HDPE PIPE MANUFACTURING UNIT

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High-density polyethylene (HDPE) is a polyethylene thermoplastic made from petroleum. It is known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97g/cm3 or 970Kg/m3. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand much higher temperatures (120°C for short periods, 110°C continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally required autoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions.

HDPE pipes are important plastic products which have wide range of applications. These have more tensile strength in comparison to other plastic pipes. These are being used for Sprinkler Irrigation System, potable water supply and sewerage purpose. Their low cost, easily installation and better durability make them ideal for the purpose. They also offer very good resistance to most of the chemicals and have excellent electrical insulation properties. These pipes are also used for circulation of acids in various chemical industries due to their acid resistant quality.

The demands of HDPE Pipes are likely to increase due to their wide use in various sectors in India. Apart from its regular uses, such as for irrigation system, water supply, sewerage, it is being used by Department of Telecommunication for conduit for optical fiber cables. Looking to its increased demand, it appears to be good scope for setting up new small scale industries. Hence the product has good market potential.

CLASSIFICATION

(A) Pipes shall be classified according to the grade of materials as MRS; Polyethylene pipes and classified by the raw materials used in the production of attachments. A MRS material strength value of 20°C is also shown by the internal pressure for 50 years.

Raw material class MRS(MPa) value
PE 63 6.3
PE 80 8.0
PE 100 10

(B) Pipes by pressure rating (PN) corresponding to the maximum shall be classified permissible working pressure at 3WC, as follows:

The pressure grades available according to European standards are:
• PN 2.5 – max pressure 2.5 bar
• PN 4 – max pressure 4 bar
• PN 6 – max pressure 6 bar
• PN 10 – max pressure 10 bar
• PN 16 – max pressure 16 bar

Color codes used to indicate the pressure grades on the pipes are:

Color Code PE Pressure Grade
Yellow PN 4
Red PN 6
Blue PN 10
Green PN 1

HDPE Pipes for following grades/sizes/pressure rating

PE 63 PN 2.5 DN 63 to 110
PE 63 PN 4 DN 40 to 110
PE 63 PN 6 DN 32 to 110
PE 63 PN 8 DN 32 to 110
PE 63 PN 10 DN 32 to 110
PE 63 PN 12.5 DN 32 to 110
PE 63 PN 16 DN 32 to 110
PE 80 PN 2.5 DN 90 to 110
PE 80 PN 4 DN 50 to 110
PE 80 PN 6 DN 40 to 110
PE 80 PN 8 DN 32 to 110
PE 80 PN 10 DN 32 to 110
PE 80 PN 12.5 DN 32 to 110
PE 80 PN 16 DN 32 to 110
PE 100 PN 6 DN 50 to 110
PE 100 PN 8 DN 40 to 110
PE 100 PN 10 DN 32 to 110
PE 100 PN 12.5 DN 32 to 110
PE 100 PN 16 DN 32 to 110

