INDEX
Sl. No.
I
1
2
3
4
5
6
7
8
9
10
11
II
12
13
14
15
16
17
18
19
20
III
21
IV
22
PRODUCTS
INJECTION MOLDING PROCESS
DISPOSBLE SYRINGES
CRATES
a) ARM CHAIR
b) ARMLESS CHAIR
ROCKING CHAIR
BATTERY BOX
TOOTH BRUSH
a) LUNCH BOX
b)BUCKET
c) COMBS
CAPS & CLOSURES
CAR BUMPER
THIN WALLED CONTAINERS
BALL POINT PEN
EXTRUSION PROCESS
WOVEN SACK
JUMBO BAG
NONWOVEN FABRICS
BLOWN FILM / BOPP
BOX STRAPING
ROPES
LENO BAGS
ROOF SHEETS
MULTILAYER FILM
BLOW MOLDING PROCESS
BLOW MOLDED CONTAINERS
THERMOFORMING
DISPOSABLE CUPS
Annexure I : Raw Material Specification
Annexure II: Machine Manufacturers
Annexure III: Accessory Manufacturers
Annexure IV: Mould Manufacturers
Annexure V: Facilities in Paradeep
Plastic Park
PAGE NO.
1
9
23
31
39
47
62
70
78
88
96
104
112
121
130
138
148
153
159
165
175
189
195
201
208
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
1. DISPOSABLE SYRINGES
INTRODUCTION
It has been known that all Medical sources use Disposable Syringes, mainly by
doctors to inject medicines through intravenous or intramuscular ways. This is
mainly used to cure patients or infuse required drugs or treat diseases. Disposable
syringes are mainly made of Polypropylene (PP) and they find applications in the
field of medical and veterinary science. As PP is the only polyolefin which can be
sterilized at temperatures and pressure for antibacterial uses, it is ready to use,
and financially, it is also cost effective. Also, upon usage, it can be also disposed
off. The age old glass syringes are completely replaced by PP syringes. Also, the
AIDS phenomenon is not spread to other streams, as the reuse of syringes is
banned worldwide and hence the demand of disposable syringes has increased
phenomenally. Syringes are available in sizes of 1 ml, 2 ml, 5 ml and 10 ml, 50ml
in a variety of designs and consist of either two or three or five components in
totality.
USAGES /APPLICATIONS

Hospitals

Clinics

Blood bank

Dentist
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MARKET SURVEY / POTENTIAL
The Present demand of Disposable Syringe is being adequately met by indigenous
production. In increasing awareness in health care, AIDs and like diseases and
improvement in per capita income is expected to create further growth in demand
of disposable syringe / needles. Since there is in need to add few more new units
for manufacturing of Disposable Syringe. The growth in domestic demand may be
conservatively expected to be 25% per annum. Assuming constant export of 100
million syringes/ year only. One additional unit every year with 25 million products
shall be needed to increase in indigenous demand alone besides increase in export
quantities is likely to be the further aggravate the demand.
EQUIPMENTS AND ACCESSORIES LIST

Injection Moulding Machine

Printing-Embossing unit

Sterilization unit

Assembly unit

Cooling Tower/ Chillier Plant

Air Compressor

Scrap Grinder
FLOW CHART
Tube by Injection
Moulding
Piston by Injection
Moulding Machine
Rubber
Assembling and
Finishing
Sterilization
Packing and Dispatching
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MANUFACTURING PROCESS

Disposable syringes are moulded using Injection moulding machines and
special Hot-Runner moulds, having 16 – 32 cavity mould.

Raw material required is polypropylene, from IOCL, Paradeep, of Injection
Moulding Grade.

Moulding is carried out in chilled condition to get better clarity of the PP used.

The moulded syringes are then assembled with the rubber.

The whole assembly is then sterilized in sterilization plant using ethylene oxide.

The completed syringe is then blister packed in automatic packing machine.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
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molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

Polypropylene homopolymer

Rubber
Processing conditions
Drying
Melt Temperature
Not normally necessary if proper storage is used.
220 - 275°C
Mould Temperature
Injection Pressure
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
Unit
Ton
mm
cc
g/sec
mm
mm
mm
Specification
110 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
435×435 / 510 × 510
mm
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
Total Oil Capacity
Total Connected Load
Machine Weight
Ltr.
KW
Kg
MACHINERY & MOULD COST FOR DISPOSABLE SYRINGES (1ML,2ML,5ML)
A. MACHINERY FOR (1ML,2ML,5ML)
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Machinery
Injection Moulding Machine,
120 Ton (for Body &
Plunger)
Crane (Manual)
Printing-Embossing unit
Sterilization Plant (Ethylene
Oxide)
Blister Packing Machine
Scrap Grinding Machine
Air Compressor
Water Pump
Chilling Plant
Total cost
 2016 CIPET Bhubaneswar. All rights reserved
Quantity
1 No.
Cost
(in Lacs)
16 - 20
1 No.
1 No.
1 No.
5-8
4-5
9 - 10
1
1
1
1
1
No.
No.
No.
No.
No.
4-5
2-3
2-3
0.5 - 1
8–9
51 - 64
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B. MOULD FOR 1ML SYRINGE
Sl.No.
1.
Mould
Hot Runner Mould, 16
Impression, for Body
Hot Runner Mould, 16
Impression, for Plunger
Total cost
2.
Quantity
1 No.
Cost
(in Lacs)
15 – 20
1 No.
5 - 10
20 – 30
MOULD FOR 2 ML SYRINGE
Sl. No.
1.
2.
Mould
Quantity
Hot Runner Mould, 16
Impression, for Body
Hot Runner Mould, 16
Impression, for Plunger
Total cost
1 No.
Cost
(in Lacs)
20 - 25
1 No.
10 - 12
30 – 37
MOULD FOR 5ML SYRINGE
Sl.No.
1.
2.
Mould
Hot Runner Mould, 12
Impression, for Body
Hot Runner Mould, 12
Impression, for Plunger
Total cost
Quantity
1 No.
Cost
(in Lacs)
20- 26
1 No.
12 - 15
32 – 41
TOTAL COST FOR 1MLSYRINGE (MACHINERY& MOULD): 71 – 94 lacs
TOTAL COST FOR 2MLSYRINGE (MACHINERY& MOULD): 81– 101 lacs
TOTAL COST FOR 5MLSYRINGE (MACHINERY& MOULD): 83 – 105 lacs
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TOTAL COST FOR 1ML, 2ML, 5ML SYRINGE (MACHINERY &
MOULD): 133 – 172 lacs
C.PRODUCTION CAPACITY (1ML,2ML,5ML SYRINGE)
Product
1 ml
Syringe
2 ml
Syringe
5ml
Syringe
Production
Capacity per day
(for 22 hours)
Production
Capacity per
annum
(300 days)
2,53,44,000 pieces
84,480 pieces
@ 15 seconds for 16
cavity mould
70,400 pieces
2,11,20,000 pieces
@ 18 seconds for 16
cavity mould
63,360 pieces
1,90,08,000 pieces
@ 15 seconds for 12
cavity mould
Raw Material
Consumption
/ annum
~ 38 MT @
1.5 g per
piece
~ 74 MT @
3.5 g per
piece
~ 91 MT @
4.8 g per
piece
D.UTILITIES REQUIREMENTS
Sl. No.
Type
Requirement (approx.)
1.
Electricity for Injection
Moulding Machine, 120 Ton
Electricity for PrintingEmbossing unit
Electricity for Sterilization
Plant (Ethylene Oxide)
Electricity
for
Blister
Packing Machine
Electricity
for
Scrap
Grinding Machine
Electricity
for
Air
Compressor
Electricity for Water Pump
Electricity for Chilling Plant
Connected Load – 45 KW
2.
3.
4.
5.
6.
7.
8.
 2016 CIPET Bhubaneswar. All rights reserved
Connected Load – 4 KW
Connected Load – 9 KW
Connected Load – 10 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
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9.
Water
80 litre/min
Water will be circulated
through fixed tank
capacity is 15000-20000
litre
10.
Land Required *
10,000 – 12,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E. MANPOWER REQUIREMENT
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Supervisor
Manager
Skilled Workers
Semi-Skilled
Workers
03
01
05
12
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2. PLASTIC CRATES
INTRODUCTION
Plastic crates are used for storage, transportation and distribution and handling of
products. Previously wooden crates were used which are now being substituted by
HDPE and PP crates. The crates are manufactured by injection moulding process. In
the today’s business world, material handling is an integral part of any industrial
activity to increase the productivity, profitability as well as ecological preservation.
It plays a very fundamental role in sustaining efficiency in financial and human
resources. The introduction of Plastic crates revolutionized material handling and
has a wide range of applications in material handling like crates for industries like
Automobile,
Supermarkets,
Pharmaceutical,
Electronics,
Engineering,
Retail,
Food
&
Electrical,
Beverages,
Logistics,
Textiles,
Agriculture,
Seafood,
Hospitality & Catering and other allied business.
The plastic crates have the following advantages
• Light weight and rigid as compared to wood and metal
• Convenience and ease of handling
• Hygienic and non-toxic
• Space saving-stackable and Nestable
• Resistant to chemicals/soaps
• Anti-rusting
• Wide choice of shape, size and colours tailored for each end-use
• Withstands wide range of temperatures and climatic conditions
encountered during service
• Environment friendly
• Longer service life as compared to wooden crates.
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USAGES / APPLICATIONS
Sector
Uses
Soft drink industry
Storage, handling, transport and distribution
Milk and dairy products
Handling, transport, distribution.
Fisheries, marine
Automobile industry
Storage, handling, transport
products distribution.
Storage
Fruits and vegetable
Storage, handling, transport.
Electronic and electrical
Storage, handling.
Pharmaceuticals
Storage, handling.
Agro-products
Storage, handling
Yarn and textiles industry
Storage, handling
Defence Sector
Storage, handling of bombs
and
meat
MARKET SURVEY / POTENTIAL
Following types of crates are generally available in market and are popular amongst
End users:
Sl. No.
01.
Types
Fully closed crates
02.
Grilled crates
03.
04.
05.
Totally grilled crates
Crates with lids
Folding crates
06.
Stacking and nesting crates
07.
Soft drink crates
08.
09.
10.
11.
Milk pouch crate
Tetra pack creates
Crates for handling PCB
Bins
Specifications
With all surfaces of crates in solid
except top
With all sidewalls grilled and bottom
close
With all sides and bottom also grilled
A lid on top to protect the contents
Entire crate can be folded to a flat
assembly to save space when not in use
Height of crate can be reduced when
stored in nesting positions
These are available with partitions to
separate bottles rattling with each other
Crate used for milk pouch
Crate used for tetra pack
Used for handling PCB
Modified shape of crate so that contents
can be removed from front without
unloading the bins stacked over it.
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EQUIPMENTS AND ACCESSORIES LIST

Injection Moulding Machine

Cooling Tower/ Chiller Plant

Dry Colour Mixer

Scrap Grinder

Air Compressor
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing
1. Feeding of PP raw material into the hopper
2. Injection moulding process.
3. Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
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the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V) Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Specification
275 – 350
60 – 90
792 – 1810
49 – 65
200 – 800
940×940 / 1030×1030
660×660 / 720×720
6.3×1.7×2.6 /
8.2×2.1×3.1
615
62.5 – 86.2
8600 – 18500
MACHINERY & MOULD COST FOR BAKERY CRATE (20L) & DAIRY CRATE
(10-12L)
A. MACHINERY COST
Sl.No.
Machinery
Quantity
1.
1 No.
1 No.
2–3
3.
Injection Moulding
Machine, 350 Ton
Dry
colour
Mixer
Machine
Crane (Manual)
Cost
(in Lacs)
60-70
1 No.
5-8
4.
Scrap Grinding Machine
1 No.
2.5 - 3
5.
Air Compressor
1 No.
2.5 - 3
6.
Water Pump
1 No.
0.5 - 1
7.
Chilling
Tower
1 No.
8 – 9/3-5
2.
Plant/Cooling
Total cost
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81 –97
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B. MOULD COST
Sl.No.
1.
Mould
Single cavity Mould for Bakery
crate
Outer dimension:
565 x 480 x 138 mm
Inner dimension:
545 x 455 x 125 mm
Volumetric capacity: ~20 litres
(or)
Single cavity Mould for Dairy
crate
Outer dimension:
570 x 298 x 173 mm
Inner dimension:
522 x 226 x 163 mm
Volumetric capacity: ~10 litres
(or)
Single cavity Mould for
Partitioned Dairy crate
outer dimension:
471 x 380 x 160 mm
Inner dimension:
427 x 335 x 144 mm
Volumetric capacity: ~12 litres
Total cost
Quantity
1 No.
Cost
(in Lacs)
25 - 28
25 –28
TOTAL COST FOR BAKER CRATE (20L) / DAIRY CRATE (10-12L)
(MACHINERY& MOULD):106-125 lacs
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C.PRODUCTION CAPACITY
PRODUCT
Bakery Crate
(20L)
Dairy Crate
(10-12L)
Production
Capacity per day
@ 120 sec for
single crate, for
22 hours
660 components
Production
Capacity
per annum
(300 days)
Raw Material
Consumption
/ annum
1,98,000
components
~ 150 MT
@750 g /piece
660 components
1,98,000
components
~ 140 MT
@700 g/piece
D.UTILITIES REQUIREMENTS
Sl. No.
1.
2.
3.
4.
5.
6.
7.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 350 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water Pump
Electricity for Chilling
Plant/Cooling Tower
Water
Connected Load – 75 KW
Connected Load – 2 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
150 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8.
Land Required*
15,000 – 20,000 sq. ft
* 70 – 80 % is required for Machineries and Utilities
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E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
Designation
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
Manager
Supervisor
Skilled Worker
01
03
03
Semi-Skilled Worker
06
INJECTION MOULDING SPECIFICATION (650 T)
650T
Model
100DD
Units
Standard
Increase
pressure
Screw diameter
mm
90
80
Theoretical injection
capacity
cm3
2,860
2,260
2,630
2,080
2,120
1,670
177
(1,800)
206
(2,100)
147
(1,500)
177
(1,800)
795
630
1,015
805
-
-
470
350
Injection
mass
Polystyrene
(PS)
g
Polyethylene
(PE)
Maximum injection pressure
Maximum holding pressure
MPa
(kgf/cm2)
Standard (S)
High-speed
Injection rate (H)
cm3/sec
Ultra highspeed (U)
Plasticizing capacity (PS)
kg/h
Screw RPM
rpm
Injection
S
kW (PS)
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160
140
130
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power
(horsepower)
(190)
(175)
H
180
(245)
165
(225)
U
-
-
Mold clamping force
kN (tonf)
Platen size (H x V)
6,370(650)
1,400×1,400
Tie bar space (H x V)
Clamping stroke, maximum
960×960
mm
1,000
Daylight, maximum
2,000
Mold thickness
Ejector
400~1,000
Ejector force kN (tonf)
Stroke
Heater capacity
Machine dimensions (L x W
x H)
Machine mass
196(20.0)
mm
200.0
kW
33.4
m
10.1×2.4×2.4
tons
38.0
MACHINERY & MOULD COST FOR FISHERY CRATE (80L)
A. MACHINERY COST
Sl.No.
1.
2.
3.
Machinery
Quantity
Injection Moulding
Machine, 650 Ton
Crane (Manual)
1 No.
Cost
(in Lacs)
75-95
1 No.
5-8
2–3
4.
Dry
colour
Mixer 1 No.
Machine
Scrap Grinding Machine
1 No.
5.
Air Compressor
1 No.
2.5 - 3
6.
Water Pump
1 No.
0.5 - 1
7.
Chilling
Tower
Plant/Cooling 1 No.
Total cost
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2.5 - 3
8 – 9/4-5
96 –122
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B. MOULD COST
Sl.No.
1.
Mould
Mould for Fishery crate@
2800 grams per crate
outer Dimension:
650x450x315mm
Inner dimensions:
610x410x300mm
Volumetric capacity:
80 litres (approx.)
Quantity
1 No.
Total cost
Cost
(in Lacs)
30-35
30 –35
TOTAL COST FOR FISHERY CRATE (80L) (MACHINERY& MOULD):126-157
lacs
C.PRODUCTION CAPACITY
Production Capacity per Production
day @140 seconds for Capacity per
single crate, for 22 hours annum
(300 days)
565 components
1,69,500
pieces
Raw Material
Consumption
/ annum
~475 MT
D.UTILITIES REQUIREMENTS
Sl.
No.
1.
2.
3.
4.
5.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 650
Ton
Electricity for Dry colour
Mixer Machine
Electricity
for
Scrap
Grinding Machine
Electricity
for
Air
Compressor
Electricity for Water Pump
Connected Load – 150KW
 2016 CIPET Bhubaneswar. All rights reserved
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Page 21 of 217
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6.
Electricity
for
Chilling Connected Load – 8 KW
Plant/Cooling Tower
7.
Water
200 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8.
Land Required*
20,000 – 25,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
Worker
01
03
03
06
Page 22 of 217
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3. a) ARMED CHAIR
INTRODUCTION
Polypropylene armed chair is manufactured by injection moulding process. The
moulded Plastic Armchair was designed on the principle of adaptability, offering
innumerable
configurations
to
serve
a
wide
variety
of
applications
and
environments. The Monobloc chair is a lightweight stackable polypropylene chair,
often describes as the world's most common plastic chair. The Monobloc chair is
named because it is injection moulded from polypropylene, the granules being
heated, and the melt injected into a mould. The gate of the mould is usually located
in the seat, so ensuring smooth flow to all parts of the tool.
USAGES / APPLICATIONS:





Houses
Offices
Hotels
Marriage/Wedding halls
Auditorium
 2016 CIPET Bhubaneswar. All rights reserved
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INDUSTRIES IN PP MOULDED PRODUCTS
MARKET POTENTIAL
Chairs are common household furniture in every home. They also have a major
applications in office use, hotel receptions, public places like parks, stations etc.
Armed chairs have the arm rest and are more commonly preferred by elderly
people for more comfort. They are on the other hand considered to be safe and also
have a higher demand across the nation. These chairs are rather preferred than
couches for their economic cost and easy affordability by everyone.
EQUIPMENTS AND ACCESSORIES LIST:




