PVC COMPOUNDING PLANT FOR CABLE GRADES

Indian plastics industry is one of the largest in the Asian Region. It had a modest beginning in the late twenties when articles like combs, soap boxes, ash trays etc. began to be manufactured in the country from imported raw materials. Three are about fifty materials identified as plastics and the list is being extended continuously. Plastics are classified as thermoplastics and thermo sets on the basic of the polymerization method adopted to produce the basic plastic material as on the basic of the primary raw materials source. Polyvinyl chloride comes under thermoplastics. Polyvinyl chloride (PVC) polymers or resins are the most important constituents of PVC compounds and are classified into bulic or mass polymers, emulsion polymers, suspension polymers and paste-forming polymers. There is a fifth type known as solution polymers which is used for coating applications.

Compounding of PVC resin is done in three steps, namely

1.    Premixing

2.    Fusion or gelation

3.    Pelletizing or granulation. Mixing of the ingredients to a high degree of homogenization is called (premixing). The premixed material is homogenized during Fusion or Gelation. In the third step namely pelletization or granulation the homogenous mass is produced in a suitable form for smooth processing. Hence it is possible to avoid one or more of the steps with the help of modern processing equipment.

Although plastic industry in India experienced many ups and downs in the 70’s it has made considerable progress not only in the output and range of plastics raw materials produced and consumed but also in learning and absorbing better processing technology as well as the manufacture of more and better machine.

INTRODUCTION
DEVELOPMENT IN PVC COMPOUND
WHAT IS THE INTENDED APPLICATION?
HOW WILL THE MATERIAL BE PROCESSED?
BASE MATERIAL
ADDITIVES
MATERIAL DEVELOPMENTS
PVC PERFORMANCE
SOFT PVC (A PLASTICIZED PVC)
PIGMENTS
RIGID (OR UNPLASTICIZED) PVC
PVC COMPOUNDING ESSENTIAL INGREDIENTS
PVC RESIN
SUSPENSION GRADE PVCH
EMULSION GRADE PVC
BULK POLYMERISED PVC
COPOLYMER PVC
K VALUE
PRIMARY PLASTICIZERS
SECONDARY PLASTICIZERS
STABILIZERS
HEAT STABILIZERS
LIGHT STABILIZERS
LUBRICANTS
FILLERS
GROUND CALCIUM CARBONATE
PRECIPITATED CALCIUM CARBONATE
PIGMENTS
MASTERBATCHES
SPECIAL ADDITIVES
FLOW PROMOTERS
IMPACT MODIFIERS
FIRE RETARDANTS AND SMOKE SUPPRESSANTS
FOAMING AGENTS
FUNGICIDES AND BIOCIDES
USES AND APPLICATION
BUREAU OF INDIAN STANDARDS SPECIFICATION
OVERVIEW OF WIRE & CABLES
TWO INDIES
POWER PLAYERS
BETTER CABLES MEAN BETTER RELIABILITY
IMPROVING TRANSMISSION FOR A BRIGHT FUTURE
MARKET TRENDS
END USERS DEMAND LONG-TERM PERFORMANCE
GOVERNMENT REFORM IS CHANGING THE ELECTRICITY MARKET
PE STRONG IN POWER CABLE INSULATION AND TELECOMMUNICATION CABLES
NEW TECHNOLOGIES
STANDARDS
INNOVATIVE WIRE & CABLE SOLUTIONS FOR INDIA
POWER CABLE MATERIALS
TELECOMMUNICATIONS CABLE MATERIALS
SPECIALTY WIRE AND CABLE PRODUCTS
ELASTOMERS FOR WIRE AND CABLES
MARKET SURVEY
U.S. PLASTIC COMPOUNDING MARKET REVENUE BY PRODUCT
2014 – 2026 (USD MILLION)
GLOBAL DEMAND OF PVC
THE PROCESSING SECTOR
PRESENT MANUFACTURERS OF PVC COMPOUND
RENEWABLE PVC COMPOUNDING AND ITS DETAILS
RENEWABLE PLASTICIZERS
RENEWABLE PVC COMPOUND
ENVIRONMENTAL IMPACT AND TOXICOLOGY
THE CALCULATION IS SUMMARIZED BELOW
FORMULATION OF PVC COMPOUND (CABLE GRADE)
FORMULATION FOR DIFFERENT GRADES OR P.V.C.
PROCESS OUTLINE OF PVC COMPOUNDING
PROCESS OF MANUFACTURE
TRANSFORMATION OF THE RAW MATERIALS COMPOUND CONSISTS
OF THE FOLLOWING
RAW MATERIAL QUALITY ASSURANCE, EVERY STEP OF THE WAY
RELIABLE, PROVEN PVC COMPOUNDING CAPABILITY.
PROCESS FLOW DIAGRAM
DETAILS OF PVC COMPOUNDING
DRY BLENDING
MELT COMPOUNDING
MELT COMPOUNDING OF ELVALOY/PVC BLENDS USING
A HIGH-SHEAR, CO-ROTATING, TWIN SCREW EXTRUDER
TABLE 1. TYPICAL SCREW DESIGN (53 MM W&P)
TABLE 1. FORMULAS
PVC COMPOUNDING EXTRUDER
PVC COMPOUNDING MACHINES
SUPPLIERS OF RAW MATERIALS
POLYMERS POLYVINYL CHLORIDE (PVC)/RESINS
STABILIZERS
PLASTICIZERS
CALCIUM STEARATE
C.P.W
CALCIUM CARBONATE
HDPE WOVEN BAGS
SUPPLIERS OF PLANT AND MACHINERY
GRANULES EXTRUSION MACHINES
HIGH SPEED MIXER
AIR COMPRESSOR
PLASTIC SCRAP GRINDER MACHINE
LABORATORY EQUIPMENTS
D.G. SETS

APPENDIX – A:

1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET