vendor, our
expert staff knows how to encourage, manage, and cultivate the digital conversation that
is relevant to your business. We believe that an event activation strategy is a three-step process
with many tactical elements; pre-event implementation, on-site execution, and post- event
follow-up.
We examine how attendees, sponsors, speakers, industry peers, vendors, and journalists
interact online and offline, looking for methods of distributing your brand message to specific
target audiences and then capturing relevant inquiries for your business. At the event level
this allows us to examine individual components and match them to like-minded
organizations at the event. It also includes researching how similar events gather audiences to
help our client’s strategist around trending topics and drive attendee interest. At the company
level it allows us to develop strategic plans to capture topical interest, gain additional
exposure, and competitively place themselves into the right opportunity. Our goal is to be
faster, nimbler, and properly positioned with target audiences to win market share.
Branding
BRANDING SOLUTIONS
Solutions for Banners, Advertising Boards, Display Hoardings, Window Graphics, Floor
Graphics, Lamppost Banners, Directional Signage.
SIGNAGE
Signs are any kind of visual graphics created to display information to a particular audience.
This is typically manifested in the form of way finding information in places such as streets or
inside/outside of buildings. We can provide Signage with backlit reverse print, Non lit
signage, Banner sign, Billboard, Channel Letters Sign, Complex outdoor sign, neon and
lettering, Complex outdoor sign, sheet metal with lettering, reversed impression lettering,
Digital Signs on LCD, Plasma, LED or similar forms of display, Distributors advertising sign,
metal, lettered, Distributor advertising sign, neon, Exterior wall sign, lettered, Handheld sign,
Hanging sign, lettered, Hanging sign, multi-listing, Interior wall sign, lettered, Lettering on
glass, Lettering on vehicle side(s), Vinyl sticker lettering, Wood sign, dimensional:
engraved, carved, sandblasted, Wood sign. We can also brand your product by signage
through:
Way Finding
Building Branding
Retail Branding
Transport Branding
Logistics & Services
39
CHAPTER TWO
Before we go deep into the mentioned topics we need to understand what PVC is all about.
Plastics are also called synthetic resins and are broadly classified into two categories;
thermosetting resins and thermoplastic resins. The thermosetting resins include phenolic
resin and melamine resin, which are thermally hardened and never become soft again.
Thermoplastic resins include PVC, polyethylene (PE), polystyrene (PS) and polypropylene
(PP), which can be re-softened by heating.
Usually, thermoplastics are supplied in the form of pelletized material (compounds) with
additives (antioxidants, etc.) already blended in it. However, PVC resin is often supplied
in powder form and long term storage is possible since the material is resistant to oxidation
and degradation. Various additives and pigments are added to PVC during the processing
stage, and the blend is then converted into PVC products. PVC is sometimes known as ‘Vinyl’
in Europe and predominantly so in North America. In Europe, ‘Vinyl’ usually refers to certain
specific flexible applications, such as flooring, decorative sheets and artificial leather.
PVC is a thermoplastic made of 57% chlorine (derived from industrial grade salt) and 43%
carbon (derived predominantly from oil / gas via ethylene). It is less dependent than
other polymers on crude oil or natural gas, which are nonrenewable, and hence can be
regarded as a natural resource saving plastic, in contrast to plastics such as PE, PP, PET and
PS, which are totally dependent on oil or gas. This chlorine gives to PVC excellent fire
resistance: when PVC is set on fire, the flames go out as the fire source is removed due to the
material’s self- extinguishing properties.
40
History of PVC
Man has worked hard from the earliest times to develop synthetic materials which would offer
benefits not found in the natural products around him. PVC is one of the oldest synthetic
materials with the longest history in industrial production. Its early history is of multiple
and accidental discovery in different places at different times as well as unsuccessful quests for
commercial application.
Early researchers accidentally discovered PVC on at least two occasions in the 19th century.
The first, in 1838, was by the French physicist and chemist Henri Victor Regnault and the
second in 1872 by the German Eugen Baumann. On both occasions, the polymer appeared as a
white solid inside flasks of the newly discovered vinyl chloride gas that had been left exposed
to sunlight. The material was difficult to work with and no one mastered the challenge of
commercial applications. In 1913, German inventor Friedrich Heinrich August Klatte took
out a patent on PVC. His method used polymerization of vinyl chloride with sunlight. The
most significant breakthrough occurred in the United States when the company BFGoodrich
hired the industrial scientist Waldo Semon to develop a synthetic replacement for the
increasingly costly natural rubber. His experiments again produced polyvinyl chloride.
However, the material was threatened by the recession in the 1920s and it was under threat of
abandonment that Semon conceived the idea of PVC as a water resistant coating for fabrics.
Sales took off quickly with a rapidly expanding product range. Demand accelerated again
during the Second World War, when PVC quickly replaced traditional material to insulate
wiring on military ships.
During the 1950's many more companies started to produce PVC and volumes increased
dramatically around the world. Developers quickly found further, innovative uses through the
decade and refined methods to enhance durability, opening the door to applications in the
building trades. By the middle of the 20th century, five companies were producing PVC, and
ground-breaking uses for PVC, or ‘vinyl’ as it is also known, continued to be found during the
1960s. A vinyl-based latex was used on inflatable structures and fabric coatings, and at the
same time, methods for improving PVC's durability were developed, allowing applications in
the building industry.
PVC products rapidly became essential to the construction industry; the plastic's resistance to
light, chemicals and corrosion made it the best option for building applications.
Improvement made to the materials’ resistance to extreme temperatures, allowed for PVC to
be transporting water to thousands of homes and industries. By the 1980s, twenty companies
were producing PVC. Today, PVC is the third largest-selling commodity plastic in the world
after polyethylene and polypropylene. PVC's low cost, excellent durability and
processability, make it the material of choice for dozens of industries such as health care, IT,
transport, textiles and construction.
How is PVC made?
The chemical process for making PVC involves taking the simplest unit, called the
monomer, and linking these monomer molecules together in the polymerisation process.
Long molecular chains are formed called polymers (which are also called macromolecules).
This is the case for PVC, which is made from vinyl chloride monomer known usually by its
initials VCM through polymerisation. Some monomers exist in the form of reactive gaseous
chemical substances, and some of these may cause health hazards when in direct contact
with humans. In these cases they are manufactured and processed under strict control for
health, safety and environmental protection. On the other hand, polymers such as PVC, which
are manufactured from monomers through polymerisation, are solid and chemically stable
substances, therefore do not affect human health. VCM, which is the raw material for PVC, is a
gas at ambient temperature but is usually stored in liquid form under pressure. Ethylene
and chlorine are raw materials for PVC. Upstream industries are those that provide these
materials and include producers of basic petrochemicals (sometimes known as feedstocks’),
which supply ethylene, and the chlor-alkali (caustic soda) industry, which supplies chlorine.
This is not used alone, but blended with other ingredients to give formulations for a wide
range of products. The chemical process for making PVC involves taking the simplest
unit, called the monomer, and linking these monomer molecules together in the
polymerisation
process. Most commodity plastics have carbon and hydrogen as their main component
elements. PVC differs by containing chlorine (around 57 per cent by weight) as well as carbon
and hydrogen. The presence of chlorine in the molecule makes PVC particularly versatile
because it makes it compatible with a wide range of other materials.
The chlorine content also helps to make PVC flame retardant. It can also be used as a
`marker' to distinguish PVC in automatic sorting systems for plastics recycling. PVC
formulations can be shaped by a variety of techniques and, using very little energy, made
into the final product form. PVC polymer is chemically stable, neutral and non-toxic.
PVC formulations have a wide range of applications including the most sensitive, such as
medical equipment, plus construction, automotive and electrical cabling.
How is PVC Used?
PVC is one of the most used plastic materials in the world. At global level, demand for PVC
exceeds 35 million tonnes per annum and it is in constant growth (+5% on global average),
with higher growth rates in the developing countries.
In Europe (EU-27), the production of PVC products – including exports – totals about 8 million
tonnes per year. European PVC resin consumption totals some 6.5 million tonnes per year, or
15% of all plastics use in Europe, with an average growth of 2-3% per year.
PVC products make life safer, more comfortable and more pleasurable. And, because PVC
has an excellent ratio of economic cost to performance, it allows people of all income levels
access to these important benefits.
The diversity of PVC applications challenges the imagination. In everyday life, they are all
around us, from construction profiles to medical devices, from roofing membranes to credit
cards, from children’s toys to pipes for water and gas.
Few other materials are as versatile or able to fulfil such demanding specifications. In this
way, PVC facilitates creativity and innovation, making new possibilities.
PVC underpins safety
Wire and cables sheathed with PVC prevent potentially fatal electrical accidents. In hospitals
around the world PVC medical tubing – which does not break or kink – delivers fluids and
medicines to the sick.
PVC is one of the most used plastic materials in the world Car components which use very
strong PVC can reduce the risk of any injuries being caused in case of an accident. Most PVC
products are long lasting – up to and over 60 years. These applications are reliable
throughout their service lives and cut down vastly on maintenance or repair. Modern cars, for
example, last many years longer simply because PVC protects the underside from water and
corrosion.
Functional performance is by no means the whole story. PVC has a distinguished role in
beauty and aesthetics. In fashion, furniture and all types of indoor and outdoor accessories,
PVC opens up functional and design opportunities that are both visually striking and
fundamentally practical.
In short, people everywhere benefit from this material. Sometimes invisible but always
reliable, PVC products make the difference when it counts.
PVC has a versatility that helps it meet the various needs of modern architecture. In addition
to new projects, PVC is also widely used in refurbishment where it often replaces traditional
materials such as metals and wood.
Key properties:
Easy to install
PVC can be cut, shaped, welded and joined easily in a variety of styles.
Durable
PVC is resistant to weathering, rotting, chemical corrosion, shock and abrasion. It is
therefore the preferred choice for a range of customers for many different long-life and
outdoor products. In fact, medium and long- term applications account for some 85 per cent of
PVC production in the building and construction sector. For example, it is estimated that
PVC pipes will have potential in-service lives of up to 100 years. In other applications such as
window profiles and cable insulation, studies indicate that over 60 per cent of them will have
working lives of over 40 years.
Cost-effective
PVC has been a popular material for construction applications for decades due to its physical
and technical properties which provide excellent cost-performance advantages. As a
material it is very competitive in terms of price, this value is also enhanced by the properties
such as its durability, lifespan and low maintenance.
Environmental Impact.
Excellent thermal insulation of PVC windows, cladding and roofing helps to significantly
increase the energy efficiency of buildings. PVC piping systems help prevent leakage and
their exceptionally smooth surfaces reduce the cost of pumping fluids. PVC products require
comparatively less energy and resource use during production, as well as in conversion to
finished products. They are lighter than those made of concrete, iron or steel requiring less
energy (and thus fewer emissions) to transport and install. PVC piping systems help prevent
leakage and their exceptionally smooth surfaces reduce the cost of pumping fluids In lifecycle
analyses and independent studies, PVC’s environmental impact has been found to be
favorable when compared with other manufactured materials used for construction. PVC
products are also so durable that frequent replacement is unnecessary. And, as a
thermoplastic, at the end of one use, PVC is relatively straightforward to separate from other
plastics and then can be easily recycled into new applications. Well-established schemes
ensure that a large proportion of PVC used in construction applications, such as pipes,
window profiles and flooring are now recycled at the end of their useful lives.