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Description

INTRODUCTION
CLASSIFICATION
COLOR CODES USED TO INDICATE THE PRESSURE GRADES ON THE PIPES ARE:
HDPE PIPES FOR FOLLOWING GRADES/SIZES/PRESSURE RATING
CHARACTERISTICS
USES AND APPLICATION
INDUSTRIES
SPECIAL SERVICES
APPLICATIONS
SUBMARINE PIPELINES
LAYING ON THE WATERBED:
LAYING IN DREDGED CHANNELS:
LAYING BY THE FLUSHING-IN METHOD:
RELINING – NEW PIPES IN OLD
SEWER PIPES
SLURRY TRANSPORTATION
IRRIGATION
DOMESTIC GAS DISTRIBUTION
CHEMICAL PROCESS PIPING
B.I.S. SPECIFICATION
SEQUENCES IN HDPE PIPES
MANUFACTURING PROCESS OF HDPE PIPES
MECHANICAL INSPECTION
OTHER QC TESTS CAN INCLUDE:
PROCESSING DETAILS OF HDPE PIPES
EXTRUDER
FEED HOPPER
BARREL
SCREW
DIE
WATER COOLING TUB
PROCESS FLOW CHART
EXTRUSION PROCESSING LINE FOR HDPE PIPES
RAW MATERIALS HANDLING
EXTRUSION BASICS
FIGURE: TYPICAL SINGLE STAGE, SINGLE SCREW EXTRUDER (RESIN FLOW FROM RIGHT TO LEFT)
FIGURE: TYPICAL EXTRUSION SCREW
FIGURE: TYPICAL RESIN MIXING DEVICES
FIGURE: MIXING PINS
FIGURE: FLUTED MIXER
FIGURE: HELICAL MIXER
EXTRUDERS
BREAKER PLATE/SCREEN PACK
DIE DESIGN
FIGURE: TYPICAL PIPE DIES
FIGURE: PIPE DIE WITH SPIDER DESIGN
FIGURE: PIPE DIE WITH BASKET DESIGN
PIPE SIZING
FIGURE: EXTERNAL SIZING SYSTEMS
FIGURE: VACUUM TANK SIZING
FIGURE: INTERNAL (PRESSURE) SIZING FOR SMALL AND MEDIUM PIPE DIAMETERS
FIGURE: TYPICAL PE PROFILE WALL PIPE FROM ASTM STANDARD F894
FIGURE: TYPICAL PROFILE WALL SECTION SHOWING BELL END (RIGHT) AND SPIGOT ENG (LEFT)
COOLING
PULLERS
TAKE-OFF EQUIPMENT
SAW EQUIPMENT AND BUNDLING
SEQUENCES IN HDPE PIPE FITTING MANUFACTURE
MANUFACTURING PROCESS OF HDPE PIPE FITTING
INJECTION MOLDED FITTINGS
FIGURE: TYPICAL PE PIPE FITTINGS
FIGURE: SOCKET TEE
FIGURE: BUTT TEE
FIGURE: SOCKET ELBOW
FIGURE: 90° BUTT ELBOW
FIGURE: SADDLE FUSION FITTINGS
FIGURE: BUTT FLANGE ADAPTER/STUB END
FIGURE: CONSTRUCTION AND MODE OF OPERATION OF A RECIPROCATING SCREW INJECTION UNIT (COURTESY OF HOECHST CELANESE CORPORATION)
FABRICATED FITTINGS
THERMOFORMED FITTINGS
ELECTROFUSION COUPLINGS
INJECTION MOLDED COUPLINGS
FIGURE: TYPICAL FABRICATED FITTINGS
QUALITY CONTROL/QUALITY ASSURANCE TESTING
WORKMANSHIP, FINISH AND APPEARANCE
DIMENSIONS
RAW MATERIALS
A. HDPE GRANULES
B. BLACK MASTER BATCH
C. ANTI-OXIDANT
QUALITY CONTROL OF HDPE PIPES
VISUAL INSPECTIONS
MECHANICAL INSPECTION
OTHER QC TESTS CAN INCLUDE:
TECHNICAL DETAILS OF HDPE PIPE MANUFACTURE
INCOMING RAW MATERIAL INSPECTION
RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
RESIN STORAGE AND CONVEYANCE
RESIN FEEDING
TESTING
(A) TYPE TEST
(B) ACCEPTANCE TEST
(C) LONGLTUDINAL REVERSION PERFORMANCE TEST
APPRATUS
1. AIR OVEN
2. THERMOMETER
TEST SPECIMENS
PROCEDURE
MARKING
OVERVIEW OF HDPE PIPES
MICRO DUCTS IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
TELECOM IS PROJECTED AS THE MOST LUCRATIVE SEGMENT.
MARKET POSITION OF INDIAN HDPE PIPES
OPPORTUNITIES OF HDPE PIPES
MARKET BY APPLICATION
MARKET BY GRADE TYPE
MARKET BY DIAMETER TYPE
MARKET BY PRESSURE RATING
GLOBAL MARKET POSITION OF HDPE PIPES
INDIAN PLASTIC PIPES MARKET
TYPES OF PLASTIC PIPES APPLICATION
MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
BARGAINING POWER OF SUPPLIERS
BARGAINING POWER OF BUYERS
INTERNAL RIVALRY
ENTRY
THREAT OF SUBSTITUTES
GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
OTHER MEASURES
SWOT ANALYSIS
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
SEWER RINGFIT PIPES AND SEWER SELFIT PIPES
DOMESTIC USE
INDUSTRIAL
OTHER
HDPE PIPES DIMENSION
MANUFACTURERS/SUPPLIERS OF HDPE PIPE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HDPE GRANULES
SUPPLIERS OF BLACK MASTER BATCH
SUPPLIERS OF ANTIOXIDANT
SUPPLIERS OF COMPLETE HDPE PIPE PLANT
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSOR
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
TORNOVER (FIRST YEAR) ON MONTHLY BASES

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)

Additional information

Plant Capacity

116 Ton/Day
Land & Building

(20,000 sq.mt.)
Plant & Machinery

US$ 1070000
Rate of Return

32%
Break Even Point

41%

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