Injection Moulding Machine
Cooling Tower/ Chiller Plant
Scrap Grinder
Air Compressor
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
 2016 CIPET Bhubaneswar. All rights reserved
Page 24 of 217
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INDUSTRIES IN PP MOULDED PRODUCTS
MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing
4. Feeding of PP raw material into the hopper
5. Injection moulding process.
6. Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
 2016 CIPET Bhubaneswar. All rights reserved
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INDUSTRIES IN PP MOULDED PRODUCTS
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
 2016 CIPET Bhubaneswar. All rights reserved
Page 26 of 217
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INDUSTRIES IN PP MOULDED PRODUCTS
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage
is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
 2016 CIPET Bhubaneswar. All rights reserved
Page 27 of 217
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INJECTION MOULDING SPECIFICATION (850 T)
850T
Model
100DD
Units
160DD
Standard
Increase
pressure
Standard
Screw diameter
mm
90
80
105
Theoretical injection
capacity
cm3
2,860
2,260
4,540
2,630
2,080
4,180
2,120
1,670
3,360
177
(1,800)
206
(2,100)
177
(1,800)
147
(1,500)
177
(1,800)
147
(1,500)
795
630
1,385
1,015
805
-
-
-
-
470
350
630
Injection
mass
Polystyrene
(PS)
Polyethylene
(PE)
Maximum injection
pressure
Maximum holding
pressure
g
MPa
(kgf/cm2)
Standard
(S)
Injection
rate
High-speed
(H)
cm3/sec
Ultra highspeed (U)
Plasticizing capacity (PS)
kg/h
Screw RPM
rpm
S
Injection
power
H
(horsepower)
kW (PS)
U
Mold clamping force
kN (tonf)
160
150
140
(190)
130
(175)
244
(332)
180
(245)
165
(225)
-
-
-
-
8,335(850)
Platen size (H x V)
1,590×1,590
Tie bar space (H x V)
1,070×1,070
Clamping stroke,
maximum
mm
Daylight, maximum
 2016 CIPET Bhubaneswar. All rights reserved
1,200
2,300
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Mold thickness
500~1,100
Ejector force kN (tonf)
Ejector
Stroke
Heater capacity
Machine dimensions (L x
W x H)
Machine mass
196(20.0)
mm
200.0
kW
33.4
47.2
m
10.8×2.6×2.6
11.4×2.6×2.6
tons
49.6
55.3
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
Machinery
Quantity
Injection Moulding
Machine, 850 Ton
Crane (Manual)
Dry
colour
Mixer
Machine
Scrap
Grinding
Machine
Air Compressor
Water Pump
Chilling Plant/Cooling
Tower
Total cost
1 No.
Cost
(in Lacs)
110-130
1 No.
1 No.
5-8
2–3
1 No.
9-10
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-5
137 –164
B. MOULD COST
Sl.No.
1.
Mould
Mould for Armed Chair
Total cost
Quantity
1 No.
Cost
(in Lacs)
40-50
40 –50
TOTAL COST (MACHINERY & MOULD): 177-214 lacs
 2016 CIPET Bhubaneswar. All rights reserved
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C.PRODUCTION CAPACITY
Production Capacity per
day @ 65 seconds for
single cavity for 22 hours
~ 1220 pieces
Production
Capacity per annum
(300 days)
3,66,000 pieces
Raw Material
Consumption
/ annum
~ 769 MT
@ 2.1Kg/piece
D.UTILITIES REQUIREMENTS
Sl. No.
Type
Requirement (approx.)
1. Electricity for Injection
Moulding Machine, 850 Ton
2. Electricity for Dry colour
Mixer Machine
3. Electricity
for
Scrap
Grinding Machine
4. Electricity
for
Air
Compressor
5. Electricity for Water Pump
6. Electricity
for
Chilling
Plant/Cooling Tower
7. Water
Connected Load – 200 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
200 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8. Land Required*
25,000 – 30,000 sq. ft.
* 70 – 80 % is required for Machineries and Utilities
E.MAN POWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled -Worker
Semi-Skilled
worker
01
03
03
10
Page 30 of 217
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INDUSTRIES IN PP MOULDED PRODUCTS
3. b) ARMLESS CHAIR
INTRODUCTION
The moulded plastic armless chair was designed on the principle of adaptability,
offering innumerable configurations to serve a wide variety of applications and
environments. The Monobloc chair is a lightweight stackable polypropylene chair,
often describes as the world's most common plastic chair. The Monobloc chair is
named because it is injection moulded from Polypropylene the granules being
heated to about 220 degrees Celsius, and the melt injected into a mould. The gate
of the mould is usually located in the seat, so ensuring smooth flow to all parts of
the tool.
USAGES/ APPLICATIONS

Houses

Offices

Hotels
 2016 CIPET Bhubaneswar. All rights reserved
Page 31 of 217
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MARKET POTENTIAL
Armless chairs are mostly preferred in corporate fields or large marriage halls and
public events. This is mainly because they consume fewer raw materials and hence
lesser cost compared to armed chair. They also consume less space upon storage.
They have a higher market potential as can be manufactured in large quantities at
cheaper cost.
EQUIPMENTS AND ACCESSORIES LIST

Injection Moulding Machine

Cooling Tower/ Chiller Plant

Scrap Grinder

Air Compressor
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection of Molten PP material in
Cooling and Opening of mould
Ejection of component
Packing
 2016 CIPET Bhubaneswar. All rights reserved
Page 32 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing
7. Feeding of PP raw material into the hopper
8. Injection moulding process.
9. Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
 2016 CIPET Bhubaneswar. All rights reserved
Page 33 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
 2016 CIPET Bhubaneswar. All rights reserved
Page 34 of 217
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INDUSTRIES IN PP MOULDED PRODUCTS
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
 2016 CIPET Bhubaneswar. All rights reserved
Page 35 of 217
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INJECTION MOULDING SPECIFICATION (650 T)
650T
Model
100DD
Units
Standard
Increase
pressure
Screw diameter
mm
90
80
Theoretical injection
capacity
cm3
2,860
2,260
2,630
2,080
2,120
1,670
177
(1,800)
206
(2,100)
147
(1,500)
177
(1,800)
795
630
1,015
805
-
-
470
350
Injection
mass
Polystyrene
(PS)
g
Polyethylene
(PE)
Maximum injection pressure
Maximum holding pressure
MPa
(kgf/cm2)
Standard (S)
High-speed
Injection rate (H)
cm3/sec
Ultra highspeed (U)
Plasticizing capacity (PS)
kg/h
Screw RPM
rpm
S
Injection
power
(horsepower) H
kW (PS)
U
Mold clamping force
kN (tonf)
Platen size (H x V)
Tie bar space (H x V)
Clamping stroke, maximum
Daylight, maximum
 2016 CIPET Bhubaneswar. All rights reserved
160
140
(190)
130
(175)
180
(245)
165
(225)
-
6,370(650)
1,400×1,400
mm
960×960
1,000
2,000
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Mold thickness
400~1,000
Ejector force kN (tonf)
Ejector
Stroke
Heater capacity
Machine dimensions (L x W
x H)
Machine mass
196(20.0)
mm
200.0
kW
33.4
m
10.1×2.4×2.4
tons
38.0
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
Machinery
Quantity
Injection Moulding
Machine, 650 Ton
Crane (Manual)
1 No.
Cost
(in Lacs)
75-95
1 No.
5-8
2–3
5.
Dry
colour
Mixer 1 No.
Machine
Scrap
Grinding 1 No.
Machine
Air Compressor
1 No.
6.
Water Pump
0.5 - 1
7.
Chilling Plant/Cooling 1 No.
Tower
Total cost
4.
1 No.
8-9
2.5 - 3
8 – 9/3-5
101–128
B.MOULD COST
Sl.No.
1.
Mould
Mould for Armed
Chair
Total cost
Quantity
1 No.
Cost
(in Lacs)
40-50
40 –50
TOTAL COST (MACHINERY & MOULD):141-178 lacs
 2016 CIPET Bhubaneswar. All rights reserved
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C.PRODUCTION CAPACITY
Production
Capacity per day
@ 50 seconds for single
cavity for 22 hours
1584 pieces
Production
Capacity per
annum
(300 days)
4,75,200
pieces
Raw Material
Consumption
/ annum
~ 808 MT
@1.7 Kg /piece
D.UTILITIES REQUIREMENTS
Sl. No.
1.
2.
3.
4.
5.
6.
7.
Type
Electricity for Injection
Moulding Machine, 650 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water Pump
Electricity for Chilling
Plant/Cooling Tower
Water
Requirement (approx.)
Connected Load – 150 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
200 litre/min
Water will be circulated
through fixed tank
capacity is 15000-20000
litre
8.
Land Required*
20000 – 25,000 sq. ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled -Worker
Semi-Skilled
worker
01
03
03
10
Page 38 of 217
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4. ROCKING CHAIR
INTRODUCTION
A rocking chair or rocker is a type of chair with two curved bands attached to the
bottom of the legs, connecting the legs on each side to each other. The rockers
contact the floor at only two points, giving the occupant the ability to rock back and
forth by shifting his/her weight or pushing lightly with his/her feet. Rocking chairs
are most commonly made of wood. Some rocking chairs can fold. Rocking chairs
are often seen as synonymous with parenting, as the gentle rocking motion can
soothe infants. One's brain may associate the rocking motion with that of the safety
and comfort felt when rocking in a mother's arms or in a cradle or perhaps even a
mother's womb. It has been shown that the motion of gentle rocking relaxes the
body and allows people to sleep better.
USAGES/APPLICATIONS


House
Play school
 2016 CIPET Bhubaneswar. All rights reserved
Page 39 of 217
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MARKET POTENTIAL
The market trend is going on in favour of plastic product very fast as every person
is observing this phenomena due to the light weight, case of transportation, low
cost, stiffness and thermal resistance, mechanical strength and durability. In the
case of furniture made of plastic, the market is in favour of producers, as people
have started investing on plastic furniture due to their durability and other
attractive features. Toddlers find these rocking chairs attractive with bright colours;
will help them to be active. Most important, the furniture is made of injection
moulding technique and hence easy to manufacture with variance in the colours.
EQUIPMENTS AND ACCESSORIES LIST





Injection Moulding Machine
Crane for mould loading and unloading
Cooling Tower/ Chiller Plant
Air Compressor
Scrap Grinder
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
 2016 CIPET Bhubaneswar. All rights reserved
Page 40 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing
10.Feeding of PP raw material into the hopper
11.Injection moulding process.
12.Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
 2016 CIPET Bhubaneswar. All rights reserved
Page 41 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
 2016 CIPET Bhubaneswar. All rights reserved
Page 42 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
 2016 CIPET Bhubaneswar. All rights reserved
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V)
Tie bar Distance (H×V)
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V) Min/Max
Machine Dimension (L×W×H)
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Specification
180 – 200
40-mm
251 – 679
30 – 57
150/560
810 × 810
570×570
6.3×1.7×2.6
525
38.2 – 54.5
8600
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Total Oil Capacity
Total Connected Load
Machine Weight
Ltr.
KW
Kg
Specification
275 – 350
60 – 90
792 – 1810
49 – 65
200 – 800
940×940 / 1030×1030
660×660 / 720×720
6.3×1.7×2.6 /
8.2×2.1×3.1
615
62.5 – 86.2
8600 – 18500
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
Machinery
Quantity
Injection Moulding
Machine, 180 Ton
Injection Moulding
Machine, 350 Ton
Crane (Manual)
Dry
colour
Machine
Mixer
 2016 CIPET Bhubaneswar. All rights reserved
1 No.
Cost
(in Lacs)
20-30
1 No.
40-60
1 No.
5-8
1 No.
2–3
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5.
Scrap Grinding Machine
1 No.
3-5
6.
Air Compressor
1 No.
2.5 - 3
7.
Water Pump
2 Nos.
1-2
8.
Chilling
Tower
1 No.
8 – 9/3-5
Plant/Cooling
Total Cost
82 –120
B.MOULD COST
Sl.No.
1.
Mould
Mould for Rocking
Chair (05 moulds)
Total cost
Quantity
1 set
Cost
(in Lacs)
30-50
30 –50
TOTAL COST (MACHINERY& MOULD): 112-170 lacs
C.PRODUCTION CAPACITY
Production Capacity per Production
day
@120
seconds for Capacity per
single cavity for 22 hours
annum
(300 days)
660 pieces
1,98,000 pieces
Raw Material
Consumption
/ annum
~218 MT
@1.1 Kg/piece
D.UTILITIES REQUIREMENTS:
Sl. No.
1.
2.
3.
4.
Type
Electricity for Injection
Moulding Machine, 180 Ton
Electricity for Injection
Moulding Machine, 350 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap Grinding
Machine
 2016 CIPET Bhubaneswar. All rights reserved
Requirement (approx.)
Connected Load – 75 KW
Connected Load – 150 KW
Connected Load – 3 KW
Connected Load – 4 KW
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5.
6.
7.
8.
Electricity for Air Compressor
Electricity for 2 Water Pumps
Electricity for Chilling Plant /
Cooling Tower
Water
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
150 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
9.
Land Required*
10,000 – 15,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled -Worker
Semi-Skilled
worker
01
03
03
07
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5. BATTERY CASE
INTRODUCTION
Any home, today, is equipped with prevention against the power failure by
installing inverters. One of the most important component of an Inverter, be it be
domestic or heavy industrial use – is the Battery and its housing. Efficient inverter
battery must be able to meet frequent deep discharges, ensure reliability over
months, be low maintenance, ensure minimum emission of gasses, no or minimum
acid spray/ fumes, with high durability and non-cracking guarantee.
A battery holder is either a plastic case with the shape of the housing molded as a
compartment or compartments that accepts a battery or batteries, or a separate
plastic holder that is mounted with screws, eyelets, glue, double-sided tape, or
other means. Battery holders may have a lid to retain and protect the batteries, or
may be sealed to prevent damage to circuitry and components from battery
leakage. External connections on battery holders are usually made by contacts with
pins, surface mount feet, solder lugs, or wire leads. PP is generally used to
manufacture majority of Battery Boxes in various variants and cost parameters.
Both recycled PP and virgin PP is used to make domestic and heavy duty Battery
Case.The PP Battery case for the tubular solar batteries, available in the market
require much superior performer with the metal insert as a chosen alloy,
incorporated microporous separators and vent plugs. The combination of virgin
polypropylene, its ruggedness along-with the vent plugs keep the water topping up
requirement very low. These features ensure high longevity and make the batteries
a reliable storage power solution.
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USAGES / APPLICATIONS

Batteries and other energy storage devices

For running an inverter

Lead-acid batteries are often used in renewable energy systems

Battery cases for Solar Cells

Batteries for cars and automobile industry

Batteries for heavy duty and industrial use

Batteries for indoor applications
MARKET POTENTIAL
There is a huge requirement of everlasting demand of non-stop electricity and
power verses the less supply of the same. The main components that are hugely
required by the Indian market as well as the one’s exported are PP Battery Box,
Heavy Duty Battery Boxes, Inverter Batteries, Automobile Batteries, Two Wheeler
Batteries, SMF Batteries etc.
Worldwide forecast of battery storage capacity (MW) and annual revenue (USD) for
utility-scale applications (Ref., 2.The International Renewable Energy Agency
(IRENA) Report on “Battery Storage for Renewable: Market Status and Technology
Outlook”, Published on January 2015.)
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The battery storage market in the power sector has seen significant growth in
recent years. For utility scale applications global 2014 revenue was around USD
220 million, in the market. This requirement is expected to grow in coming years,
thereby giving a huge push to the demand section of manufacturing and processing
of Battery Boxes.
EQUIPMENTS AND ACCESSORIES LIST

Injection Moulding with metal insert

Dry Colour Mixer

Cooling Tower/ Chiller Plant,

Crane for Mould Loading & Unloading

Air Compressor

Scrap Grinder
FLOW CHART
PP Raw material
Put Metal
Insert (for Lid)
Colourant
PP Master batch
Injection moulding
Labelling
Handle Fitting
Printing & Stickering
Packing
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MANUFACTURING PROCESS
• PP is fed into the hopper of the injection moulding machine
• The mould is held between the two platens which are kept closed by the locking
pressure. Prior to mould closure, the metal insert is skilfully kept in the mould.
• The material which gets plasticized in the barrel is injected under higher pressure
into the Mould which results in a molded article i.e. Battery Lid with Metal Insert.
On similar terms, a Battery Case is also manufactured, but with or without rim,
depending upon the mould.
• The Battery Case is then finished by removing the injection feed etc.
• The second stage processing operations such as printing, labelling are carried out
on the Battery housing.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
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when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
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typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch

Metal Insert (only for Battery Lid – optional)
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V)
Tie bar Distance (H×V)
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V) Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
 2016 CIPET Bhubaneswar. All rights reserved
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Specification
180 – 200
40-60
251 – 679
30 – 57
150/560
810 × 810
570×570
6.3×1.7×2.6
525
38.2 – 54.5
8600
Specification
275 – 350
60 – 90
792 – 1810
49 – 65
200 – 800
940×940 / 1030×1030
660×660 / 720×720
6.3×1.7×2.6 /
8.2×2.1×3.1
615
62.5 – 86.2
8600 – 18500
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MACHINERY & MOULD COST
1) PRODUCT NAME: 1110 GRAM BATTERY BOX
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
Machinery
Quantity
Injection Moulding
Machine, 350 Ton
(for Battery case)
Injection Moulding
Machine, 180 Ton
(for lid)
Cranes (Manual)
Dry colour Mixer
Machine
Scrap
Grinding
Machine
Air Compressor
Water Pump
Chilling
Plant/Cooling Tower
Total Cost
1 No.
Cost (in
Lacs)
50 – 60
1 No.
25 – 30
1 No.
1 No.
3–5
2–3
1 No.
2.5 - 3
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-5
94 – 114
B.MOULD COST
Sl.No.
1.
2.
Mould
Mould for 1Litre
Battery Case
Mould for 1Litre
Battery Lid
Total Cost
Quantity
1 No.
Cost
(in Lacs)
15 – 20
1 No.
5–6
20 – 26
TOTAL COST (MACHINERY& MOULD):114 – 140 Lacs
 2016 CIPET Bhubaneswar. All rights reserved
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C.PRODUCTION CAPACITY
PRODUCT
Production
Production
Capacity per day
Capacity per
(for 22 hours)
annum
Raw Material
Consumption
/ annum
(300 days)
1Litre
1760
pieces
Battery Case
seconds
for
@
45 5,28,000
single pieces
~ 586 MT @
1110 g/piece
Battery Case
1Litre
3168
pieces
Battery Lid
seconds
for
@
25 9,50,400
single pieces
~ 266 MT @
280 g/ piece
Battery Lid
D.UTILITIES REQUIREMENTS
Sl.
No.
1.
Type
Requirement (approx.)
Connected Load – 75 KW
8.
Electricity for Injection
Moulding Machine, 350 Ton
Electricity for Injection
Moulding Machine, 180 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water Pump
Electricity for Chilling
Plant/Cooling Tower
Water
9.
Land Required*
2.
3.
4.E.
5.
6.
7.
Connected Load – 52 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
100 litre/min
Water will be circulated
through fixed tank
capacity is 15000-20000
litre
15,000 – 20,000 sq.ft.
* 70 – 80 % is required for Machineries and Utilities
 2016 CIPET Bhubaneswar. All rights reserved
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E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
worker
01
03
04
05
INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V) Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Specification
450
90
2290
93
300
1200 × 1200
830×830
9.2×2.4×3.3
750
112.9
25500
2) PRODUCT NAME:1500 GRAM BATTERY BOX
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
Machinery
Injection Moulding
Machine, 450 Ton (for
Battery case)
Injection Moulding
Machine, 180 Ton (for
lid)
Cranes (Manual)
Dry
colour
Mixer
Machine
Scrap
Grinding
Machine
 2016 CIPET Bhubaneswar. All rights reserved
Quantit
y
1 No.
Cost
(in Lacs)
60 – 70
1 No.
25 – 30
1 No.
1 No.
3–5
2–3
1 No.
2.5 - 3
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6.
7.
8.
Air Compressor
1 No.
Water Pump
1 No.
Chilling Plant/Cooling 1 No.
Tower
Total Cost
2.5 - 3
0.5 - 1
8 – 9/3-5
104 – 124
B. MOULD COST
Sl.No.
1.
2.
Mould
Quantity
Mould for Battery
Case
Mould for Battery Lid
Total Cost
1 No.
1 No.
Cost
(in Lacs)
15 – 20
5–6
20 – 26
TOTAL COST (MACHINERY& MOULD):124 – 150 Lacs
C. PRODUCTION CAPACITY
PRODUCT
Battery Case
Battery Lid
Production
Capacity per day
(for 22 hours)
Raw Material
Consumption
/ annum
1320 pieces
seconds
for
Battery Case
3168 pieces
seconds
for
Battery Lid
Production
Capacity per
annum
(300 days)
@ 60 3,96,000
single pieces
~ 594 MT @
1500 g/piece
@ 25 9,50,400
single pieces
~ 266 MT @
280 g/ piece
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D.UTILITIES REQUIREMENTS
Sl. No.
1.
8.
Type
Electricity for Injection
Moulding Machine, 450
Ton
Electricity for Injection
Moulding Machine, 180
Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water
Pump
Electricity for Chilling
Plant/Cooling Tower
Water
9.
Land Required *
2.
3.
4.
5.
6.
7.
Requirement (approx.)
Connected Load – 80 KW
Connected Load – 52 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
100 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
12,000 – 15,000 sq.ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
worker
01
03
04
05
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3) PRODUCT NAME:2000 GRAM BATTERY BOX
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
Machinery
Quantity
Injection Moulding
Machine, 650 Ton (for
Battery case)
Injection Moulding
Machine, 180 Ton (for
lid)
Cranes (Manual)
Dry colour Mixer Machine
Scrap Grinding Machine
Air Compressor
Water Pump
Chilling
Plant/Cooling
Tower
Total Cost
1 No.
Cost
(in Lacs)
80 – 90
1 No.
25 – 30
1
1
1
1
1
1
3–
2–
2.5
2.5
0.5
8–
No.
No.
No.
No.
No.
No.
5
3
-3
-3
-1
9/3-5
124
144
–
B. MOULD COST
Sl.No.
1.
2.
Mould
Mould for Battery
Case
Mould for Battery Lid
Total Cost
Quantity
1 No.
Cost
(in Lacs)
21 - 26
1 No.
5–6
26 – 32
TOTAL COST (MACHINERY& MOULD):150 – 176 Lacs
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C. PRODUCTION CAPACITY
PRODUCT
Battery Case
Battery Lid
Production
Capacity per day
(for 22 hours)
Raw Material
Consumption
/ annum
1056 pieces
seconds
for
Battery Case
3168 pieces
seconds
for
Battery Lid
Production
Capacity per
annum
(300 days)
@ 75 3,16,800
single pieces
~ 475 MT @
1500 g/piece
@ 25 9,50,400
single pieces
~ 266 MT @
280 g/ piece
D. UTILITIES REQUIREMENTS
Sl. No.
1.
8.
Type
Electricity for Injection
Moulding Machine,650
Ton
Electricity for Injection
Moulding Machine, 180
Ton
Electricity for Dry
colour Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water
Pump
Electricity for Chilling
Plant/Cooling Tower
Water
9.
Land Required
2.
3.
4.
5.
6.
7.
Requirement (approx.)
Connected Load – 90 KW
Connected Load – 52 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
100 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
15,000 – 20,000 sq.ft.
* 70 – 80 % is required for Machineries and Utilities
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E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
worker
01
03
04
05
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6. TOOTH BRUSH
INTRODUCTION
The tooth brush is in daily use for almost the entire population. The toothbrush is
an oral hygiene instrument used to clean the teeth and gums that consists of a
head of tightly clustered bristles mounted on a handle, which facilitates the
cleansing of hard-to-reach areas of the mouth. It is made of polypropylene. Tooth
brush handle is first formed by injection moulding process and then nylon bristles
are fixed on it to form the brush. Quality of the brush and its satisfactory
performance depends upon the type of nylon bristles, fixing of bristles etc. It is
available in different attractive colours.
USAGES / APPLICATIONS



Houses
Hotels
Travelling kit
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MARKET POTENTIAL
Indian oral care industry, over the last few years, has been one of the fast growing
FMCG sectors. The growth in the industry is driven by rising disposable income,
change in consumer lifestyle, entry of international players in the market and
introduction of new product categories in toothpaste, toothbrush and mouthwashes.
On the account of these factors, the oral care industry witnessed a substantial
growth in the revenue. Toothbrush is the second largest oral care products segment
in the industry after toothpaste and majorly including products such as manual and
electric toothbrushes. The toothbrush market in the country has grown at a very
high CAGR during the period FY'2008-FY'2013. Overall, the toothbrush market
revenues have grown at a CAGR of ~% from FY’2010 - FY’2015. According to the
research report, the India toothbrush Market will grow at a considerable CAGR rate
thus exceeding INR 26 billion by FY’2020 due to development of premium category
products, rising advertisement and promotional efforts by FMCG companies to make
consumers aware particularly in rural areas along with the rising awareness levels
leading to higher replacement rate of toothbrush. “Manual toothbrushes are
anticipated to maintain their dominance in the toothbrush market due to their easy
availability at low prices in comparison to power toothbrushes. Thus, swift growth
of manual toothbrushes is likely to overpower the growth of power toothbrush in
the country over the next five years”, according to the Research Analyst, Ken
Research (http://www.news.kenresearch.com/).
EQUIPMENTS AND ACCESSORIES LIST





Injection Moulding Machine
Filling Machine
Cooling Tower/ Chiller Plant
Air Compressor
Scrap Grinder
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FLOW CHART
Moulding the tooth brush handles using
Injection moulding Machine
Bristle fixing using filling machine
Trimming the bristles
Packing the tooth brushes
MANUFACTURING PROCESS
Generally, toothbrushes consist of plastic handles and nylon bristles.
Moulding the handles
The pellets are then placed in an injection moulding machine, which heats the
plastic until it is melted. A rotating screw or plunger forces the liquid plastic into the
handle moulds. The moulds form the entire handle, including the small holes, called
cores, into which the bristles are inserted. The moulds are securely clamped, and
pressure is applied to the moulds while the plastic cools. Once the moulds have
adequately cooled, the clamps are removed, and small pins push the handles out of
the moulds.
Bristle Fixing
The bristles, which are usually made of nylon, are positioned into the core of the
handle automatically. The bristles are then stapled into the core with tiny metal
staples.
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Trimming the bristles
Next, the toothbrush passes through a trimming machine which slices the bristles
to the correct length and shape for the particular design.
Packaging the toothbrushes
The toothbrushes are packaged into cardboard and/or plastic containers. Labels are
attached to the package, providing product information such as bristle hardness, as
well as recommendations for usage. If the brand is approved by the American
Dental Association, the Seal of Acceptance is also stamped on the container. Finally,
the packaged toothbrushes are bundled into larger shipping boxes or crates.
.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
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the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch

Nylon Bristles
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION
Sl. No
1
2
3
4
5
6
7
8
9
10
11
MOULDING MACHINE SPECIFICATION
Injection Unit
Unit
Clamping Force
Ton
Screw Diameter
mm
Swept Volume
cc
Plasticizing Capacity (GPPS)
g/sec
Mould Height (Min/Max)
mm
Platen size (H × V)
mm
Tie bar Distance (H×V)
mm
Machine Dimension (L×W×H)
mm
Total Oil Capacity
Ltr.
Total Connected Load
KW
Machine Weight
Kg
Specification
180 – 200
40-60
251 – 679
30 – 57
150/560
810 × 810
570×570
6.3×1.7×2.6
525
38.2 – 54.5
8600
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Machinery
Quantity
Injection Molding machine
180 Ton
Dry colour Mixer Machine
Crane (Manual)
Bristle Filling machine
Packing Machine
Scrap Grinding Machine
Air Compressor
Water Pump
Chilling Plant
Total cost
1No.
1 No.
1 No.
1No.
1No.
1 No.
1 No.
1 No.
1 No.
Cost
(in Lacs)
25-30
2–3
5-8
20-25
5-8
2.5 - 3
2.5 - 3
0.5 - 1
8-9
71 - 90
B.MOULD COST
Sl.No.
1.
Mould
Hot Runner Mould, 16 cavity
Total cost
Quantity
1 No.
Cost
(in Lacs)
20 - 25
20-25
TOTAL COST (MACHINERY & MOULD): 91-115 Lacs
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C.PRODUCTION CAPACITY
Production
Capacity per day
(@ 20 seconds for 16
cavity mould, for 22 hours)
63,360 pieces
Production
Capacity per
annum
(300 days)
1, 90,08,000
pieces
Raw
Material
Consumption /
annum
~ 285 MT @ 15 g
per piece
D.UTILITIES REQUIREMENTS
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Type
Electricity for Injection
Molding machine 180 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Bristle Filling
machine
Electricity for Packing
Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water Pump
Electricity for Chilling Plant
Water
Requirement (approx.)
Connected Load – 52 KW
Connected Load – 3 KW
Connected Load – 10 KW
Connected Load – 4 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
100 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
10.
Land Required *
8,000 -10,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled Workers
Semi-Skilled
Workers
01
03
04
06
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7. a)LUNCH BOX
INTRODUCTION
A reusable container, usually with a handle, designed for storing
and carrying
one's lunch. The lunch box, also referred to as a lunch pail or lunch kit, is used to
store food to be taken anywhere. A lunch kit comprises the actual "box" and a
matching vacuum bottle. However, the latest culture has more often embraced the
singular term lunch box, which is now most commonly used. The lunch box has
most often been used by schoolchildren to take packed lunches, or a snack, from
home to school. Lunch boxes are often brightly coloured or matte finished
depending on the age of the individuals using it. Generally two step lunch box is
preferred for extra storage.
USAGES / APPLICATIONS:

For office goers

For School Children
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MARKET POTENTIAL
Polypropylene is found to be the best to manufacture lunch boxes, as no harmful
hazards have been found on it even when used as microwave applicable products.
Almost everyone uses lunch boxes, except the variation in the number of sets or
layers. The demand for plastic lunch boxes are high, as they are easy washable and
safe for use. Moreover, they can be prepared with attractive colours with the help
of master batches and hence a higher demand among school going kids.
EQUIPMENTS AND ACCESSORIES INVOLVED

Injection Moulding Machine

Cooling Tower/ Chiller Plant

Dry Color Mixer

Air Compressor

Scrap Grinder
FLOW CHART BASIS:
PP + colourant (optional)
Fixing of mould in machine
Injection of Molten PP material in
Cooling and Opening of mould
Ejection of component
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of PP raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
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is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOULDING MACHINE SPECIFICATION
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Unit
Ton
mm
cc
g/sec
mm
mm
mm
Specification
110 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
435×435 / 510 × 510
mm
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
Ltr.
KW
Kg
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
Machinery
Injection Moulding
Machine, 120 Ton
Dry colour Mixer
Machine
Packing Machine
Scrap
Grinding
Machine
Air Compressor
Water Pump
Chilling
Plant/Cooling
Tower
Crane
(Manual
Operation)
TOTAL COST
 2016 CIPET Bhubaneswar. All rights reserved
Quantity
1 No.
Cost
(in Lacs)
15 – 20
1 No.
2–3
1 No.
1 No.
9 – 10
2.5 - 3
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-4
1 No.
5-8
45 – 57
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B.MOULD COST
Sl.No.
1.
Mould
Quantity
Mould
1 Set.
TOTAL COST
Cost
(in Lacs)
20 - 25
20 - 25
TOTAL COST (MACHINERY& MOULD):65 - 82 lacs
C.PRODUCTION CAPACITY
Production Capacity
per day (@ 25 seconds
for single lunch box, for
22 hours)
3168 pieces
Production
Capacity
per annum
(300 days)
9,50,400
pieces
Raw Material
Consumption
/ annum
~ 72 MT @ 75
g / piece
D.UTILITIES REQUIREMENTS:
Sl. No.
1.
2.
3.
4.
5.
6.
7.
Type
Electricity for
Injection Moulding
Machine, 120 Ton
Electricity for Dry
colour Mixer Machine
Electricity for Packing
Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water
Pump
Electricity for Chilling
Plant/Cooling Tower
Water
Requirement (approx.)
Connected Load – 45 KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
80 litre/min*
Water will be circulated
through fixed tank
capacity is 15000-20000
litre
8.
Land Required*
8,000 -10,000 Sq. Ft
* 70 – 80 % is required for Machineries and Utilities
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E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
Worker
01
03
03
03
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7. b) BUCKET
INTRODUCTION
Thermoplastic materials like PP homopolymer, recycled PP and clarified PP can be
injection moulded into buckets of different sizes and shapes. Some of the common
items that are produced from PP include buckets, cans and mugs. Their light
weight, flexibility, corrosion resistance and chemical resistance have made these
plastic products popular for storage and handling of water, petrol, diesel etc.
USAGES / APPLICATIONS


Water Storage
House hold applications

Industrial applications
MARKET SURVEY / POTENTIAL
Bucket is a conventional utensils being used in house since long. Plastic bucket is
strong, rough & tough in use. The metal bucket has threatened it to same extent
but could not replace it due to issues occurring for pitting and corrosion issues, that
is due to salty the water which varies from place to place. Buckets are known for its
durability. Even now there is wide scope of the bucket not only is rural area but
also in urban houses and industries.
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Generally, Plastic comb, mug, bucket and containers are considered as necessity
items for every household. Considering, on an average, that five persons constitute
a household the total household in the region is in lakhs. Again considering that
every year there is a replacement demand to change these items by at least 30%
of total number of households, the requirement of these items on this basis
becomes huge. This may be in addition to the new demand for these items by at
least 15% of total number of household every year which is beyond calculation.
EQUIPMENTS AND ACCESSORIES LIST

Injection Moulding Machine

Cooling Tower/ Chiller Plant

Dry Colour Mixer

Scrap Grinder

Air Compres
Flow Chart
PP Raw material
Colourant
PP Master batch
Injection moulding Machine
Labelling (optional)
Handle Fitting
Printing & Stickering
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of PP raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
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is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch

Metal handle
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V)
Tie bar Distance (H×V)
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Ltr.
KW
Kg
Specification
180 – 200
40-60
251 – 679
30 – 57
150/560
810 × 810
570×570
6.3×1.7×2.6
525
38.2 – 54.5
8600
MACHINERY & MOULD COST
A. MACHINERY COST FOR 5L& 10L BUCKET
Sl.No.
1.
2.
3.
4.
5.
6.
7.
Machinery
Quantity
Injection Moulding
Machine, 180 Ton
Cranes (Manual)
Dry
colour
Mixer
Machine
Scrap
Grinding
Machine
Air Compressor
Water Pump
Chilling Plant/Cooling
Tower
Total Cost
1 No.
Cost
(in Lacs)
25 – 30
1 No.
1 No.
3–5
2–3
1 No.
2.5 - 3
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-5
44–54
B.MOULD COST FOR 5L& 10L BUCKET
Sl.No.
1.
2.
Mould
Mould for 5 L Bucket
Mould for 10 L Bucket
Total Cost
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Quantity
1 No.
1 No.
Cost
(in Lacs)
3-5
5-7
8 – 12
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TOTAL COST FOR 5L BUCKET (MACHINERY& MOULD):47-59 Lacs
TOTAL COST FOR 10L BUCKET (MACHINERY& MOULD):49-61 Lacs
TOTAL COST FOR 5L & 10 L BUCKET (MACHINERY& MOULD):51-65 Lacs
C.PRODUCTION CAPACITY FOR 5L& 10L BUCKET
PRODUCT
5 L BUCKET
10 L
BUCKET
Production
Capacity per day
(for 22 hours)
Raw Material
Consumption
/ annum
3960 pieces
seconds
for
bucket
3168 pieces
seconds
for
bucket
Production
Capacity per
annum
(300 days)
@ 20 11,88,000
single pieces
~ 238 MT @
200 g/piece
@ 25 9,50,400
single pieces
~ 285 MT @
300 g/ piece
C.UTILITIES REQUIREMENTS FOR 5L &10L
Sl. No.
1.
Type
Electricity for Injection
Moulding Machine, 180 Ton
Requirement (approx.)
Connected Load – 52 KW
Connected Load – 3 KW
7.
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water Pump
Electricity for Chilling
Plant/Cooling Tower
Water
8.
Land Required
2.
3.
4.
5.
6.
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
100 litre/min*
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
5,000 – 8,000 sq.ft.
* 70 – 80 % is required for Machineries and Utilities
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D.MANPOWER REQUIREMENTS FOR 5L & 10L
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
worker
01
03
03
09
INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V) Min/Max
Machine Dimension (L×W×H)
Unit
Ton
mm
cc
g/sec
mm
mm
mm
mm
Total Oil Capacity
Total Connected Load
Machine Weight
Ltr.
KW
Kg
Specification
275 – 350
60 – 90
792 – 1810
49 – 65
200 – 800
940×940 / 1030×1030
660×660 / 720×720
6.3×1.7×2.6 /
8.2×2.1×3.1
615
62.5 – 86.2
8600 – 18500
A. MACHINERY COST FOR BUCKET (15L & 20 L)
Sl.No.
1.
2.
3.
4.
5.
6.
7.
Machinery
Quantity
Injection Moulding
Machine, 275 Ton
Cranes (Manual)
Dry
colour
Mixer
Machine
Scrap
Grinding
Machine
Air Compressor
Water Pump
Chilling Plant/Cooling
tower
Total cost
1 No.
Cost
(in Lacs)
25 – 30
1 No.
1 No.
3–5
2–3
1 No.
2.5 - 3
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-5
 2016 CIPET Bhubaneswar. All rights reserved
44 –54
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B. MOULD COST FOR BUCKET (15L & 20L)
Sl.No.
1.
2.
Mould
Mould for 15 Lit
Bucket
Mould for 20 Lit
Bucket
Total cost
Quantity
1 No.
Cost
(in Lacs)
5-7
1 No.
10 - 12
15 - 19
TOTAL COST FOR 15L BUCKET (MACHINERY& MOULD):47-61 Lacs
TOTAL COST FOR 20L BUCKET (MACHINERY& MOULD): 54-66 Lacs
TOTAL COST FOR 15L & 20 L BUCKET (MACHINERY& MOULD):59-73 Lacs
C.PRODUCTION CAPACITY
Product
15L Bucket
20 L Bucket
Production
Capacity per day
for 22 hours
Production
Capacity
per annum
(300 days)
2640 pieces @ 30 7,92,000
seconds for single component
bucket
1980 pieces @ 40 5,94,000
seconds for single component
bucket
 2016 CIPET Bhubaneswar. All rights reserved
Raw Material
Consumption
/ annum
~ 317 MT @
400 g/ piece
~ 238 MT @
400 g/ piece
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D.UTILITIES REQUIREMENTS
Sl.
No.
1.
Type
Requirement (approx.)
Connected Load – 70 KW
7.
Electricity for Injection
Moulding Machine, 275
Ton
Electricity for Dry colour
Mixer Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water
Pump
Electricity for Chilling
Plant/Cooling Tower
Water
8.
Land Required*
2.
3.
4.
5.
6.
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
130 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
12,000 – 15,000 sq.ft.
* 70 – 80 % is required for Machineries and Utilities
E. MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled
worker
01
03
03
09
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7. c) COMBS
INTRODUCTION
A comb is a toothed device used for styling, cleaning and managing hair and scalp.
Combs consist of a shaft and teeth that are placed at a perpendicular angle to the
shaft. Combs can be made out of a number of materials, most commonly plastic,
metal or wood. Combs can vary in shape according to function. Hairdressing combs
may have a thin, tapered handle for parting hair and close teeth. Common hair
combs usually have wider teeth half way and finer teeth for the rest of the
comb. An unbreakable plastic comb is a comb that, despite being made of plastic
rather than (more expensive) metal, does not shatter into multiple pieces if
dropped on a hard surface such as bathroom tiles, a hardwood floor, or a
pavement.
USAGES / APPLICATIONS





House
Hotels
Beauty Parlour
Hair Sallon
Travel kit
MARKET POTENTIAL
Plastic comb is considered as the most important item for every household and
wellness health and grooming parlours. As per the census and the population of
India that constitute of five persons on an average, a household comprises of every
individual using a comb, either on sharing basis or a common one. On that note,
that every year there is a replacement demand to change these items by at least
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30% of total number of households, the requirement of these items on this basis
becomes a huge requirement which cannot be met alone by SSI industries.
EQUIPMENTS AND ACCESSORIES LIST





Injection Moulding Machine
Pad Printing Machine
Cooling Tower/ Chiller Plant
Air Compressor
Scrap Grinder
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection of Molten PP material in
Cooling and Opening of mould
Ejection of component
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of PP raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
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is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
INJECTION MOULDING MACHINE SPECIFICATION
Sl. No
1
2
3
4
5
6
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
 2016 CIPET Bhubaneswar. All rights reserved
Unit
Ton
mm
cc
g/sec
mm
mm
Specification
110 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
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7
8
9
10
11
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
mm
435×435 / 510 × 510
mm
Total Oil Capacity
Total Connected Load
Machine Weight
Ltr.
KW
Kg
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
6.
7.
8.
Machinery
Quantity
Injection Moulding Machine,
120 Ton
Dry colour Mixer Machine
Pad Printing machine/Hot
Stamping machine
Crane for loading/
unloading
Scrap Grinding Machine
Air Compressor
Water Pump
Chilling Plant/Cooling Tower
Total Cost
1 No.
Cost
(in Lacs)
20 – 26
1 No.
1 No.
2–3
1–2
1 No.
3–4
1
1
1
1
No.
No.
No.
No.
1–2
2.5 - 3
0.5 - 1
8 – 9/3-5
38 – 50
B.MOULD COST
Sl.No.
1.
Mould
Hot Runner Mould,
16 cavity Impression
Total Cost
Quantity Cost
(in Lacs)
1 No.
20 – 22
20 – 22
TOTAL COST FOR COMB (MACHINERY& MOULD): 58 – 72 lacs
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C.PRODUCTION CAPACITY
Production
Capacity
per day @ 20 seconds
for 16 cavity mould, for
22 hours)
Production
Capacity
per annum
(300 days)
Raw Material
Consumption
/ annum
63,360 pieces
1,90,08,000
pieces
~ 190 MT
@ 10 g / piece
D.UTILITIES REQUIREMENTS:
Sl. No.
1.
Requirement (approx.)
Connected Load – 45 KW
5.
Type
Electricity for Injection
Moulding Machine, 120 Ton
Electricity for Dry colour
Mixer Machine
Electricity for Pad Printing
machine/Hot Stamping
machine
Electricity for Scrap Grinding
Machine
Electricity for Air Compressor
6.
Electricity for Water Pump
Connected Load – 3 KW
7.
Electricity for Chilling
Plant/Cooling Tower
Water
Connected Load – 8 KW
2.
3.
4.
8.
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 4 KW
Connected Load – 5 KW
80 litre/min
Water will be circulated
through fixed tank
capacity is 15000-20000
litre
9.
Land Required*
6,000 – 8,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
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E. MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Supervisor
Manager
03
01
Skilled -Worker
03
Non-Skilled Worker
02
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8. CAPS & CLOSURES
INTRODUCTION
A bottle cap seals the top opening of a bottle. A cap is typically colourfully
decorated with the logo of the brand of beverage. Plastic caps are widely used for
water, soft drinks, fruit juice plastic bottles. A screw cap or closure is a common
type of closure for bottles, jars, and tubes.
USAGES/ APPLICATIONS







Beverages Bottles
Fruit Juices
Water
Milk
Drugs
Chemicals
Cosmetic
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MARKET POTENTIAL
Plastic bottle caps find extensive use for bottles used in packaging cosmetics,
drugs, chemicals, adhesives, toffees, etc. These caps can with stand corrosive
chemicals and are available in attractive colours at low cost. Gradually, the demand
is more for packing the products in attractive plastics containers to appeal the
customers. Therefore bottle caps would be in growing demand for such containers.
A small unit can manufacture the caps with indigenously available machinery and
raw material.
EQUIPMENTS AND ACCESSORIES LIST




Injection Moulding Machine
Cooling Tower/ Chiller Plant
Air Compressor
Scrap Grinder
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection of Molten PP material in mould
Cooling and opening of mould
Ejection of component
Rubber liner (optional)
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of PP raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
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is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP material + colourant (or) PP master batch

Rubber Liner (optional)
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Processing conditions
Drying
Melt Temperature
Mould Temperature
Injection Pressure
Not normally necessary if proper storage is used.
220 - 275°C
40 - 80°C
Up to 1800 bar ( 26000 psi)
INJECTION MOULDING MACHINE SPECIFICATION
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
Unit
Ton
mm
cc
g/sec
mm
mm
mm
Specification
90 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
435×435 / 510 × 510
mm
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
Ltr.
KW
Kg
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
1.
2.
3.
4.
5.
Machinery
Quantity
Injection Moulding
Machine, 90 Ton
Dry
colour
Mixer
Machine
Crane (Manual)
Packing & Sealing
Machine
Scrap
Grinding
Machine
1 No.
Cost
(in Lacs)
22 – 25
1 No.
2–3
1 No.
1 No.
5-8
5-6
1 No.
2.5 - 3
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6.
7.
8.
9.
Air Compressor
Water Pump
Chilling Plant/Cooling
Tower
Rubber Liner Fixing
machine
TOTAL COST
1 No.
1 No.
1 No.
2.5 - 3
0.5 - 1
8 – 9/3-5
2 nos.
10 -12
58 – 72
B.MOULD COST
Sl.No.
1.
Mould
Quantity
Hot Runner Mould,
64 Impression
TOTAL (Mould)
1 No.
Cost
(in Lacs)
70 – 80
70 – 80
TOTAL COST (MACHINERY & MOULD): 128-152 lacs
C.PRODUCTION CAPACITY
Product
Production
Capacity per day
(for
64
cavity
mould,
for
22
hours)
Bottle
cap 2,53,440 pieces @
(without rubber 20 seconds
liner)
Bottle cap (with 2,02,752 pieces @
rubber liner)
25 seconds
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Production
Capacity
per annum
(300 days)
Raw Material
Consumption
/ annum
1,90,08,000 ~152 MT
pieces
6,08,25,600 ~122 MT
pieces
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D.UTILITIES REQUIREMENTS
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 350
Ton
Electricity for Dry colour
Mixer Machine
Electricity for Packing &
Sealing Machine
Electricity for Scrap
Grinding Machine
Electricity for Air
Compressor
Electricity for Water
Pump
Electricity for Chilling
Plant/Cooling Tower
Electricity for Rubber
Liner Fixing machine
Water
Connected Load – 75 KW
Connected Load – 3 KW
Connected Load – 6 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 2 KW
Connected Load – 8 KW
Connected Load – 4 KW
150 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
10.
Land Required *
5,000 – 8,000 sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E. MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled Worker
01
03
03
06
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9. CAR BUMPER
The automotive industry is on the brink of a revolution, and the plastics industry
poised to play a major role. The real plastics revolution in automotive industry
began in 1950 when thermoplastics made their debut, starting with ABS and going
on to polyamide, polyacetal,polypropylene
and polycarbonate together with
introduction of alloys and blends of various polymers. The ongoing development of
advanced, high-performance polymers has dramatically increased their usage.
Originally plastics were specified because they offered good mechanical properties
combined with excellent appearance, including the possibility of self-coloring. The
application of plastic components in the automotive industry has been increasing
over the last decades. Nowadays, the plastics are used mainly to make cars more
energy efficient by reducing weight, together with providing durability, corrosion
resistance, toughness, design flexibility, resiliency and high performance at low
cost. The light weight of plastics makes for more fuel efficient vehicles.
It is
estimated that every 10% reduction in vehicle weight results in a 5 to 7% reduction
in fuel usage. Current economic and environmental concerns make the creation of
more fuel efficient cars a top priority in the automotive industry.
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ADVANTAGES:





minimal corrosion, allowing for longer vehicle life
substantial design freedom, allowing advanced creativity and innovation
flexibility in integrating components
safety, comfort and economy
recyclability
USAGES /APPLICATIONS

Car
MARKET POTENTIAL
The average vehicle uses about 150 kg of plastics and plastic composites versus
1163 kg of iron and steel – currently it is moving around 10-15 % of total weight of
the car. The automotive industry uses engineered polymer composites and plastics
in a wide range of applications, as the second most common class of automotive
materials after ferrous metals and alloys (cast iron, steel, nickel) which represent
68% by weight; other non-ferrous metals used include copper, zinc, aluminum,
magnesium, titanium and their alloys . The plastics contents of commercial vehicles
comprise about 50 % of all interior components, including safety subsystems, door
and seat assemblies.Many types of polymers are used in more than thousand
different parts of all shapes and sizes. A quick look inside any model of the car
shows that plastics are now used in exterior and interior components such as
bumpers, doors, safety and windows, headlight and side view mirror housing, trunk
lids, hoods, grilles and wheel covers, just three types of plastics make up some 66
% of the total plastics used in a car: polypropylene (32 %), polyurethane (17 %)
and PVC (16 %).
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FLOW CHART
Glass filled PP + colourant
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of Glass filled PP +colorant raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
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INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
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Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
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RAW MATERIAL

Glass filled PP
Processing conditions
Drying
Melt Temperature
Not normally necessary if proper storage is used.
220 - 275°C
Mould Temperature
Injection Pressure
40 - 80°C
Up to 1800 bar ( 26000 psi)
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MACHINERY & MOULD COST FOR BUMPER
A. MACHINERY COST
Sl.No.
1.
2.
3.
Machinery
Quantity
Injection Moulding
Machine,2500 Ton
Crane
1 No.
Cost
(in Lacs)
150-250
1 No.
20-25
5-10
4.
Dry
colour
Mixer 1 No.
Machine
Scrap Grinding Machine
1 No.
5.
Air Compressor
1 No.
7-10
Water Pump
1 No.
0.5 - 1
6.
7.
Chilling
Tower
Plant/Cooling 1 No.
Total cost
3-5
8 – 9/4-5
194 –310
B. MOULD COST
Sl.No.
1.
Mould
Mould for Bumper
Total cost
Quantity
1 No.
Cost
(in Lacs)
80-100
80-100
TOTAL COST FOR BUMPER (MACHINERY& MOULD):274-410 lacs
C.PRODUCTION CAPACITY
Production Capacity per Production
day @140 seconds for Capacity per
Bumper, for 22 hours
annum
(300 days)
565 components
1,69,500
pieces
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Raw Material
Consumption
/ annum
~339MT
@ 2 Kg
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D.UTILITIES REQUIREMENTS
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 2500
Ton
Electricity for Dry colour
Mixer Machine
Electricity
for
Scrap
Grinding Machine
Electricity
for
Air
Compressor
Electricity for Water Pump
Electricity
for
Chilling
Plant/Cooling Tower
Water
Connected Load – 400KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
300 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8.
Land Required*
20,000 – 25,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
01
03
03
Semi-Skilled Worker
06
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10. THIN WALLED INJECTION MOLDED PRODUCTS
Thin
wall
injection
molding is
a
specialized
form
of
conventional injection
molding that focuses on mass-producing plastic parts that are thin and light so that
material cost savings can be made and cycle times can be as short as possible.
Shorter cycle times means higher productivity and lower costs per part.
The definition of thin wall is really about the size of the part compared to its wall
thickness. For any particular plastic part, as the wall thickness reduces the harder it
is to manufacture using the injection molding process. The size of a part puts a limit
on how thin the wall thickness can be. For packaging containers thin wall means
wall thicknesses that are less than 0.025 inch (0.62mm) with a flow length to wall
thickness greater than 200.
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ADVANTAGES

Cheap, safe and clean plastic parts.

Thin wall molding reduces resource consumption and cuts weight, reducing
fuel usage and carbon emissions in shipping – further supporting
sustainability efforts.

Allows faster cycle times compared with thicker walled plastic parts. This is
good for injection molders because it reduces their delivery lead time and
cost per part.

Lighter parts reduce fuel emissions in automotive applications.