And additional recycling facilities for waste PVC construction materials are being developed
each year across Europe. If not recycled, it is possible to recover energy from PVC by
incineration. PVC can also safely be deposited in landfill if no recovery solution is available.
Safe
PVC is a non-toxic inert polymer. It is a socially valuable resource that has been used for more
than half a century. It is also the world’s most researched and thoroughly tested plastic. It
meets all international standards for safety and health for both the products and applications
for which it is used.
In the beginning of the sixties this resulted in a revolution within the health care sector. The
PVC based devices improved medical safety by reducing the risk of life-threatening
infections caused by the multiple-use of traditional devices.
The two main application areas for medically approved PVC compounds are flexible
containers and tubing: containers used for blood and blood components for urine or for
ostomy products and tubing used for blood taking and blood giving sets, catheters, heart-lung
bypass sets, hemodialysis set etc. The PVC based devices improved medical safety by
reducing the risk of life-threatening infections caused by the multiple-use of traditional devices
Historically, PVC was introduced into flexible tubing and containers as a replacement for
natural rubber and glass. It began to dominate the market when the need for single use pre-
sterilized components became recognized. PVC is the most widely used thermoplastic material
in medical devices due to its:
Safety
Before medical devices can be used all the components must be fully understood from a
toxicological point of view. Consequently, all the materials used to make such components
have to be thoroughly tested and assessed in the EU before being accepted. Experience
based on all available knowledge from international environmental and healthcare authorities
shows that PVC is safe. It is the best material existing today which optimizes all performance
and safety requirements at lowest cost.
Chemical stability
Material used in medical applications must be capable of accepting or conveying a variety of
liquids without themselves undergoing any significant changes in composition or properties.
Bio compatibility
Whenever plastics are used in direct contact with the patient’s tissue or blood, a high
degree of compatibility is essential between the tissue/blood and the material.
The significance of this property increases with time over which plastic is in contact with the
tissue or blood.
Sterilizability
The absence of sources of infection is a fundamental requirement in medical product
applications. PVC products can be easily sterilized using such methods as steam, radiation or
ethylene oxide.
Compatibility
PVC is compatible with virtually all pharmaceutical products in healthcare facilities today. It
also has excellent water and chemical resistance, helping to keep solutions sterile.
Resistance
to chemical stress cracking PVC's resilience helps assure that medical products function
consistently, for extended use, in demanding applications.
This versatility is a major reason why PVC is the material of choice for medical product and
packaging designers.
Low cost
The use of PVC plays a big role in containing rising healthcare costs. With PVC accounting for
almost one third of medical plastics currently in use, a switch to an alternative could cost the
healthcare community hundreds of millions of euro.
No less important for the wide variety of applications of PVC are its printability, its
transparency or translucency as required by the application, its low tendency to form micro
voids (significant for gloves) and its gloss.
These qualities help to maintain the safety of patients and medical staff, while also limiting the
cost of healthcare. Indeed, PVC is the best material to meets the performance, safety and cost
criteria for a wide variety of medical applications today, especially those intended for single
use.
As a result, almost one third of all plastic-based disposable medical devices used in
hospitals are made from PVC.
In addition to its specific healthcare benefits, PVC's very versatile properties mean that it is
used in a broad range of other applications. For example, within a hospital it may be used in
water and drainage pipes and in fire resistant cabling in electrical and telecommunications
equipment.
Flooring in operating theatres - PVC helps eliminate cross-infection due to seamless joints
PVC coated mattress covers - hygienic and easy to clean
Easily fabricated oxygen tents, relying on the welding characteristics of PVC combined
with good transparency.
Furniture covered by a PVC film is easy to clean and helps reducing the risks of infection
Sustainability
PVC plays a major role in delivering and sustaining the quality, comfort and safety of
modern life-styles. Its impressive ratio of cost to performance also means that people of all
income groups can enjoy these benefits. High living standards are not just about the present,
however. Future generations also have the right to material and other benefits. This is the
foundation of the concept of ‘Sustainable Development’. PVC products are already helping
every day to improve people’s lives and conserve natural resources in a world that is
growing in population, with ever-increasing demands for water, food, shelter, sanitation,
energy, health services and economic security.
55
PVC is used in various fields ranging from essential services (water supply, sewage, supply
of electric power, etc.), housing, transportation, consumer products, and electronics, to
medical devices and products. The applications are generally divided on the basis of the
hardness of products, e.g., rigid, flexible. PVC products feature most prominently in those
requiring long service lives. A well understood material PVC is a synthetic material derived
from natural resources (oil and salt) like many others used in our modern world, and is one
of the most scientifically investigated substances on the planet. And investigations have
consistently found that far from being the problem material that some NGOs have portrayed
it to be, science indicates that It is not very different from other materials and indeed
posseses some interesting natural advantages.
With a lower carbon footprint The magnitude of CO2 emission for the material we use
throughout its lifecycle, from production to consumption and disposal, is an important
factor when considering the global warming issue. PVC is proven as a material with minimal
environmental load in terms of CO2 emission, when compared with metal or glass products
of the same application .The carbon foot print of PVC also compares favourably against
other polymers requiring relatively less energy in production due to the manufacturing
process of its raw material, VCM. According to the results of eco-profiles published by
PlasticsEurope – the association which represents all plastic material producers – PVC
requires only about 80% of the energy required for production of other major polymers. This
has positive environmental effects, such as fewer CO2 emissions from production processes.