Some thin wall parts can be made from sustainable plastics.
USAGES /APPLICATIONS

Food packaging

Automotive

Mobile Telecommunications

Computing Equipments
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MARKET POTENTIALS
The trend towards thin wall molding continues to increase in many plastic industries
as plastic material and energy costs continue to rise and delivery lead times are
squeezed.
The following industries make use of thin wall molding:





food packaging (food containers and lids)
automotive (both structural and non-structural car parts)
mobile telecommunications (mobile phone housings)
medical (syringes)
computing equipment (computer housings)
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing
13.Feeding of PP raw material into the hopper
14.Injection moulding process.
15.Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
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and ejects the moulded parts. The stationary platen is attached to the barrel side of
the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
RAW MATERIAL

PP + Colourant (or) PP master batch
Processing conditions
Drying
Melt Temperature
Not normally necessary if proper storage is used.
220 - 275°C
Mould Temperature
Injection Pressure
40 - 80°C
Up to 1800 bar ( 26000 psi)
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INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
Unit
Ton
mm
cc
g/sec
mm
mm
mm
Specification
110 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
435×435 / 510 × 510
mm
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
Total Oil Capacity
Total Connected Load
Machine Weight
Ltr.
KW
Kg
MACHINERY & MOULD COST FOR THIN WALLED PRODUCT
A. MACHINERY COST
Sl.No.
1.
2.
3.
Machinery
Quantity
Cost
(in Lacs)
Injection Moulding
Machine,150 Ton *
Crane (Manual)
1 No.
20-25
1 No.
5-8
2–3
4.
Dry
colour
Mixer 1 No.
Machine
Scrap Grinding Machine
1 No.
5.
Air Compressor
1 No.
2.5 - 3
6.
Water Pump
1 No.
0.5 - 1
7.
Chilling
Tower
Plant/Cooling 1 No.
Total cost
2.5 - 3
8 – 9/4-5
41 -52
*Capacity ranges from 150 Ton to higher Tonnage
based on the design and output
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B. MOULD COST
Sl.No.
1.
Mould
Quantity
Hot Runner Mould, 4
Impression, for Thin
Walled Product
Total cost
TOTAL COST FOR
MOULD):51-67 lacs
THIN
1 No.
Cost
(in Lacs)
10-15
10-15
WALLED
PRODUCT
(MACHINERY&
C.PRODUCTION CAPACITY
Production Capacity per
day @20 seconds for 4
impressions,
for
22
hours
Production
Capacity per
annum
(300 days)
Raw Material
Consumption
/ annum
15840components
47,52,000
pieces
~17 MT@3.5g
per piece
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D.UTILITIES REQUIREMENTS
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 150
Ton
Electricity for Dry colour
Mixer Machine
Electricity
for
Scrap
Grinding Machine
Electricity
for
Air
Compressor
Electricity for Water Pump
Electricity
for
Chilling
Plant/Cooling Tower
Water
Connected Load – 45KW
Connected Load – 2 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
200 litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8.
Land Required*
20,000 – 25,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
01
02
03
Semi-Skilled Worker
06
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11.BALL PEN
INTRODUCTION
Any office or work site or any educational institute is governed by the printed media
along-with the writing essential, including home. The one foremost important thing
to etch the writing onto a paper or book, is a Pen – most generally and commonly
used, a Ball Pen. A ballpoint pen is a writing instrument which features a tip that is
automatically refreshed with ink. It consists of a precisely formed metal ball seated
in a socket below a reservoir of ink. As the pen is moved along a writing surface,
ink is delivered. Ink is a viscous and coloured fluid composed of reflux blue,
varnishes, oil and drier. Now, ballpoint pens dominate the writing instrument
market, selling over one hundred million pens each year worldwide. A variety of
raw materials are used for making the components of a ballpoint pen, including
metal for tip, other chemicals for dye and ink and most importantly, the body which
is made up of plastic – preferentially Polypropylene.
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USAGES / APPLICATIONS

Office

School

Gift item
MARKET POTENTIAL:
Ball pen is the most common tool for all schools, colleges and university going
students for writing purpose. As greater emphasis is being laid on removal of
illiteracy, the prospects of Ball pen ink industry are bright. There is a huge
requirement of the use-and-throw pens, especially because of its low cost and easy
maintenance. This leads to a huge demand of PP bodied Pens, for human of every
strata.
The market for writing pens is estimated at 1600 to 2400 million pieces a year. By
value, the total market for writing instruments is estimated at Rs 22 billion and is
growing at around 8 to 9% annually. The informal sector's contribution to the
market is placed at over Rs 6.6 billion or 30% of the total market by value and
65% by quantum. While by numbers the low-end market accounts for 90%, the
premium and top-end segment accounts for less than a percent. The balance is
accounted for by the moderately priced mid-priced products. The global market in
writing instruments is estimated at about USD 38 billion, of which global pen
market accounts for nearly USD 30 bn. The Indian market size is relatively small. In
terms of quality of pens, India ranks amongst the best in the world, well ahead of
even China. However, India's export market is abysmally low at Rs 2 billion, while
China exports Rs 50 billion worth of pens every year. Corporate gift segment in
India is valued over a billion, growing at 15%.The Indian market consists of around
15 large scale, 100 midsize and 900 small scale manufacturing units. These units
have a combined production capacity of over 10 million pieces a day. About 80% of
the revenues of the pen industry in India come from pens with a price range of up
to Rs 15. While the market for lower price range (up to Rs 15) is growing at a rate
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of 7 to 8% annually, the market for pens above that range is growing at 8 to 10%.
The rate of growth of high priced writing instruments is much higher - basically
because of a small base.The market is segmented broadly into products required by
young students (many of whom depend only on pencils and ball point pens),
frequent users (in offices, commercial and public establishments), occasional users
(like housewives and literate manual workers).
The existing scenario gives an indication that the market in being dominated by the
ball point pens, which accounts for 70% of the total demand for pens in India,
followed by gel pens (20%), fountain pens (4%). The rest accounts for only 6% of
the market. A majority of users, 85%, use blue ink, while black, red and other
colour inks are used by about 15%.The major players in India include Luxor Writing
Instruments, Cello, Reynolds, Add Pens, Goldmate, Today's Writing Products,
Rotomac Pens, Stic Pens, Linc Pens & Plastics, GM Pens International, Flair Pen.
FLOW CHART
PP + colourant (optional)
Fixing of mould in machine
Injection Molten PP material in mould
Cooling and Opening of mould
Ejection of component
Packing
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MANUFACTURING PROCESS
In this injection moulding process, the cold, hard plastic material is loaded into the
machine via hopper, plasticized by heating and then injected under pressure into a
cold mould, where it sets and is then ejected as the finished products.
The three successive main stages that are followed in the procedure of
manufacturing



Feeding of PP raw material into the hopper
Injection moulding process.
Finishing of the moulded product.
INJECTION MOULDING TECHNIQUE
Plastic granules for the part is fed via a hopper into a heated barrel, melted using
heater bands and the frictional action of a reciprocating screw barrel. The plastic is
then injection through a nozzle into a mould cavity where it cools and hardens to
the configuration of the cavity. The mould tool is mounted on a moveable platen –
when the part has solidified, the platen opens and the part is ejected out using
ejector pins.
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Screw Profile
The standard metering screw has three zones with a ring plunger assembly. The
feed zone, where the plastic first enters the screw and is conveyed along a constant
root diameter, the transition zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper, and the
metering zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
Moulds
The mould system consists of tie bars, stationary and moving platens, as well as
moulding plates (bases) that house the cavity, sprue and runner systems, ejector
pins and cooling channels. The mould is essentially a heat exchanger in which the
molten thermoplastic solidifies to the desired shape and dimensional details defined
by the cavity. A mould system is an assembly of platens and moulding plates
typically made of tool steel. The mould system shapes the plastic inside the cavity
and ejects the moulded parts. The stationary platen is attached to the barrel side of
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the machine and is connected to the moving platen by the tie bars. The cavity plate
is generally mounted on the stationary platen and houses the injection nozzle. The
core plate moves with the moving platen guided by the tie bars. Occasionally, the
cavity plate is mounted to the moving platen and the core plate and a hydraulic
knock out (ejector) system is mounted to the stationary platen.
INJECTION MOLDING MACHINE SPECIFICATIONS
Sl. No
1
2
3
4
5
6
7
8
9
10
11
Injection Unit
Clamping Force
Screw Diameter
Swept Volume
Plasticizing Capacity (GPPS)
Mould Height (Min/Max)
Platen size (H × V) Min/Max
Tie bar Distance (H×V)
Min/Max
Machine Dimension (L×W×H)
Total Oil Capacity
Total Connected Load
Machine Weight
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Unit
Ton
mm
cc
g/sec
mm
mm
mm
Specification
110 to 150
35 to 50
150 to 400
15.7 to 41
150/510
670×670 / 740×740
435×435 / 510 × 510
mm
5.2×1.4×2 /
5.4×1.5×2.5
265-415
26.3 - 45.4 Kw
4500-7100
Ltr.
KW
Kg
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RAW MATERIAL

PP + Colourant (or) PP master batch – for Pen Barrel and cap

Styrene Acrylonitrile (SAN) – for Pen front
Processing conditions
Drying
Melt Temperature
Not normally necessary if proper storage is used.
220 - 275°C
Mould Temperature
Injection Pressure
40 - 80°C
Up to 1800 bar ( 26000 psi)
MACHINERY & MOULD COST FOR PEN
A. MACHINERY COST
Sl.No.
Machinery
Quantity
1.
Injection Moulding
Machine, 120 Ton
Dry
colour
Mixer
Machine
Crane (Manual)
Scrap Grinding Machine
Air Compressor
Water Pump
Chilling
Plant/Cooling
Tower
Total cost
1 No.
Cost
(in Lacs)
16-20
1 No.
2–3
2.
3.
4.
5.
6.
7.
1
1
1
1
1
No.
No.
No.
No.
No.
5-8
2.5 - 3
2.5 - 3
0.5 - 1
8 – 9/3-5
37 –47
B. MOULD COST
Sl.No.
1.
2.
3.
Mould
Mould for Pen Barrel@
2.60 grams
Mould for Pen Front@
1.25 grams
Mould for Pen Cap@
1.01 grams
Total cost
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Quantity
1 No.
Cost
(in Lacs)
15-20
1 No.
20-25
1 No.
5-10
40 –55
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TOTAL COST FOR BALL PEN (MACHINERY& MOULD):77-102 lacs
C.PRODUCTION CAPACITY PEN BARREL
Production
Capacity per day for
16 cavity mould, for
22 hours
Production
Capacity
per annum
(300 days)
Raw Material
Consumption
/ annum
PEN BARREL
84,480 components
@15 seconds
2,53,44,000
pieces
PEN FRONT
(SAN
Copolymer)
PEN CAP
2,53,440 components 7,60,32,000
@5 seconds
~65 MT
@2.60g per
piece
~99 MT
@1.3g per
piece
~76MT@1.0g
per piece
2,53,440 components 7,60,32000
@5 seconds
D.UTILITIES REQUIREMENTS
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
Type
Requirement (approx.)
Electricity for Injection
Moulding Machine, 120Ton
Electricity for Dry colour
Mixer Machine
Electricity
for
Scrap
Grinding Machine
Electricity
for
Air
Compressor
Electricity for Water Pump
Electricity
for
Chilling
Plant/Cooling Tower
Water
Connected Load – 45KW
Connected Load – 3 KW
Connected Load – 4 KW
Connected Load – 5 KW
Connected Load – 3 KW
Connected Load – 8 KW
80litre/min
Water will be circulated
through fixed tank capacity
is 15000-20000 litre
8.
Land Required *
10,000 – 12,000 Sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
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E.MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
01
03
03
Semi-Skilled Worker
06
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12. WOVEN SACK
INTRODUCTION
PP woven sacks are becoming increasingly popular in India & have caught the eye
of many end users for their requirement of packing materials, low weight and high
strength characteristics. Woven sacks can be made in circular looms as well as in
flat looms. In circular looms, woven fabric in tubular form is obtained, which can
be converted to bags by stitching one side (bottom). Flat looms produce an open
fabric and in this case the bag is formed by stitching three sides.
Advantages of PP over HDPE sacks

PP sacks are becoming more popular to account of their better tensile
strength (25 to 30% more) and higher tenacity compared HDPE sacks of
equivalent Denier. Therefore, at equivalent raw material price, PP sacks are
expected to be much more economical than HDPE sacks

PP tapes/fabrics have 30 to 40% higher co-efficient of friction in comparison
to HDPE tapes/fabrics leading to better and higher stack ability of sacks

The softening temperature of PP is higher than that of HDPE and hence PP
sacks are more suitable for products which are filled hot.
CHARACTERISTICS OF PP BAGS

Inertness towards chemical, moisture

Excellent resistance towards rotting & fungus attack
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
Non toxic

Lighter in weight & have more advantages than conventional bags
PP woven sacks are much stronger & can withstand much higher impact
loads

Multi-wall paper bags, another popular material used for packaging cement is
still largely depend on the import of kraft paper. In comparison, the raw
material for woven sacks is easily availble in the country. Further these sacks
are lighter, more economical and have superior resistance to bursting when
dropped. They also do not get damaged in contact with water or moisture
like paper sacks.

PP woven sacks laminated with LDPE/PP liner have wider applications. These
sacks are much cleaner & resist fungal attack. Jute prices are very unstable
in the market since Jute is an agriculture product. PP sacks have many
advantages over other conventional sacks materials & are quite competitive
in price.

PP woven sacks for same size, weave density and strength, would normally
be one-fourth in weight as compared to jute bags. Consequently, the weight
per bag or per square metre of fabric would be lower. This also results in
cutting down transportation cost of empty sacks.

PP woven fabrics are odourless. Unlike jute, these woven fabrics can be
made in different colours and can be printed in clear and multi-coloured
marking. This help in giving the sacks a nice appearance and brightness so
important for promotional purposes.
APPLICATIONS

Fertilizer, sugar, cattle feed, cement & other chemical Industries. Oil seeds,
salt, starch, pesticides, detergents & many other items are also being packed
in woven sacks.

Air permeable sacks made from PP are suitable for the packaging of
potatoes, carrots, onions, grains, rice, cement etc.

For packaging of fertilizers, sugar, coffee etc., LDPE laminated woven sacks
are used.

Fabric woven from PP tapes are also ideal for the manufacture of shopping
bags, deck chairs, carpet backing etc.
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EQUIPMENTS AND ACCESSORIES LIST



Extruder for tape plant
Cheese Winder
Circular loom
MARKET POTENTIAL
Market demand of plastic woven sack has increased due to non availability and high
costs of Jute bags. They were preferred over jute bags due to low cost, weight per
piece. A few years back Flat looms were used for the manufacture of woven sacks.
Now it has been manufactured on circular looms, which have high productivity.
This helped in minimizing the cost of production; however due to high cost of jute
bags & also due to poor resistance to chemicals.
Moisture etc. most of industry
prefer PP woven sacks for packaging.
MANUFACTURING PROCESS
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
Rafia Tape of PP is first produced by extruder, which is equipped with a
suitable die, cooling ring, temperature and process controls etc. From the
extruder, the tape is taken off by a set of rollers.

The tape then goes to a slitting unit where it slits into tapes of 6 to 12 mm
width depending upon the requirements. The tapes thus made are conveyed
to stretching orientation oven in which hot air circulates at controlled
temperature. The tapes are stretched to the desired level.

The oriented tapes are passed through a second godet station and then
through the stabilizing oven. The stabilized tapes are passed through a third
gadget station and then to a cheese winder unit where each tape is wound on
a separate cheese.

The monoaxially oriented tapes of PP produced are woven into fabrics in
circular looms. The necessary working machine and prim winders are
provided. The woven fabric can then be stitched into bags in an industrial
stitching machine. After converting the fabric into bags, it is printed with
suitable ink wherever necessary.

For some cases laminated woven sacks are used.
For packaging of
fertilizers, it is necessary to laminate the fabric before making it into bags.
Whereas, in woven sacks, for cement packaging, lamination is not required.
RAW MATERIAL

PP Homopolymer (or) PP Master batch
A. PLANT & MACHINERY DETAILS
(a) EXTRUDER TAPE PLANT
Sl. No.
1
2
3
Machinery details
Extruder
Screw Diameter D
Screw Length L
Screw Speed max
Main Drive Power
Barrel Heating Cpacity
Tape Extrusion Line
Die Width
Working Width
Line speed max
Screen Changer
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Specifications
120mm
30D
105rpm
160Kw
60Kw
1500mm
1400mm
425mtr/min
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Heating Load
Sheet Die
Slit Width
Heating capacity
Control Zone
Type of Lip
4
5
6
7
8
9
10
11
Water quench Tank
Blower Motor
Take up Roller 1
Take up Roller 2
Air Knife motors
Six
station
Indexible
Slitter
Oscillating Drive
Edge Trim Recycling unit
Shredding Mill Motor
Blower Motor
Holding Unit
Holding unit motor rating
Holding unit max speed
Hot Air oven
Length of heating Channel
Fan motors(2nos.)
Heating load
Air velocity adjustable
Modular Stretching and
annealing unit
Stretching unit motor rating
Annealing unit motor rating
Maximum speed of stretching
unit
Maximum speed of Annealing
unit
Tape Extraction Devices
Suction Blower Motor
Filament/Tape Winder
Tape width range (mm)
Tape width range (optional)
(mm)
Denier range (D)
Length of Traverse
Bobbin core ID (mm)
Bobbin core OD (mm)
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9.3Kw
1500mm
19.8Kw
05
Flexible
non
exchangeable plain lip
–
5.5Kw
3.7Kw
3.7Kw
11.0Kw
0.18Kw
3.7Kw
3.7kw
5.5Kw
100m/min
6.0Mtr
7.5Kw each
72.0Kw
10-20Mtr/Sec
37Kw
22Kw
460m/min
425m/min
11Kw
1.8-4.0
4.0-6.0
400-3000
200
35
40
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Bobbin core length(mm)
Maximum bobbin diameter
(mm)
Winding speed (m/min)
Voltage (V)&Frequency (Hz)
218
160
160-450
415V50Hz
(b) CHESSE WINDER INVERTA 45 M
Sl. No.
1.
2.
3.
4.
5
6
7
10
11.
Equipment/Accessories details
Material to be wound
Tape Width
Denier
Transverse
Core tube
Maximum bobbin diameter
Winding speed
Lay out
Dimension of standard Frame
Specifications
PP
2.2-3.2 mm
400-2000
200 mm
35x38x218 mm
130 mm
180-425 m/min
7 high, 4 cross
1672 x 575 x
1710 mm
(c) CIRCULAR LOOM
Sl. No.
1.
2.
3.
4.
5
6
7.
8
9
Details
Working width (Double Flat)
No. of Shuttle
Weft Insertion Rate
Weft Density
No. of Tapes
Wrap Bobbin
Internal Diameter
Length of core
Max.bobbin diameter
Length of Travers
Weft bobbin
Internal diameter
Length of core
Max.bobbin diameter
Length of Travers
Creel Capacity
Bobbin per machine
Fabric Winder
 2016 CIPET Bhubaneswar. All rights reserved
Specifications
46 – 92
6
900/minute
20 – 75 per 10 cm.
720
35mm
218mm
130mm
200mm
35mm
218mm
115 mm
200mm
720
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Max.roll diameter
Machine dimensions
10.
Weight with creel (approx.)
1250mm
9900mmx2800mmx290
0mm
2525Kg.
B. MACHINEY COST
Sl. No.
1.
2.
3.
4.
5.
Size
Cost (Lacs.)
Extrusion Tape line (120mm)
250-270
Cheese Winder (840 nos. @ Rs.
168- 175
20,000)
Circular loom line (width 1.1 mtr
504-510
surface winder 84nos.@ Rs.6,00000)
Stitching Machine 35 nos. @ 20,000
7-10
Bailing Machine
35-37
Total Cost
964-1002
C. UTILITY REQUIREMENT
Sl. No.
1.
Utility
Power Consumption
2.
Power requirement
Tape line
Cheese
Winder
Circular loom
Stitching&
Cutting
Machine
Quantity
3.7
KW-phase
415V 50Hz
48 KW
45Wx120=5.4KW
4KWx 12=48KW
5KW
3.
Air Compressor 3 HP
5 KW
4.
Water Cooling
Tower
Land Requirement*
8 KW
5.
240, 000 - 280,
000 sq. ft
6.
Machine output rate
550 kg/hr
* 70 – 80 % is required for Machineries and Utilities
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D. MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
01
04
Skilled-workers
12
Semi-Skilled
workers
21
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13. WOVEN JUMBO BAG/FLEXIBLE INTERMEDIATE BULK CONTAINERS
INTRODUCTION
Jumbo Bags made out of HDPE or PP material is also known as Flexible
Intermediate Bulk Containers (FIBC) and are those having capacity to carry
material ranging from 0.5-2 M.T. and are generally used for packing of minerals,
sand, crushed
stone, gravels, starch, pellets, plastic granules, ceramic, clays,
cement etc.
Following are some of the features of the flexible bulk container that are unique to
this package:

The weight of a bulk bag used to ship one metric ton of product weighs about
4Kg

Offering a low package: product weight ratio

The cost of FIBCs is competitive with other forms of packaging as it is usually
utilized without pallets

They are easy to store and handle in warehouses with standard equipment

When shipping by boat the FIBCs are gang-loaded with up to 14 bulk bags on
a spreader bar, and are shipped as break bulk
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
The standard filled diameter of FIBCs is 45-48 in., designed to fit two across
in a truck or a shipping container

Special configured containers are made to meet specific requirements of the
container user

It can be folded flat and bailed for shipment to the user
USAGES / APPLICATIONS
• Food Industry – Sugar, Salt, Flour, Dextrose, Starch, Food Additives
• Pharmaceutical
• Plastics – Resin, Pellets, Granules etc.
• Chemicals – which cover a multitude of industries
• Ferro Alloys
• Crushed Stone, Sand, Gravel, Cement, Absorbent Polymer
• Minerals and Specialty Minerals
• Refractory – Abrasive Grit, Ceramics, Clays, Lime, Powdered Metals
• Rubber
• Carbon Black
• Agriculture – Seed, Grain, Popcorn and Beans
MARKET POTENTIAL
Market demand of plastic woven sack has increased due to non availability and high
costs of Jute bags. They were preferred over jute bags due to low cost, weight per
piece. A few years back Flat looms were used for the manufacture of woven sacks.
Now it has been manufactured on circular looms, which have high productivity.
This helped in minimizing the cost of production; however due to high cost of jute
bags & also due to resistance to chemicals, moisture etc., most of industry prefer
PP or HDPE/woven sacks for packaging.
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FLOW CHART
Extrusion
Weaving
Lamination (optional)
Cutting
Printing
Webbing
Sewing
Packing & Bailing
MANUFACTURING PROCESS
Production of FIBC involves the conversion of PP Granules to long tapes and later
woven, cut to size, printed and stitched to be used. The step wise production
process is explained below.
Extrusion
Here the mix of virgin and recycled PP(optional) granules are being melted and
converted into form of tapes in a extrusion plant and at the end of the process are
wound on bobbins of required size. This is the first stage of process which
determines the tensile strength of the tape.
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Weaving
Extruded tape bobbins will be loaded in the Circular weaving machine or Flat
weaving machine. Here the tapes will be woven to fabric of required specification
and will be wound in roll form. These fabrics will become the body fabric of the
FIBC.
Lamination (Optional)
PP fabric is being laminated with LDPE film for making the fabric moisture proof.
This is optional process as per the requirement of the customer.
Cutting
The woven PP fabric in rolls will be fed in the automatic cutting machine and will be
cut in to cut bit of required size. This Automatic process is adopted to get better
accuracy in cut size.
Printing
The cut bits that are the body fabric will be fed into the heavy duty printing
machine to make the printing impression on the fabric. Heavy duty printing
machine, gives the best impression with maximum of three colours.
Webbing
Heavier Polypropylene Tapes are woven in to webbing which forms the lifting loop
of the Jumbo bag.
Sewing
Here all the components used to manufacture Jumbo bags are brought together
along with the printed body fabric. All the gathered parts are assembled to a Jumbo
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bag by highly skilled labours under the supervision of technically qualified
supervisors.
Packing / Bailing
Here the bags which have been produced will be compressed with the help of the
bale press and neatly packed as per the requirement of the customers.
Storage
Once the bag is baled, it will be immediately shifted to a clean storage room, from
where the dispatches are affected.
RAW MATERIAL

PP Homopolymer (or) PP Master batch
A.PLANT & MACHINERY DETAILS
(a)TAPE EXTRUSION LINE
Sl. No.
1
2
3
Machinery details
Extruder
Screw Diameter D
Screw Length L
Screw Speed max
Main Drive Power
Barrel Heating Cpacity
Tape Extrusion Line
Die Width
Working Width
Line speed max
Screen Changer
Heating Load
Sheet Die
Slit Width
Heating capacity
Control Zone
Type of Lip
 2016 CIPET Bhubaneswar. All rights reserved
Specifications
120mm
30D
105rpm
160Kw
60Kw
1500mm
1400mm
425mtr/min
9.3Kw
1500mm
19.8Kw
05
Flexible
non
exchangeable plain lip
–
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4
5
6
7
8
9
10
11
Water quench Tank
Blower Motor
Take up Roller 1
Take up Roller 2
Air Knife motors
Six
station
Indexible
Slitter
Oscillating Drive
Edge Trim Recycling unit
Shredding Mill Motor
Blower Motor
Holding Unit
Holding unit motor rating
Holding unit max speed
Hot Air oven
Length of heating Channel
Fan motors(2nos.)
Heating load
Air velocity adjustable
Modular Stretching and
annealing unit
Stretching unit motor rating
Annealing unit motor rating
Maximum speed of stretching
unit
Maximum speed of Annealing
unit
Tape Extraction Devices
Suction Blower Motor
Filament/Tape Winder
Tape width range (mm)
Tape width range (optional)
(mm)
Denier range (D)
Length of Traverse
Bobbin core ID (mm)
Bobbin core OD (mm)
Bobbin core length(mm)
Maximum bobbin diameter
(mm)
Winding speed (m/min)
Voltage (V)&Frequency (Hz)
5.5Kw
3.7Kw
3.7Kw
11.0Kw
0.18Kw
3.7Kw
3.7kw
5.5Kw
100m/min
6.0Mtr
7.5Kw each
72.0Kw
10-20Mtr/Sec
37Kw
22Kw
460m/min
425m/min
11Kw
1.8-4.0
4.0-6.0
400-3000
200
35
40
218
160
160-450
415V50Hz
(b) CIRCULAR LOOM (30 to 90 cm)
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Sl. No.
1
Details
Working width (double flat)
2
3
4
5
Specifications
30 – 90 cm
at reduced speed
30 – 45cm & 70- 90cm
06
720
900 picks/min
No. of shuttles
No. of tapes
Max. weft insertion rate
WARP PACKAGE
Internal diameter
35mm
Length of core
218mm
Max. package diameter
130mm
Length of traverse
200mm
6
WEFT PACKAGE
Internal diameter
35mm
Length of core
218mm
Max. package diameter
115mm
Length of traverse
200mm
*Actual weft insertion rate depends upon fabric width, construction, tape specificati
ons, quality of tape & winding
(c) CIRCULAR LOOM (85 to 100 cm)
Sl. No.
1
Details
Working width (double flat)
2
3
4
5
Specifications
85–140 cm
at reduced speed 85–
100cm & 125- 140cm
06
1296
620 picks/min
No. of shuttles
No. of tapes
Max. weft insertion rate
WARP PACKAGE
Internal diameter
35mm
Length of core
218mm
Max. package diameter
130mm
Length of traverse
200mm
6
WEFT PACKAGE
Internal diameter
35mm
Length of core
218mm
Max. package diameter
115mm
Length of traverse
200mm
*Actual weft insertion rate depends upon fabric width, construction, tape
specifications, quality of tape & winding
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(d) CIRCULAR LOOM ( 150 to 200 cm)
Sl. No.
1
Details
Working width (double flat)
2
3
4
5
No. of shuttles
No. of tapes
Max. weft insertion rate
WARP PACKAGE
Internal diameter
Length of core
Max. package diameter
Length of traverse
WEFT PACKAGE
Internal diameter
Length of core
Max. package diameter
Length of traverse
6
Specifications
85– 140 cm
At reduced speed 85–
100cm & 125- 140cm
08
2240
560 picks/min
35mm
218mm
130mm
200mm
35mm
218mm
115mm
200mm
(e) FABRIC CUTTING MACHINE
Sl. No.
1
2
3
4
5
6
Details
Maximum width of fabric(mm)
Specifications
1400
Maximum diameter and weight of fa
bric roll(mm/kg)
Cutting length(mm)
Production speed (1 mt length) pcs/
min
Cuts with spout pcs/min
Cuts without spout
Cutting accuracy (mm)
1500/1000
500-20,000
22
28
±2
(f) BELT CUTTING MACHINE
Sl. No.
1
2
3
4
Details
Belt width range (mm)
Minimum & maximum length fro
m cutter (mm)
Maximum number of marking
Maximum diameter of belt roll
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Specifications
20-120(5-10 belts)
250-2000
25Nos.
1000
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5
6
(mm)
Cutting length (mm)
Production speed (1 mt length)
cuts/min
7
Cutting accuracy
(mm)
200-50000
13*(*Depends on mat
erial used &Thickens o
f belts)
±2
(g) HYDRAULIC BALE PRESS
Sl. No.
1
2
3
4
5
6
Details
Press capacity(Tons)
Max Operating pressure (Bar)
Cabin dimensions :
Length x Width x Height (mm)
Stroke length (mm)
Stroke speed Max(m/min)
Space requirement (mm)
Specifications
100
210
950x 1115 x 2250
2000
2
2060x2500x5600
B. MACHINEY COST
Sl. No.
1
2
3
4
5
6
7
8
Machinery Name
Tape line
Winder
Circular loom (30-90)
Circular loom (85-130)
Circular loom (150-200)
Fabric cutting machine
Belt cutting machine
Bale press(100Ton)
 2016 CIPET Bhubaneswar. All rights reserved
Quantity
01
264
20
08
02
01
01
01
Total Cost
Cost
(in Lacs)
250 – 260
80 -85
150-155
115-120
45 - 50
14-16
11 - 10
20-24
685-720
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C.UTILITY REQUIREMENT
A
1.
Utility for Tape Extrusion line
Compres Capacity
sor
Pressure
Quantity
165CFM
6-7bar
Separate air receiver tank of ca
pacity 1,000 litres is recommen
ded for tape line & winders
(excluding tape guns).
2.
Air
Capacity
165CFM
Drying
Pressure
6-7bar
unit
Dew point
30C
3.
Chilled
Process requirement
58TR
water
Flow rate
42,686 L/hr
requirem Intel Temp
180C
ent
Water Pressure
4bar
4.
Machine output Rate
500 kg/hr
5.
Land area requirement *
35,000 – 40, 000 sq. Ft
B.
Utility
for
Filament/Tape Three‐phase voltage with mains
Winder
supply of 3X400V / 50Hz or 3X
415V / 50Hz or 3X420V / 50Hz
with separate neutral and earth
Admissible fluctuations
Voltage: ‐10% to +5%
Frequency: +/‐ 2%
C.
Utility for Fabric cutting
machine
&
Belt
cutting
machine
Compres Capacity
10CFM
sed air
Pressure
6-7bar
* 70 – 80 % is required for Machineries and Utilities
D.MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
Skilled-workers
Semi-Skilled
workers
01
04
12
21
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14. NON WOOVEN FABRIC
INTRODUCTION
High processed products from PP spun bonded nonwoven fabric is widely used in
garments, shoes, hats, bedding articles, inner lining, sofa, decorative materials,
medical and hygienic products, civil works, water-proof materials, travel products,
automotive products, agricultural protection, etc. They are producing Spun bond
nonwoven fabric, melt blown nonwoven fabric and Spun bond melt blown
combination (SMS) Composite nonwoven fabric.
USAGES/APPLCATIONS
Medical Supplies & Hygiene
Wound Care Bandage & Gauze, Hospital Gowns & Patient Drapes, Face Masks,
Protective Apparel, Baby Diapers & Training Pants, Adult Incontinence Pads,
Underwear, Femcare Napkins, Panty Liners
Packing and Industry
Shopping Bags, Tarpaulins, Tents, Bags for Rice / Sugar, Luggage internal Liners,
Vacuum Cleaner Bag, Buff Pad, Interlining and Cloth, Shoulder Padding, Packing &
Coverings, Beach Umbrellas.
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Agriculture
Cover for Trees & Plantations, Garden Covers
MARKET POTENTIAL
India’s nonwoven market is growing at a rate of 8-10%. However, in the coming
years, the continuous growing India’s GDP, increasing Purchasing Power Parity
(PPP) and India’s initiative in the economic development will give a boost to this
niche field, and it is assumed that it would fetch a growth rate of 12-15%. At
present, the production of Nonwoven in India is touching 1,90,000 MT out of which
Spunbond nonwoven fabrics production is approximately 83,000 MT. As per the
expert report, the per capita Nonwoven fabric consumption in India is 155 g; which
will touch to 350 g by 2015 and 600 g by 2020. India is touching a population of
over 1.3 billion with increasing disposable income to cater to the health and
hygiene needs. The Spun bond nonwoven fabric is the main raw material for the
Sanitary Napkins, Baby and Incontinence Diapers, Hospitals accessories like Caps,
Masks, Drapes, Gowns, Aprons, Beddings, Disposable Underwear and general
accessories like Teabags, Vacuum Filter bags, Shoe Covers, Hair nets, Facemask,
Car cover, Coat covet, Luggage and Bags, Shopping Bag, Dust covers, shade Net,
agro Net etc.
EQUIPMENTS AND ACCESSORIES LIST

Extruder

Winding Machine

Sealing and Cutting Machine

Printing Machine (optional)
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FLOW CHART
PP Granules
Feeding & Mixing
Melting & extruding
Filtering
Spinning
Air cooling
Stretching
Web forming
Hot rolling into fabric
Winding
Slitting
FINAL
PRODUCT
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MANUFACTURING PROCESS

The mix of virgin and recycled PP granules (optional) along with additives
and colour are fed to the extruder. The molten PP is fed to a spinning die via
a filter and measuring pump. After this step the fibres are passed through
the orientation zone for stretching to get the required tensile strength.

The fibres are spread /arranged to form the web and then hot rolled to form
the fabric. The thickness and weight of fabric will depend on the quantity of
fibre that are used to form the web.

The fabric thus formed is trimmed/silted on the sides and wound on a winder
to get the roll.
A.PLANT & MACHINERY DETAILS
Sl.
No.
1
Name of Part
Qty
Specifications
Main Extruder
1set
1set
1set
5
6
Waste Recycling Extruder
Auto. Suction Device for Granules or
Powders
Screw for Color Masterbatch and
Cooling Masterbatch
Filter
Metering Pump & Driving Control
170/30 with 132kw AC
motor
105/15 with 15kw AC motor
7.5kw AC motor
7
Spinneret Plate
2sets
8
9
10
11
12
13
14
15
16
17
18
Spinning Box
Stretching Unit
Cooling Box
Side Blowing, Suction Air Passage
Web Forming Machine
Web Forming Belt
Double-roller Hot Rolling Mill
Oil Furnace for Die
Oil Furnace for Hot Rolling Mill
Winding Machine
Cooling Air Blower
1set
1set
1set
1set
1set
2pc
1set
1set
2sets
1set
1set
19
Suction Blower
1set
2
3
4
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2sets
1set
1set
0.75kw*2 AC motor
(inverter control)
7.5kw AC motor (inverter
control), 300cc
3590x216
Pore diameter 45S
(0.45mm)
AC motor
150m/min
48kw
48kw
With inflatable shaft*3
75kw AC motor (inverter
control)
55kw, AC motor (inverter
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20
Monomer Blower
1set
21
22
23
24
25
Air Conditioner
Refrigerating Unit
Slitting Machine
Steel Platform
Distribution Box with Touch Screen
1set
1set
1set
1set
1set
control)
7.5kw AC motor (inverter
control)
200000 kilocalorie
200000 kilocalorie
Siemens inverter
B. MACHINERY COST: PRICE Rs. 370 – 400 Lacs
PRODUCT SPECIFICATION & OUTPUT:
Width of Finished Fabric
Daily Output Based on 40gsm (24Hrs)
Max. Diameter of Product in Roll
Monofilament Fineness
GSM of Product
Mechanical Design Speed
Actual Production Speed
3200 mm
9 Tons
Φ1200 mm
S: 2.0-2.5 denier
10-180 g/㎡
150m/min
100-120m/min
C.UTILITY REQUIREMENT:
Sl No.
1.
2.
3.
Utility
Electricity
Cooling Tower
Air Compressor
Quantity
Connected load 455 KW
80T/hr
7.5KW motor
4.
5.
6.
7.
Land requirement
Machinery Cost
Machine output
Type of Enterprises
30,000 – 40,000 sq.ft
370 – 400 Lacs
375 kg/hr
Large
D. MANPOWER REQUIRMENT
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
Designation
Manager
Supervisor
Skilled Worker
01
04
06
Semi-Skilled
Worker
18
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15. BLOWN FILM (BOPP)
INTRODUCTION
PP is a popular ingredient that is applied to produce transparent and light weight
packaging films. Polyethylene is the mostly used material for packaging film;
however, in flexible packaging PP is used as the preferred material for film
formation. For packaging industries that requires greater productivity in low
investment and low power consumption, monolayer blown film production is the
right option.
Food packaging industry is the major consumer for packaging films. However,
pharmaceutical and personal care packaging is increasingly finding application of
packaging films. These films are formed by extrusion-blown, extrusion-cast and
extrusion-coating process.
USAGES / APPLICATIONS




Garment & Textile Packing
Hosiery Product Packing
Bakery Product Packing
Vegetable & Fruit Packing
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MARKET POTENTIAL
The global packaging film market is expected to register decent growth during the
coming decade driven by middle class of China and India. With rapid urbanization
and increasing disposable income, demand for packaged food and pharmaceutical
products are rising in China, India and other emerging nations. Growth in such
emerging nations is expected to impact the packaging films industry positively.
Geographically, Asia-Pacific is the major segment in packaging film market with
around 35% of the market share in 2012. North America and Europe held market
shares of 25.3% and 24.1% respectively. The global packaging film consumption is
expected to grow at a CAGR of 4.5% from 2013 to 2018. In Terms of value the
market is expected to grow at a CAGR of 5.8% from 2013 to 2018. China and India
are expected to drive the global market in the coming future. Increasing demand
for packaged food and improving healthcare infrastructure is the major reason for
growth in China and India.
Global Packaging Film: Market Consumption, by Geography, 2012
In terms of raw materials, polyethylene leads the packaging film market,
representing 64% of the total raw materials used in 2012. However, PP films
demand is growing at a faster rate than PE films. BOPP is the mostly preferred raw
material for flexible packaging films in the recent past and expected to report
higher growth as compared to the cast PP.
RAW MATERIAL

PP Homopolymer
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EQUIPMENTS AND ACCESSORIES LIST
1. Extruder
2. Die Head
3. Rotary Die Device
4. Air Ring
5. Water Ring
6. Cooling System
7. 1st Take Up Unit
8. 2nd. Take Up Unit
9. Dry System
10. 3rd Take Up Unit
11. Winder
12. Control Panel
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FLOW CHART
Extruder
Die Head
Bubble
Cooling system
Nip Roller
Collapsible Frame
Corona discharge
Winder
MANUFACTURING PROCESS
Process Description

PP is first melted by subjecting it to heat and pressure inside the barrel of an
extruder and finally forcing the melt through a narrow slit in a circular die.
The resulting thin film has a form of a tube, also called a “bubble” (blown
film). As the film comes out of the die, it is cooled and then rolled up on a
core.