PVC products can also contribute significantly to energy efficiency through low thermal
conductivity. PVC window profiles have three times the heat insulation efficiency of
aluminium profiles. They cut down energy consumption for heating and air conditioning.
That uses less natural resources to make 57% of PVC is made out of chlorine, which is
derived from common salt that is abundant on earth. Therefore PVC contributes significantly
to saving oil, which is a nonrenewable resource, in contrast to other plastics whose
composition depends entirely on oil. Usefully durable and 100% recyclable Plastics are
often perceived as symbols of throwaway or single use. However, in reality plastics are
durable materials that do not rust or corrode. PVC is an exceptionally durable plastic, used
for instance in water supply and sewage pipes, which can be used for over 50 years. Most of
PVC products are used in durable applications. More than half of all PVC products are long
life products with service lives of over 15 years
PVC is a material well-suited to recycling. It has the longest history of recycling among
plastics, and it is most advanced in mechanical recycling. For example, in Japan about 50% of
56
end-of-life agricultural films (agro-films) is recycled and used for flooring, etc. In Europe, more than
150,000 tons of post-consumer products were recycled in 2007 through industry-sponsored schemes.
All materials, and PVC is no exception, have sustainability issues, arising from both from their specific
properties but also from the ways in which they are used and disposed of across the life cycle.
Where PVC differs from other materials is that the PVC industry perhaps has a better understanding of its
product’s sustainability than manufacturers of most other synthetic materials; and is working systematically
to address these to ensure that it will continue to play a useful role in a more sustainable future for
mankind.
In 1999, the PVC Co-ordination Group (UK) commissioned a study of the industry from The Natural Step
Office in the UK. As a parallel exercise, The Natural Step in the UK, in collaboration with the Environment
Agency, ran a ‘2020 Vision’ to broaden the debate and work towards consensus.
PVC Flex Banner. PVC material is made up of PVC and polyester. PVC or Polyvinyl chloride banners are
commonly referred to as vinyl banners. It is used as vinyl siding and outdoor advertising.
Coated Frontlit Flex banner; PVC coated polyester fabrics; Is applied for solvent-based inkjet printing, Der's Frontlit
is feathered by good flat surface, superb reflet, high tensile and tear strength, good ink absorption and so on, the high
quality guarantee the printed image clear and vivid.
Feature:
1) Glossy and Matt type available
2) White substrate for wide format digital printing
3) Applicable to Vutek, Scitex, Nur, Infinity, Flora, etc.
4) Weather resistant (UV, rain and frost)
Seamless Application:
1) Billboard (frontlit)
2) Displays (indoor and outdoor)
3) Banners
4) Building murals and instore displays
5) Exhibition booth decoration
Specifications:
1) 1000D X 1000D, 20 X 20, 550GSM
2) Width: 1.60-3.20m
3) Length: 50m or customized.
Features:
1. High strength
2. Weather resistant
3. Waterproof
4. Self-cleaning
5. Good smoothness
6. Perfect printing ability
7. Best color fastness
8. Gloss or Matt available
9. Customer's requirement available
Application:
1.Digital printing on Vutek, HP, Nur, Roland etc, as well as screen printing.
2. For large format indoor and outdoor advertising, banner, posters.
3. Display (indoor or outdoor), billboard, exhibition booth decoration.
4. Building murals and in store display.
Features:
1. All PVC flex banners are printed at high resolution 1440dpi for quality print.
2. Hem and eyelets on all sides as standard with flex Banner.
3. Eyelets equally spaced to make your banner look neat and hang straight.
4. Quality flex banner material for strength & durability.
5. Printed with full solvent plain stable waterproof inks for maximum life.
Global PVC Demand to Grow 3.2% Annually Thought 2021
Global demand for polyvinyl chloride (PVC) is expected to increase about 3.2% per year until 2021,
according to market research organization Ceresana.
PVC is a key product of the chemical industry and, along with polypropylene and polyethylene, one of the
most widely produced plastics. Approximately 39.3 million tonnes of PVC were consumed globally in 2013.
Asia-Pacific has 56% of the global market share, making it the largest sales market. The report says this
market is also poised to see the strongest growth in the foreseeable future. North American and Western
European markets have returned onto a growth path after incurring severe losses in previous years.
The construction industry is the prime sales market for PVC products. In China, while there has been some
slowing, construction continues to grow at higher rates than in most other countries.
In India, which Ceresana calls one of the world PVC market's "growth motors," demand is expected to
increase 4.9% per year.
The United States suffered from weak domestic demand in recent years, but is seeing local demand for
PVC products rise again, thanks to positive developments in the construction sector.
In Western Europe, the research firm said that crisis-affected countries on the Mediterranean Sea seem to
have touched bottom. It views markets in Germany, France, and the United Kingdom as comparatively
stable.
Overall Western European consumption of PVC is projected to rise again by approximately 1% in the
coming years.
United States PVC producers have offset low demand at home by considerably increasing their export
volume. Feedstock prices in the U.S. have come down notably, thanks to the shale gas boom; U.S.
manufacturers have the opportunity to capitalize on low prices when competing internationally.
Europe's weak demand has led to a dynamic industry in recent years. Small and medium PVC producers
have largely been acquired by competitors or have disappeared from the market. in some countries, such
as Italy, PVC production has ceased altogether. Some large-scale manufacturers, such as Arkema, sold their
PVC business. Producers Solvay and INEOS merged their divisions, and the joint venture Inouye is
scheduled to be operational at the end of 2014. The research firms sees this move, which establishes the
largest European PVC manufacturer, to be another sign of increasing pressure for market concentration.
Capacity utilization in North America and Western Europe is very high, while Asia-Pacific still has notable
excess capacity. China, the world's largest PVC producer, is able to increase output to satisfy increasing
domestic demand. Chinese producers mainly rely on coal-based vinyl chloride to make PVC; other
countries, like the United States, use only ethylene-based vinyl chloride.
Pipes and conduits are the most important PVC products. PVC is also used for plastic profiles and
films/sheets. PVC is also used in cables and cable sheathing, floorings, automotive coatings, medical
products such as infusion bags, and shoes.
The research firm expects development of individual application areas to remain balanced in the next eight
years. It reports that Asia-Pacific countries, particularly India and China, as well as the Middle East, produce
large amounts of PVC pipe. Turkey and Russia have high output share of profiles. In Germany, as well,
most PVC output goes into producing profiles. The German market is being buoyed by a boom in
refurbishing for energy efficiency.
Global Market Demand has witnessed continuous growth in the recent years. The market demand has
increased from 38.3 million tons in 2013 to 41.3 million tons in 2016.
Increasing demand from end segment markets (construction, automotive, packaging, footwear & medical
etc).
Their unique properties (high performance, lightweight & durability) increase their demand from
different sectors.
Continuous research & innovation for usage of this material in different forms or as the replacement also fuel
the market demand.
Per Capita Consumption of PVC (In 2016)
In the year 2016 Global Per capita Consumption for these plastic materials was up to 5.5 kg per capita.
Asian-pacific regions have the maximum contribution in the global consumer market among which China
& India have the largest share. Per capita consumption of China in 2016 was 12 kg per capita and India
contributed 2.5 kg per capita.
The other two prominent European countries selling this polymer globally are Hungary with sales of 275.09
kilo tons in 2016 followed by the UK with sales of 246.87 kilo tons.
It the third most produced and consumed the type of polymer after polypropylene and polyethylene.
Demand for these plastic resins have increased over a period of time and is expected to increase in near
future with an increased growth rate.
The global market demand is expected to more than US$ 68bn by 2020.
These materials involve a wide range of applications including electric cables, pipes, furniture, healthcare,
fiber, and clothing. They are also being used in a number of daily use products like bottles, credit cards,
films & packaging etc.
Why is PVC the most Preferred Material?
It is an ideal choice for producing a variety of daily use goods due to its good impact strength and
weatherproof quality.
It has a number of approvals to be used for consumable and medical products (especially European
countries).
They are long lasting, tough and offer ease of processing to manufacturers.
These polymers consume less amount of energy during the production process as compared to their
competition plastics.
It has smaller carbon footprint which means the carbon dioxide impact of these materials is less than other
resins.
They offer a high amount of clarity and excellent organoleptic properties which make them an ideal choice
for packaging goods (especially consumables).
Even the windows made from these materials are energy efficient and help to cut energy bills.
Lastly, they are fully recyclable which helps to maintain environmental balance.
Applications of PVC
It is a versatile form of polymer applicable for a variety of end segment industries due to its suiting
physical, chemical and mechanical properties. The uses of this material vary from windows, roofs, blood
storage and automotive interiors to synthetic and coated fabrics.
Some of the prominent uses of these plastic polymers in products of different end segment industries are:
Construction Sector
Nowadays it is most commonly used the material in the commonly used material in construction sector
because of its low production cost, ease of processing & is also lightweight. It is widely used as a
replacement for metal in a number of construction activities to avid corrosion and keeps the maintenance
cost low.
Properties of this material like strength, durability, lightweight, resistance and availability at an economical
price make it an ideal choice in the construction sector to be used as windows, doors, pipes, and others.
PVC Pipes & Fittings -The most commonly used pipes and fittings globally for sewage, industries, housing
and drinking water supply are polyvinyl chloride pipe. Half of the pipes produced are consumed by
municipal & industrial.
These pipes are fused together with various solvents in a fusion process which help to create permanent
joints to avoid any kind of leakages.
Electronics Market
Nowadays these resins are commonly used as the insulation on electric cables. It was first used in cables as
a replacement of rubber during The Second World War and is being still used due to its flexibility, flame
retardation, ease of handling & installation.
The cables made from these materials do not crack easily and are used in a wide range varying from
telecommunications to electric blankets.
Healthcare
It is being used in a number of life-saving product for more than half a century. These materials are widely
used in surgeries, pharmaceuticals, drug delivery devices and packaging due to its suitable properties and
high performance.
Examples of products used in healthcare industry produced using these plastic polymers:
Instrument panels
Interior doors & pockets
Sun Visors
Seat Coverings
Mud Flaps
Sports bags
Underbody coatings
Sports
As it is a versatile plastic polymer with unique properties it even has its applications associated with sports
in different forms. It is used on a large scale in construction sports venues. It includes seating, roofing,
flooring also piping and electric wiring in stadiums.
Apart from construction activities associated with sports, it is also used in clothes and shoes of athletes
also in the equipment used in different sports.
These sheets & films are used for producing commercial signage boards and other products including car
body stripes or stickers etc.
Clothing
These plastic resins have also made their ways in clothing & fabrics industry as they are water resistant,
durable and wrinkle-free materials.
They are used in coats, jackets, shoes, aprons, skiing equipment and clothes. It is also being used widely to
create artificial leather materials as it is less expensive than original leather or latex.