Air is introduced in the center of die to blow up the tube like a ballon.

Air ring blows onto the hot film to cool it from inside and outside of the tube.

The tube passes through nip rolls where it is flattened.

Collapsed tube is taken back down the extrusion tower via more idler rollers.

On winder the tube or film is wound into rolls.
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A.PLANT & MACHINERY DETAILS
Sl. No.
Parameter
1
2
3
Screw Dia(mm)
L/D Ratio
Lay Flat Width
(mm)
Thickness
(Microns)
Main Moto(Kw.)
Out Put (Kg/hr.)
Die Size(mm)
Take off width
(mm)
Winder type
Total Machine
Connected
Load (KW.)
Dimensions Mtr
(LxWxH)
4
5
6
7
8
9
10
11
Specifications
MAF/40/PPTQ
MAF/65/PPTQ
40
65
26:1
26:1
120 325
375-750
20-60
20-100
7.5
15 -20
100
350
18.5
40 – 50
250
800
CENTER
25.86
CENTER
46.62
3.5×1.5×4
10x5x6.5
B.MACHINERY COST
Extruder Cost(lac)
40mm
25-30
65mm
45-50
C.UTILITY REQUIREMENT
Sl. No.
1.
2.
3.
4.
5.
* 70
Utility
Power requirement - 40mm dia
Extruder
65mm dia
Air Compressor for
40mm dia
extruder
65mm dia
Cooling Tower
Quantity
30 KW
50KW
9CFM
15CFM
≤200C≥0.3MPa
10T/h
Machine output rate
15-20 Kg/hr 40-50 Kg/hr
Land
area 15,000
– 15,000
–
requirement* (sq.ft) 20,000
20,000
– 80 % is required for Machineries and Utilities
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D.MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
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Designation
Manager
Supervisor
01
03
Skilled-workers
04
Semi-Skilled
workers
06
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16. BOX STRAP
INTRODUCTION
PP is ideal for ease of carrying and benefits from light weight, adequate elongation
properties that enable the strap to contract around packages that may settle. The
strap however, can only be as strong only if the correct method of joining a strap
for its given weight load is achieved. Joining methods either by hand tool manually
with metal buckles or a range of seals, friction weld joint, or heat sealed. Small
packages can be secured using plastic buckles. PP can be specified for any number
of uses, the most widely applied being for unitising, bundling, stabilising,
preventing breakage in transit, security whilst minimising additional package
weight.
PP strapping is the most commonly used and least expensive of all strapping
materials. It's light and easy to apply and recycle. PP is the most accepted and
widely used strapping material for packaging due to its properties of better heat
sealing and pricing. PP strap is an economical packaging solution designed for light
to medium duty utilizing, palletizing carton closing and bundling. PP is the most
accepted and widely used strapping material for packaging due to its properties of
better heat sealing and pricing.
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CHARACTERISTICS OF PP STRAP

Low density

High rigidity

Excellent chemical resistance

Resistant to abrasion & ageing gives the benefits of easily carried

Does not corrode, mark or rust recyclable

Long life/will not damage products

Black strapping is also resistant to UV degradation
APPLICATIONS

Corrugated

Food

Timber

Newspaper bundles

Light and medium weight packages
MARKET POTENTIAL
There is a huge demand for PP strapping due to its following characteristic. Demand
for PP Straps for binding and packaging will grow with the population of country due
to its requirement for packing materials.
RAW MATERIAL

PP Homopolymer (or) PP Master batch
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EQUIPMENTS AND ACCESSORIES LIST





Extruder
Hot water tank
Stabilizing Hot air oven
Water tank
Winder
FLOW CHART
Colouring agent/Additives
PP Raw material
Extrusion by
Extruder
Die Head
Quenching
Pulling
Hot water tank for
stretching
Stabilizing hot air oven
Cooling
Quality Checking
Winding
Packing & Shipping
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MANUFACTURING PROCESS

PP homopolymer along with colorant and reprocessed material is fed into the
hopper of the extruder which was preset with the processing temperature.

Extruder started and molten material passes through the die .The molten
strap so produced is quenched in the water tank.

The strap is then fed to the first godet unit for pulling the strap.

The strap is then fed to the hot water tank for heating the strap in order to
make it stretchable .The hot strap is pulled by Stretching godet unit.

The stretched strap is then passed through the stabilizing hot air oven for
maintaining the temperature to get proper orientation and the strength. It is
then cooled by pulling through a cold water tank with the help of last godet
unit.

The final strap so obtained is checked for its properties and processing
parameters are set for the right process, which gives the required properties.

The strap is then wound on to bobbins and rolls of marketable lengths are
packed and shipped
A. MACHINERY DETAILS
Sl. No.
1.
2.
3.
4.
5.
Details
Size of screw
Barrel type
L/D ratio
Space required
Material of Screw & Barrel
6.
Gear box
7.
8.
9.
10.
Main Motor
Heating zone
Heating load
Structure
11.
Screen Changer
Type
Heating zone
Heating load
Die
12.
 2016 CIPET Bhubaneswar. All rights reserved
Specifications
65mm
Smooth Feed
30:1
90’L X 20’ W X 15’H
EN-41B Alloy steel duel
gas nitride
helical gear box with
thrust bearing
15HP with AC drive
3 zone
18 kw (approx)
MS fabricated
channels,Angels
Manual Screen Changer
1 zone
4.5 kw
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13.
14.
15.
16.
17.
Type
One insert for 09mm
One insert for 12mm
One insert for 15mm
One insert for 19mm
Heating zone
Heating load
Quenching Tank
Tank Material
Tank size
Stand
First godet unit
No. of Roll
Pressure Roll
(With Knurling & printing unit
All rollers are driven by duplex
chain with gear box)
Motor Drive
Hot water tank
Working width
Length of heating channel
Heating load
Stretching godet unit
Total no.of Roller
Drive
18.
19.
20..
21.
Stabilizing hot air oven
Working width
Length of heating channel
Heating load
Motor
Air velocity adjustable
Water tank
Chilled water tank
Last godet unit
Total no. of rollers
Pressure rollers
Drive
Winder
No.of stations
 2016 CIPET Bhubaneswar. All rights reserved
T- Die
Two lines
Two lines
Single lines
Single lines
2 zone
4 kw
SS sheet
500Wx450Dx1000L(MM)
M.S fabricated
5 rollers M.S plated
2 rubberized roller
2 hp ac motor with
reduction gear box with
chain socket frequency
drive
200mm
3500mm
12kw
7 Rollers Ms hard
chrome
7.5 Hp AC motor with
drive
200mm
3000mm
9Kw
2HP 2800rpm
10-20 mt/sec
4mt length
3 rollers
2 rollers
3HP
3(Three station)
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Core size
Core length
Drive
Total motor load
200mm dia
165-190mm
Individual torque control
motor 0.5HP with
controller
1.5HP
B.MACHINERY COST: 30-40 lacs
C.UTILITY REQUIREMENT:
Sl. No.
1.
Utility
Power
Quantity
3-phase 440V+10%
50Hz±5%
2.
Electricity
connected load 133
KW
Electric Running Load
80 KW
3.
Air Compressor
5 HP with Air and OIL
Filter
4.
Water Cooling Tower
10 TR
5.
Water
Recirculation 2
HP
Pump
and
System
Related
Piping
Arrangement
6.
Machine output rate
65kg/hr
7.
Land area
5000 – 8000 sq. ft
Requirement*
* 70 – 80 % is required for Machineries and Utilities
D. MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled-workers
Semi-Skilled
workers
01
03
04
06
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17. ROPE
INTRODUCTION
Plastic fibres are produced in our country through conventional process which needs
huge investment in plant and machinery. Where ever application of yarn does not
require finer denier, the new technology i.e.
the film fibrillating technology can be used to produce medium and heavy duty yarn
with less investment.
Pattern fibrillation is used in Europe and America for the
manufacture of PP Ropes for versatile applications.
APPLICATIONS


Shipping
Fishing Industries
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MARKET POTENTIAL
In our country, there is good market for PP Ropes and scope for export to USA,
Middle East and European Countries.
Apart from Ropes, other items can also manufacture with the help of attachment/
equipment. There is good demand for these products such as –
(a) Stitching yarn can be sold in large quantity for Fertiliser Companies and other
woven sacks manufacturers export from captive consumption. It can also be used
as industrial Sewing Thread for stitching of upholstery, shoes and leather products.
(b) Carpet Backing Yarn made from PP Fibrillated tapes are being used world over
instead of Jute Carpet Backing Yarn because of various advantages. In view of this
there is good demand for Exports of PP Fibrillated carpet backing yarn.
(c) India has a very good market for Fishing Twines. PP is light in weight, does not
absorb water and is fungus free. Therefore, Fishing Twins made from PP has wide
scope.
(d) PP Fibrillated yarn is also used as cable filling yarn (Cable Fillers) because of its
light
weight
and
high
tensile
fibre
quality.
Telecommunication
cables
are
strengthened with these tapes.
(e) It is also used as Synthetic Grass for making Synthetic Grass Carpet/Lawns with
tufting process.
(f) Other applications are Industrial Filters, Table or Floor Mating Fabric, Fancy
Yarn, Ultra Violet Display Card with inside core of fibrillated tapes
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RAW MATERIAL

PP Homopolymer (or) PP Master batch
EQUIPMENTS AND ACCESSORIES LIST

Monofilament extrusion plant

Color mixer

Extra bobbin winder

Ply yarn twister

Rope making machine

Coiling machine

Feeding bobbins

Box strapping machine
FLOW CHART
EXTRUSION PROCESS FOR
GETTING PP YARNS
RING TWISTER
EXTRUDER TWISTER
ROPE MAKING MACHINE
2 MM TO 3.5 MM
ROPE MAKING MACHINE
4MM TO 20 MM
PACKING & DISPATCH
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MANUFACTURING PROCESS

EXTRUSION
Plastic granules are extruded and monofilament is produced from the die
head and drawn in water bath and subsequently dried by hot air as
well as stretched

YARN TWISTER
Ring twisters are used to twist the bunched strands for 2 mm to 3.5 mm
ropes for getting higher outputs

Extruder twisters are used for twisting the yarns for 4 mm and above rope
sizes.

The twisted yarns are converted into rope by a combined strander/ rope
making
machine and coiling in one single operation. The resulting rope is wound into
a bundle and packed.
A.MACHINERY DETAILS
(a) EXTRUSION PLANT
Extruder screw dia: 100mm
For 80 hole 3000 denier PP DANLINE Complete plant
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Details
PP dia
Main motor
Main Gear
Heater
Screen Changer
Hydraulic motor
Heater
Neck heater
Die Heater
Cold water tank
Tank
Dimensions
First Goddet
Specifications
8O HOLE
60 HP AC, 3 Phase, 1440 RPM, 440V
1:12.5 heavy duty helical gear box
20HP(4HPx5Nos.)
A.C motor 5HP
10HP
1.5HP AC
4HP AC
S.S sheet with stand and Guide Roller
1400mm Length x 900mm width x
600mm Height
7 Rolls(300mmOD x 900 mm Length)
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13.
14.
15.
16.
Gear
Motor
Orientation unit
Dimension
17.
18.
19.
20.
21.
Heater
Second Goddet
Gear
Motor
Total power
consumption
Production
capacity
Overall
dimensions
22.
23.
1:50 reduction gear box
7.5HP AC
Hot air oven made out from S.S sheet
4200mmLength x 800mmwidth x
170mm Height
20HP(2HP x 10Nos.)
7 Rolls (300mm OD x 900mm Length)
1:7.5 Helical gear box
15HP
85HP(approx)
160-180kgs/Hour
70’x25’ (Lengthxbreadth)
(b) EXTRUDER TWISTING MACHINE
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
Details
No. of
positions
Winding
Motor power
Travers Drive
Winding speed
Packing size
Take up
capacity
Machine
Dimension
Specifications
26 positions control system
ABS or steel Flange Bobbin
40 HP,440 volts
Electrical geared motor
As per requirement
250mmdiax300mmTraversex38mm
hole
7kg with Bobbin
18’Lengthx7’widthx7’Height
(c) RING TWISTING MACHINE
Sl. No.
1.
2.
3.
4.
5.
6.
7.
Details
No.of positions
Winding
Motor power
Travers Drive
Winding speed
Packing size
Take up
Specifications
60 positions control system
ABS or steel Flange Bobbin
40 HP,440 volts
Electrical geared motor
As per requirement
250mmdiax300mmTraversex38m
m hole
7kg with Bobbin
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capacity
Machine
Dimension
8.
18’Lengthx7’widthx7’Height
(d) ROPE MAKING MACHINE
FOR ROPE DIA: 6MM TO 12MM
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Details
No. of Strand(Ply)
Strand flyer speed
Rope flyer speed
Twist per minute
Rope lay
Twist range
Twist in strand
Drive
Feeding Bobbin
10.
Motor
11.
12.
Gear Box
Rope die set
13.
15.
16.
17.
18.
19.
A.V.M.PADS
Auto cut off
system
Balancing
Control panel
Board
Take up system
Take up capacity
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Specifications
4 strand(4ply)
1400rpm
700 rpm
Twice the flyer speed
S&Z
13 to 63 TPM
Adjustable
V Belt & Timing belt
48(4x12)=48
250mmdia
300mmTRAx38mm hole
20 HP 1440 RPM With
A.C Drive
For getting perfect
roundness of the rope)
For vibration free smooth
working
Preventing raw material
wastage
Electronically balanced
Direct Cooling head
25 Kg ( 455 MM Dia x
330 MM Transverse x 120
MM Hole)
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(e) ROPE MAKING MACHINE
FOR ROPE DIA: 8MM TO 20MM
Sl No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Details
No. of Strand(Ply)
Strand flyer speed
Rope flyer speed
Twist per minute
Rope lay
Twist range
Twist in strand
Drive
Feeding Bobbin
10.
Motor
11.
12.
Gear Box
Rope die set
13.
A.V.M.PADS
14.
Auto cut off
system
Balancing
Control panel Board
Take up system
15.
16.
17.
18.
Take up capacity
19.
20.
Sliding door with
limit switches
ON/OFF switches
 2016 CIPET Bhubaneswar. All rights reserved
Specifications
4 strand(4ply)
900rpm
450 rpm
Twice the flyer speed
S&Z
13 to45 TPM
Adjustable
V Belt & Timing belt
48(4x18)=72
250mmdia
300mmTRAx38mm hole
20 HP 1440 RPM With
A.C Drive
For getting perfect
roundness of the rope)
For vibration free smooth
working
Preventing raw material
wastage
Electronically balanced
Direct Cooling head
40 Kg ( 550MM Dia x
400 MM Transverse x 120
MM Hole)
For safety & quick
operation
Fitted different places for
easy & speedy operation
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(f) ROPE MAKING MACHINE
FOR ROPE DIA: 3MM TO 7MM
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Details
No. of Strand(Ply)
Strand flyer speed
Rope flyer speed
Specifications
4 strand(4ply)
1400rpm
700 rpm
Twist per minute
Rope lay
Twist range
Twist in strand
Drive
Feeding Bobbin
Twice the flyer speed
S&Z
35 to 125 TPM
Adjustable
V Belt & Timing belt
48(4x12)=48
250mmdia
300mmTRAx38mm hole
15 HP 1440 RPM With
A.C Drive
10.
Motor
11.
12.
Gear Box
Rope die set
13.
A.V.M.PADS
14.
Auto cut off
system
Balancing
Control panel Board
Take up system
Take up capacity
15.
16.
17.
18.
19.
20.
Sliding door with
limit switches
ON/OFF switches
 2016 CIPET Bhubaneswar. All rights reserved
For getting perfect
roundness of the rope)
For vibration free smooth
working
Preventing raw material
wastage
Electronically balanced
Direct Cooling head
25 Kg (455MM Dia x 330
MM Transverse x 120 MM
Hole)
For safety & quick
operation
Fitted different places for
easy & speedy operation
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B.MACHINE COST
Sl.
No.
1
2
3
4
5
6
Name
of
the Quantity
Cost (in Lacs)
machine
PP Extrusion line
3 no.
500 - 525
Extruder Twisting line
6 units
144-150
Ring Twisting Machine
3 no.
114-120
Rope making machine
3 no.
48-60
(6mm-12mm)
Rope making machine
8 nos.
60-68
(8mm-20mm)
Rope making machine
5nos.
69-75
(3mm-7mm)
Total Cost
935-998
C. UTILITY REQUIREMENTS
Sl.
No.
1.
2.
3.
4.
5.
Utility
Specifications
PP Extrusion line
Extruder twisting line
Ring Twisting Machine
Rope making machine
(6mm-12mm)
Rope making machine
(3mm-7mm)
Rope making machine
(8mm-20mm)
Air Compressor
Cooling Tower
Machine output rate
Land
area
requirement*
Quantity
65KW
60KW
30KW
15KW
12KW
15KW
3HP
30TR
540Kg/hr
200,000
–
240,000 sq.ft
* 70 – 80 % is required for Machineries and Utilities
Rope size
6 MM
08 MM
10 MM
12 MM
Production
Capacity (Kg/hr)
90
180
130
140
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D.MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
01
Supervisor
04
Skilled-workers
21
Semi-Skilled
workers
30
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18. LENO BAGS
INTRODUCTION:
LENO Bags production that come under the banner of polypropylene woven fabrics,
specifically catering to the packing applications for all regular sectors (Onions,
Potato, vegetables etc) in India.
Leno Bags being permeable allow the air to pass through the bag which helps to
keep the product fresh. With their low weights and cost effective nature, they
provide a superior packaging alternative to other materials. The Leno Bags are
known for their excellent re-usability and washability characteristics.
The
transparent material of these bags, provides a clear view of the products packed
inside and also the air circulation keeps the products fresh.
Leno bag for packing vegetables can keep the vegetables fresh. Permeability of
these bags helps in significant saving in energy cost in cold storage systems. These
bags are strong enough to carry and carry bulk loads and the transparent fabric
provides better visibility of the product. Hence these bags keep the fruits safe and
fresh for long durations. Leno Bags are used to carry flowers in bulk quantity. Leno
Bags will reduce the cost of outer packing, when compared with woven bags of
higher weight / corrugated boxes / crates and are widely used in shopping malls. In
bulk, by using of leno Bags reduce the Packing Cost up to 50%.
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ADVANTAGES OF LENO BAGS

Good tensile and burst strength

Lighter in weight than Corrugated Boxes hence transportation cost will be
lower (Corrugated
Box of similar capacity is 6 times heavier than leno
bags)

Cheaper in comparison to jute bags
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
Reusable, however number of cycles depends upon the material packed,
storage, handling and other relevant parameters.