Other Applications
Other applications include home playgrounds, foam, toys, greenhouses, tarpaulins and other types of
interior claddings. It is even used in a number of musical instruments as it is cheaper than metal and has
better performance results.
Advantages & Disadvantages of Polyvinyl Chloride
This resin material is a perfect mix of desired properties for different kind of plastic products. This material
number of benefits to manufacturers which include:
It is Biocompatible
Offers clarity & transparency
Low thermal conductivity
Little or no maintenance is requiring
Cheap & readily available
Good resistance
Though it offers a number of benefits but also has some limitation involved with it which is:
It has poor heat stability and stabilizers are needed to maintain stability.
In its production process, it releases some harmful fumes and is also subjected to fire.
This is one of the major plastic polymer grades which are working toward sustainable development on a
very large scale. It offers a balanced kind of sustainability in all aspects of the environment which include:
Economic Sustainability
It is being used and manufactured globally on a very large scale, as a result, requires a huge amount of
human force. This material is proving employment to a number of people and help in maintaining
economic sustainability.
Social Sustainability
Manufacturing companies are providing the safe working environment, good quality homes, energy
efficient windows & safe drinking water to fulfill their social responsibility towards employees.
Environmental sustainability
Industries producing these materials have shifted their focus towards maintaining environmental stability
by reducing pressure on scarce resources. They are trying to recycle maximum number of products
produced to achieve balance in the environment.
Recycling
The structure and composition of the material allow itself to be recycled mechanically and produce good
quality products. They offer ease of recycling as they break down at low temperature and avoid
degradation in the recycling process.
Then plastics are cleaned to remove remaining dirt or liquid so that contamination is avoided.
Plastic is even sorted by their colors to achieve good quality recycled form.
Further, these used plastics are shredded into flakes and again washed
Lastly, the shredded form of plastic is melted into granules or pellets to be reused.
Recycling of these polymers can help to reduce dependence on the number of natural resources including
oil and gases. It will also help to reduce landfill waste and release of harmful greenhouse gases into the
atmosphere.
It can be recycled into film sheets, fibers, strapping, flower pots, gardening equipment, toys, packaging
material, carry bags, containers & bottles and many other products.
CHAPTER THREE
MARKETING STARTAGY
STEP MEDIA’S success is built on its core values of sustainability, quality and leadership
and the entrepreneurial boldness of the promoters.
Our strategy is to grasp three hallmarks that will enable us to capture leading positions in the
industry:
THREE MOTIFS
Leading Industry
We look to expand our leadership role in the markets by leveraging our technical and creative
capabilities, scale and scope. These are critical disparities for sophisticated customers that
value the distinctive technical and service capabilities we offer. Step Media’s goal is to be the
supplier of choice by anticipating customers’ requirements and exceeding their expectations.
We will invest to develop and grow these businesses and enhance our ability to serve our
customers.
All Operations
Step Media aspires to achieve top-notch competitiveness. Operational excellence, including
health and safety, is at the core of our strategy. Technical and creative capabilities and the
diversity of our portfolio of businesses reinforce a strong commitment to institutional learning
and continuous improvement.
THREE KEYS
Responsible Attitude
Many of Step's businesses are located in regions that are in the early stages of economic
development. We recognize that we have an obligation to act responsibly towards all
stakeholders. Sustainability is a core value that underlies Step's efforts to be the best
committed company.
It is evident that the demand of the PVC Flex is growing more than 25% in a year. Bangladesh imported
4503 tons in 2015-16 which went to 9547 ton in 2017-18 which is around double. Our home demand is
growing at a very rapid scale but it is unfortunate that we don’t have any manufacturing unit in
Bangladesh and so we are totally dependent on import resulting huge flight of foreign currency every year
to meet up the importing needs.
Besides we have own consumption as we are involved in this line of printing business for the last two
decades. Our monthly consumption is around 100 ton having a yearly demand of 1200 ton which we
currently procure the same from home and abroad. Setting up of factory will ensure our consumption at a
lower cost resulting increase of profitability.
It is to be noted that in our country there are around 6000-7000 printing units who are in continuous
operation having a huge demand. Setting up the industrial unit here we can have the competitive
advantage. The business is dealt in cash, no credit at all. We would be able to take order and money first
and then prepare and give supply to our vast clients. So our market receivables in the beginning will be
very less which is very rare in case of dealing other business in Bangladesh.
It is noticeable that because of the China America business war we can get an advantage of exporting it as
our price would be far lower than that of the Chinese counterpart. So there is an ample scope of exporting
the goods to other neighboring countries in a bulk amount.
Moreover, we have a vast customer base in our country as we are involved in this line of business for a
long time. Our clients are ready to take products from us as they will get the quality product at a lower
price, in a minimum time frame and without any sort of banking or other hazard. And as we have a good
market reputation, our penetration in the market will be easier.
CHAPTER FOUR
4 Others 36,400,000.00
2,399,562,070 28,230,142
Total Project Cost
2,000,000/decimal
Auxiliary Machinery:
Total Price of the Machinery both Local & imported at USD 11,668,494.12
in BDT 991,822,000.00
Material Cost of Production:
Kgs Taxes
1 PVC resin LS100 E 75 97.96 97.96 7,346.85
2 Calcium Carbonate 90 15.98 15.98 1,437.82
3 Titanium Di Oxide 3.5 247.44 247.44 866.03
4 DOP 24 160.85 160.85 3,860.36
5 BCR - 3610 3 135 135 405
6 Lubricant 1 GMS 0.25 188.06 188.06 47.02
7 Blue MB 0.015 264.95 264.95 3.97
8 Violet MB 0.003 6,061.83 6,061.83 18.19
10 AC 316A 0 680.9 680.9 -
11 Epoxy Plasticizer 0.5 117.23 117.23 58.61
12 Ressol 0 70 70 -
13 Stabilizer 0.5 194.3 194.3 97.15
Total
Per Hour Total Production MT/
Per Day Working hour Total Production Production/
Production Month (72MT *26
for the Machine MT/Day (16*4.50) Year
Capacity(Piece) day working)
(1872*12
Motnhs)
Each day working day Machine for plant will be run in 16 hours
Raw Material and other Cost for - 3 months Cycle
Cost of Raw Cost Unit in Total Cost BDT/ Cycle Month Working Capital Total Required
Material / BDT Month(26 days) for Raw Material Working Capital
Month ( 3 months Cycle for Raw
) Material
Particulars Tied Up Period Per day End of 1st Year End of 2nd Year End of 3rd Year End of 4th Year End of 5th Year
(days) Unit Cost
Net Working Capital For Raw Materials 646,312,070.00 775,174,484.00 839,605,691.00 904,036,898.00 904,036,898.00
77
Total Cost of the Project
4 Others
36,400,000.00
2,399,562,070 28,230,142
78
PVE Panaflex Sales Amount at Rated Capacity
MT QTY Total ASP Total BDT QTY ASP Total BDT QTY ASP Total BDT
Capacity Per
Day (KG)
100% 1,000 72,000 243 17,496,000 1,872,000 243 454,896,000 22,464,000 243 5,458,752,000
capacity
Total
79
Machinery Cost & Means of Finance
Assets Cost Breakup in Taka Source of Fund Amount in Taka Source of Fund as %
Total Project Cost 426,000,000.00 1,283,472,000.00 1,709,472,000.00 631,478,956.80 1,077,993,043.20 1,709,472,000.00 37% 63% 100%
80
Debt Equity Structure in this Project against Machinery, Structure and Others
Fig. in BDT
Proposed
Particulars Amount
81
Financial Analysis
Income Statement
3rd Year 4th Year
Particulars 1st year 50% 2nd Year 60% 5th Year 70%
65% 70%
Capacity P 50% 60% 65% 70% 70%
Price (BDT)
2,729,376,000.00 3275251200 3548188800 3931200000 3931200000
COGS 2409264000 2594592000 2594592000
1,853,280,000.00 2,223,936,000.00
Gross Profit 876,096,000 1,051,315,200 1,138,924,800 1,336,608,000 1,336,608,000
Less-Admin 43356000 43,356,000 43,356,000 43,356,000 43,356,000
Less: Utility
6,000,000 6,500,000 6,500,000 6,500,000 6,500,000
Expenses
Less: Promotional
40,000,000 40,000,000 40,000,000 40,000,000 40,000,000
Expenses
Less: Depreciation
57400000 57400000 57400000 57400000 57400000
expense
Total Operating Cost 146756000 147256000 147256000 147256000 147256000
Total Operating
729,340,000 904,059,200 991,668,800 1,189,352,000 1,189,352,000
Profit
Profit Before
729,340,000 904,059,200 991,668,800 1,189,352,000 1,189,352,000
Interest & Taxes
Financial Expenses 344,800,000 344,800,000 344,800,000 344,800,000 344,800,000
Profit Before Taxes 384,540,000 559,259,200 646,868,800 844,552,000 844,552,000
Retained Earnings
288,405,000 377,499,960 412,378,860 538,401,900 538,401,900
for the year
Facility Structure:
Facility Structure:
Particulars of Proposed Term Loan Facility: Machinery & Building Structure LC Limit: To Import Capital Machinery
USD
To Import Capital
Machineries
B)
Term Loan
BDT 150,000,000
(Building Structure)
D)
Term Loan
BDT 500,000,000
(Machinery -Local)
LC Limit Sight/UPAS
BDT. 25,00,000.00
(To Import Raw
Materials and Spare
Parts)
LC Limit: Sight/UPAS 5%
F)
LTR Limit:
BDT. 22,00,000.00
To Import Raw
Materials
Margin 9%
6 months Revolving
Term Loan
BDT. 22,00,000.00
Margin 9%
Period --
Type Revolving
H)
Enhancement of
OD(G) Limit:
Note: It is assumed that the Working capital outstanding will be used as per the capacity
utilization of the project. So, the calculation of ROI has been done based on around 60%
capacity Utilization.
Summary of R.O.I.:
Const. year 1st year 2nd year 3rd year 4th year 5th year
NON- CURRENT
ASSETS:
Fixed Assets
1,709,472,000 1,709,472,001 1,709,472,002 1,709,472,003 1,709,472,004 1,709,472,005
at Cost
Depreciation
90
CURRENT
Const. year 1st year 2nd year 3rd year 4th year 5th year
ASSETS:
Total Current
1,074,319,840 1,230,788,640 1,309,023,040 1,424,775,840 1,434,775,840
Assets
TOTAL
2,726,391,841 2,825,460,642 2,846,295,043 2,904,647,844 2,857,247,845
ASSETS
91
SHAREHOLDER'S
Const. year 1st year 2nd year 3rd year 4th year 5th year
EQUITY:
NON - CURRENT
Const. year End of 1st year End of 2nd year End of 3rd year End of 4th year End of 5th year
LIABILITIES
UPAS L/C
0
Liabilities/Term
Loan
Total Non-
1,450,600,300 1,110,235,000 750,235,000 403,000,235 50,032,500
Current
Liabilities
CURRENT Const. year 1st year 2nd year 3rd year 4th year 5th year
LIABILITIES
Provision for
89,496,888 347,230,257 347,230,257 369,596,895 504,729,418
Taxation
Total Current
489,496,888 722,230,257 697,230,257 684,596,895 794,729,418
Liabilities
TOTAL EQUITY
& 769,496,971 2,429,594,076 2,554,695,514 2,144,695,514 1,772,194,025 1,639,491,336
LIABILITIES
Year wise
Working days 300 300 300 300 300
in a year
Year wise
Working hours 16 16 16 16 16
in a day
Yearly
Production in
13,478,400 15,724,800 15,724,800 16,848,000 17,971,200
Kg at rated
capacity
Yearly
sales at rated
capacity
utilization 3275251200 3821126400 3821126400 4212000000 4492800000
94
Key Financial Indicators
Fig in BDT
Gross
876,096,000.00 1,051,315,200.00 1,138,924,800.00 1,336,608,000.00 1,336,608,000.00
Profit
Total
Operating 729,340,000.00 904,059,200.00 991,668,800.00 1,189,352,000.00 1,189,352,000.00
Profit
Net Profit
288,405,000.00 419,444,400.00 485,151,600.00 633,414,000.00 633,414,000.00
/ Loss
Total
Current 1,074,319,840.00 1,230,788,640.00 1,309,023,040.00 1,424,775,840.00 1,434,775,840.00
Assets
95
Non-
Current 1,652,072,001 1,594,672,002 1,537,272,003 1,479,872,004 1,422,472,005
Assets
Total
2,726,391,841 2,825,460,642 2,846,295,043 2,904,647,844 2,857,247,845
Assets
Total Non
Current 1,450,600,300 1,110,235,000 750,235,000 403,000,235 50,032,500
Liabilities
Total
1,057,901,971 1,146,996,931 1,181,875,831 1,307,898,871 1,307,898,871
Equity
Total
Current 489,496,888 722,230,257 697,230,257 684,596,895 794,729,418
Liabilities
Total
2,429,594,076 2,554,695,514 2,144,695,514 1,772,194,025 1,639,491,336
Liabilities
96
Key Financials Ratios:
Operating
26.72% 27.60% 27.95% 30.25% 30.25%
Profit Margin
(in %)
Debt Service
0.34 0.50 0.70 1.16 1.84
Coverage
Ratio
Cash Flow Statement:
Fig in (BDT)
CF Before Investing
690,605,000 779,699,960 814,578,860 940,601,900 940,601,900
Activities
Less: Capital
Expenditures
98
CF Before Working
690,605,000 779,699,960 814,578,860 940,601,900 940,601,900
Capital Changes
Plus/Minus: Bills
682,344,000.00 818812800 887047200 982800000 982800000
Receivable
Plus/Minus: Change in
291,975,840 291,975,840 291,975,840 291,975,840 291,975,840
Inventory
Plus/Minus: Change in
20,000,000 25,000,000 30,000,000 35,000,000 40,000,000
Accounts Payable
Plus/Minus: Change in
Dividends Payable
CF Before
Intercompany 426,890,160 473,611,280 480,134,680 641,427,960 646,427,960
Transaction
99
Calculation: Break Even Point
Yearly Production in
Unit (KG) 22464000
at 100 Capacity
Production (KG) at
Rated 13478400 15724800 15724800 16848000 17971200
Capacity
Contribution Margin 78 78 78 85 85
Per Unit
100
Break Even Analysis:
Comments:
101
Sensitivity Analysis: 5% Decrease in Sales
Situation – 1: If Cost of Production is increased by 5% Amount in BDT
Operating 146,756,001.00
146,756,000.00 146,756,002.00 146,756,003.00 146,756,004.00
Expenses
Operating 629,099,840.00
500,207,200.00 693,796,160.00 863,062,400.00 863,062,400.00
Profit
213,224,880.00
Net Profit 116,555,400.00 261,747,120.00 388,696,800.00 388,696,800.00
Situation – 2: If Cost of Production is increased by 10% Amount in BDT
Expenses
Profit
CONCLUDING REMARKS
Sales Revenue:
Net Profit:
Net Profit of the Project is calculated after meeting up all operational and financial expenses and taxes. In
1st, 2nd & 3rd year of its operation, the Net Profit will stand at BDT 28.84 Crore, BDT 41.94 Crore and BDT
48.51 Crore respectively.
Pay Back Period for the project has been calculated and found below 5 years which is satisfactory
considering the nature of the business.
Sensitivity Analysis:
Net Profit Margin of the company in 1st Year of its operation is more than 18.7% is a good case we believe
and Step Media will be able to capitalize this benefit for a longer period of time as the competition will be
created after a pretty long time.
104
Risk & Mitigation
Financial Risk:
Financial Risk may arise due to high leverage position and non-payment of credit facility.
- Debt Service coverage ratio is quite satisfactory and cash generation will be excellent. So, the
debt servicing ability is outstanding against this extension.
Comments: Above analysis and ratios show the company’s liquidity, Debt Equity & Debt service
coverage is favorable for financing.
Management Risk
Management Risk may arises due to adverse changes in key management personal & weak decision
making capacity.
Management Risk Mitigation:
Meridian Apparels Ltd is a Limited Company and a going concern having efficient directors as its owner and
a highly efficient Management, sales & marketing team.
Security Risk:
Security risk arises due to Security/collateral coverage & support.
Relationship Risk
Relationship risk refers to Account conduct, utilization of limit, Compliance of covenants & conditions &
Personal deposits.
FCMG Companies
Telecommunications:
Electronics:
Banks:
Local Organizations:
Non Profit Organizations:
Government Organizations:
The End
Prepared by