Not attacked by fungus, insects and rats

Resistant to corrosive chemicals

Safe in direct contact with food products and do not cause physical
contamination.

Easy visual inspection of contents packed is possible in leno bags.
Leno Bags are specially woven and designed to maintain freshness of the packed
goods by allowing air inside the bags to prevent inner moisture that may spoil the
goods. These are UV-stabilized and made according to the customers desired
specification and colours. These are available in 5 kg up to 20 kg capacity, with or
without tie string. Leno bags also incorporate certain solutions that address the
need for proper handling and packaging of perishable items like onions and
potatoes, ginger, tomatoes, carrots, coconuts, apples, and other vegetables and
fruits. This technique is specifically useful not only by growers or consumers but
also by the various merchandising associations, traders and authorities involved in
marketing of agricultural produce.
USAGES / APPLICATIONS:
Leno bags are used for packing fresh vegetables, fruits, potatoes, onions, etc, like;

Leno Bag For Packing Fruits

Leno Bag For Packing Flowers

Leno Bag For Outer Packing

Leno Bag For Packing Onion

Leno Bag For Packing Potato

Leno Bag For Packing Vegetables
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MARKET SURVEY / POTENTIAL:
India is the largest producer of various commodities like milk vegetables, fruits,
tea, pulses, butter, cereals, and meat. India ranks first in the production of fruits
and vegetables. Unfortunately it has also highest level of wastage for the
above mentioned items in the world, resulting in money loss of about Rs.
25000 crore annually. This is mainly due to poor handling and packaging
techniques adopted. The packaging materials currently being used are mostly used
/ reused jute bags and old designed plastics raffia bags.
The leno bags, as suggested here, are an ideal alternative to packaging of these
conventional materials and can be used for variety of agricultural applications.
The biggest advantage of these bags is the excellent air permeability that
increases more than 50 % of onions and potatoes life. Various other
advantages of these bags are discussed at length in this paper. With little extra
cost, Leno bags can be made on modified flat or circular looms, and can be
laminated and made of attractive colours.
Leno Bags are available in the market in various variants and also known as Leno
Mesh Bags. Leno Mesh Bags can be widely used for packing of various Agricultural
products such as Onion, Garlic, Potato, Carrot, Ginger, Orange, Pineapple etc., and
marketed mainly and popularly known as mesh bags.
These leno mesh bags or mesh leno bags can be made with or without a
drawstring. Hence, the potential of utilizing these products are available as the
drawstring is made of braided flat tape and sold at reasonable prices.
The market knows leno bags with the following types and names like:
 PP Leno Bags
 Tubular Leno Bags
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 Raschel Bags
 Mono Bags
 Circular Bags
 Extruded Bags
India is the world’s 2nd largest producer of fruits & vegetables. There is a huge
demand and potential market for Leno Bag usage in India (~81 KTA)
corresponding to 2700 Leno Looms. The Leno bag Project shall offer a good
investment opportunity for entrepreneurs as well as help to improve the bottom line
of existing woven products manufacturers.
Based on the annual agricultural projection, the total requirement for leno bag was
22 Million tons way back in 2006-7, only for onion, potato and orange. (Ref: Study
by Directorate of Economics and Statistics, New Delhi, Year 2006 – 7)
EQUIPMENTS AND ACCESSORIES LIST

Flat looms / Circular Looms

Rotogravure Printing Machine

Dry Colour Mixer

Crane for Mould Loading & Unloading

Scrap Grinder

Air Compressor
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FLOW CHART
PP RAW MATERIAL
TAPE FROM
TAPE PLANT
PP MASTER
BATCH
FLAT/ CIRCULAR LOOMS
LEBELLING
CUTTING & STICHING
BALE OF 100 OR 500 /
PACKING
ROTOGRAVE
PRINTING
MANUFACTURING PROCESS
The Circular woven looms are used to make leno sacks for fruits and vegetables –
machinery with a worldwide standard. The smooth surface of the open mesh leno
fabric protects the delicate surface of the fruits.
The leno bag specific loom combines the advantages of standard and leno weave in
a single sack concept: The leno sack is an open mesh weave for maximum
breathability, with a closed weave section allowing printing in top quality for a new
type of high grade leno bag.
I.
Primary Process:
Tape Manufacturing

The granules of plastics raw materials are fed to the extruder hopper, where
they are plasticized and the melt flow is passed through a T-die.
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
This molten film is then passed through a water quench tank which has a
thermostatic pump controlled temperature of chilled water in the tank.

The molten film is hence solidified at constant temperatures.

Solidification of the film at controlled temperatures has marked influence on
the final tape parameters.

Film formed is slit into thin strips.

These strips are then oriented by stretching them under heated condition at
a pre-determined ratio.

The stretched tapes have a tendency to shrink.

These have to be stabilized a special stretching and annealing unit
comprising of cooled gadgets.

II.
Finally, the tapes are wound on winders.
Secondary Process:
a. Weaving:-The tapes so obtained by above step are fed to circular looms
and woven into tubular fabrics on cloth winder.
b. Cutting:-The fabric is then cut and stitched to produce bags
c. Stitching:-The stitching of bags is done as per the required size and
specifications.
d. Printing:-The stitching bags are then sent to a printing machine. These
are printed as per buyer’s requirement.
e. Bailing and Dispatch:-The printed bags are then sent to a bailing machine
where they compressed and packed for transportation.
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Advantages of the




Advanced Leno Bag Loom;
Production speed of 360 ppm
Efficiency above 92 %
Wear and tear resistant
Oil-free fabric for food-safe products
Stage 1: The four (4) Shuttle Loom:
The 4 shuttle loom is used for the production of open mesh leno fabric, used for
packaging fruits and vegetables. This also imparts a smooth surface to the leno
fabric, thereby protecting the delicate skin of the products.
Stage 2: The Advanced Leno Bag Loom:
This loom provides advantages of a standard loom plus the leno
weave in together one machine. The surface of the weave section
also permits the printability in top quality for a new type of
superior leno-bags
Stage 3: The Weft:
As any other looms, the weft -stop -program -motion -system
reduces the take-up speed in case a weft break is detected. This
further stops the loom before the weft bobbin goes empty. Hence,
the bobbin change problem can also be met with lowest possible
waste rate.
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Stage 4: The Surface Winder:
The surface winder attached with the equipment, has a tension
controller attached to it, to give perfectly wound up fabric rolls.
RAW MATERIAL
PP Homopolymer+ color compound
A.MACHINERY DETAILS
TECHNICAL SPECIFICATIONS OF LENO BAG LOOM:
WORKING WIDTH, DOUBLEFLAT
250 - 800 MM
NO. OF TAPES
576
SHUTTLES/MACHINE
4 PCS
WEFT INSERTION*
360 PPM
WEFT PACKAGE WEIGHT (MAX.)
7 KG
WARP/WEFT CORE INSIDE DIAMETER *
35 MM
WARP/WEFT LENGTH OF CORE *
218 MM
WARP BOBBIN DIAMETER (MAX.)
160 MM
WEFT BOBBIN DIAMETER (MAX.)
115 MM
WINDING ROLL DIAMETER (MAX.)
1200 MM
* DEPENDING ON WEAVING CONSTRUCTION, FABRIC, AND
QUALITY OF TAPES
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Specification and design:
III (i) Technical Features

Bags are made on circular weaving leno looms.

Flexibility from 100 mm width to any desired width &
length.

Available in wide range of colours.

Draw String or a handle at the top can be provided.

Bag Dimensions – 25kgs – 52 x 80 cms
30kgs – 60 x 85 cms

Can be printed.

Flexibility from 35cm to 75cm in width & any length7.

Denier of tapes will be 700-750

Mesh combination will be:
Warp 5 pairs /inch x weft 5 tapes per inch.

Sewing in bottom will be chain sewing type.

Mouth sewing will be seam or over lock/chain stitching.

Available in wide range of colours.
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
Label ling/lamination can be done on the bags.

Printing can be done on the bags.

Cost effective for capacities from 25 kgs to 90 kgs than jute.

Circular Weaving Machine: This machine is used mainly for the production of
endless tubular air permeable fabric from PP tapes suitable for packing
perishable goods.
(ii) Popular Sizes:
Based on type of vegetable, capacity, weight and mode of transportation, the size
and strength of bag is decided. This is summarized below in Table below
Table: The Size and Strength of Bag.
Bag size
(cm)
60x100
55x100
50x80
60x90
65x100
Denier Capacity Wt.
(Kg)
of bags
(gms)
650
60
65
650
64
64
650
53
53
650
58
58
750
83
83
57.5x22.5 600
17
17
67.5x30
22
22
600
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Vegetables packed
Garlic/Onions/Potatoes
Garlic/Onions/Carrots
Garlic/Capsicum
Garlic/Onions/Potatoes
Potatoes/Cabbages(40
kgs)
Onions/Potatoes
(export)
Garlic/Onions/Potatoes
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(a) LIST OF EQUIPMENTS FOR EXTRUDER TAPE PLANT:
Sl No.
1.
2.
3.
Equipment/Accessories details
screw
Barrel dia
Steel Roll
4.
5
6
7
8
9
Main gear
Rubber roll
Main Motor
Pneumatic operate
Drive panels
Heating panels
10
11.
Nip 3 Nos.rubber roll and 1 steel roll
Water tank
Specifications
65mm
100mm
320mmdia
700mm length
160D
135OD 700length
20HP
10 zones
(Multispeed
Controller)
(SS 304) size 800
mm (W) x 1200
(L) mm x 508
mm (H)
(b) SPECIFICATIONS OF CHESSE WINDER INVERTA 45 M
Sl No.
1.
2.
3.
4.
5
6
7
8
9
10
11.
Equipment/Accessories details
Material to be wound
Tape Width
Denier
Transverse
Core tube
Maximum bobbin diameter
Winding speed
Voltage/frequency
Winder frames configuration (Back
to back / Front to front)
Lay out
7 high, 4 cross
Dimension of standard Frame
 2016 CIPET Bhubaneswar. All rights reserved
Specifications
PP
2.2-3.2mm
400-2000
200mm
35x38x218mm
130mm
180-425m/min
1672 x 575 x
1710 mm
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(c)CIRCULAR LOOM
TECHNICAL SPECIFICATION
Sl No.
1.
2.
3.
4.
5
6
6.0
6.1
6.2
6.3
7.
7.0
7.1
7.2
7.3
8
8.0
9
9.0
10.
Equipment/Accessories details
Working width (Double Flat)
No. of Shuttle
Weft Insertion Rate
Weft Density
No. of Tapes
Wrap Bobbin
Internal Diameter
Length of core
Max.bobbin diameter
Length of Travers
Weft bobbin
Internal diameter
Length of core
Max.bobbin diameter
Length of Travers
Creel Capacity
Bobbin per machine
Fabric Winder
Max.roll diameter
Machine dimensions
Weight with creel (approx.)
Specifications
46 - 92
6
900/minute
20 – 75 per 10 cm.
720
35mm
218mm
130mm
200mm
35mm
218mm
115 mm
200mm
720
1250mm
9900mmx2800mmx2900mm
2525Kg.
B. Machinery Cost:
Sl No.
1
2
3
Machinery
Size
Extrusion
Tape
line(65mm)
CheeseWinder
(120nos.@20,000)
Circular loom line
(width
1.1
mtr
surface
winder
12nos.@6,00000)
Total Cost
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Cost
Cost in (Lacs.)
35-40
24
72
131-136
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C.UTILITY REQUIREMENT:
Sl No.
1.
Utility
Power Consumption
2.
Power requirement
3.
4.
Air Compressor
Water Cooling
Tower
Machine output rate
5.
Tape line
Winder
Circular loom
Stitching&
Cutting
Machine
Quantity
3.7kw-phase
415V
50Hz
48KW
45Wx120=5.4KW
4KWx12=48KW
5KW
3 HP
30 TR
110Kg/hr
6.
Land
35,000 – 40,000
requirements(sq.ft)*
sq ft
* 70 – 80 % is required for Machineries and Utilities
(D). MANPOWER REQUIREMENTS:
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled worker
01
03
06
04
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19.ROOFING SHEET
INTRODUCTION
PP Waveplate roofing sheet has high mechanical strength, chemical resistance,
weldability characteristics, excellent corrosion resistance, weather resistance, easy
processing, low cost and many other characteristics. Wave plate sheet is widely
used for roof material of workshops, warehouses.
Sheet extrusion is used to extrude plastic sheets that are too thick to be blown in a
blown film plant. There are two types of dies used: T-shaped and coat hanger. The
purpose of these dies is to reorient and guide the flow of polymer melt from a
single round output from the extruder to a thin, flat planar flow. In both die types
ensure constant, uniform flow across the entire cross sectional area of the die.
Cooling is typically by pulling through a set of cooling rolls. In sheet extrusion,
these rolls not only deliver the necessary cooling but also determine sheet thickness
and surface texture. Often co-extrusion is used to apply one or more layers on top
of a base material to obtain specific properties such as UV-absorption, texture,
oxygen permeation resistance, or energy reflection.
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USAGES /APPLICATIONS













Roofing
Partitions
Signboards
Family shelter
Repair of damaged buildings
Upgrade of tents and shelters.
Latrines - Washrooms
Protection of water tanks
Fencing
Repair of schools and clinics
Temporary structure
Market stalls
Food storage and drying
MARKET POTENTIAL
The plastic sheets market is expected to grow at a decent pace during the coming
decade. Plastic sheets are primarily made of PE and PP. The market is projected to
register a CAGR of 5.0% between 2014 and 2019 to reach $118,623.8 million, by
2019. Asia-Pacific holds a significant market share in the plastic sheets market.
China leads the Asian market in terms of demand for plastic sheets. Asia-pacific is
thus expected to maintain its dominance in the global market owing to the steady
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growth in China and India. The market is experiencing slow growth in Europe and
North America due to maturing of these economies.
RAW MATERIAL

PP Homopolymer (or) PP Master batch
FLOW CHART
PP Granules
Feeding & Mixing
Melting& Extruding
Filtering
T –sheet die
Calibrator
Haul off
Cutter
Final Product
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MANUFACTURING PROCESS

PP granules along with additives and colour are fed to the extruder.

The molten PP is fed to a T- die via a filter. After this step the emerged sheet
is checked for the required thickness and passed through the calibrator which
shapes the surface pattern of the sheet as wave, groove, channel etc.

The shaped sheet was then passed through specially designed rollers called
haul off unit which pulls the sheet and also controls the thickness.

The sheet while conveying gets cooled by air .The sheet after being cooled
fully is cut into required length by the help of a cutter .

The sheets are placed one above other and packed for dispatch.
A.PLANT &MACHINERY DETAILS
1. LSJ90/33 single screw extruder
Sl NO.
1
2
3
2 sets
Name of Part
Screw
Diameter
L/D
Material
Surface Treatment
Speed
Barrel
Heating control zones 6
zones
Heating method 380V, 50HZ
Heating power 40 KW
Cooling
Cooling power
Cooling for feeding zone
Gear Box
Gearbox
Material of the house
Gear type
Heat treatment of the gear
surface
Material of the gear
Bearings
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Specifications
90mm
33:1
Alloy steel 38CrMoAlA
Nitrided and Polished Rotation
10-120r/min 1.3
6 zones
380V, 50HZ
40 KW
By blower fan
370W×6zones
Water cooling
QT280
Helical gears
Quenching
20CrMnTi
Imported high bearing
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2. T-type Extrusion Die head
Sl No
1
2
3
4
1 set
Description
Flow Channel Forms
Feeding Mode
Die Mouth Width
Adjusted Thickness
Specifications
T-type, or clothes rack type
Middle-down roller feeding
1400 mm
1-12mm
3. Corrugated Sheet Calibrating Machine
Sl No
1
2
3
4
5
1 set
Description
Specifications
1250 mm
Material of Mould40Cr
600mm*2 sections
Pneumatic
3Kw
Calibrating Mould Width
Material of Mould
No. of Calibrating Mould
Clamping Force
Water Pump Power
4. Corrugated Sheet Haul-off Machine
Sl.
No.
1
2
3
4
5
Description
3
4
5
Specifications
Diameter of NBR Roller
Length of Rubber Rolls
Clamping Force
Driving Motor
Speed Regulating Mode
Hauling Speed
5. Guillotine- knife cutting machine
Sl No
1
2
1 set
220 mm
1250mm
Pneumatic
3Kw
Inverter Adjustment
0.5-4.5m/min
1 set
Description
Main Motor Power
Available
Cutting
Width
Available
Cutting
Thickness
Working Height
Dimension
Specifications
5.5kw
1250mm
Up to 12 mm
800 mm
1860*2210*1180mm
B.Total Machine Cost: Rs.96 – 100 Lakhs
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C.PRODUCT SPECIFICATION & OUT PUT
Width of Finished Sheet
Product Output
Max. Thickness of sheet
1100 mm
450 KG./HR.
12 mm
D.UTILITY REQUIREMENT:
Sl No.
1.
2.
3.
4.
5.
Utility
Power Consumption
Quantity
Installation power is about 320 kw,
normal running power is about 230 kw
Air Compressor
7.5Kw motor
Water
Cooling 2.2cu.mtr/hr
Tower
Build
up
area 35mtrx35mtr
requirements(sq.ft)
Type of Enterprises
Large
E. MANPOWER REQUIREMENTS:
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
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Designation
Manager
Supervisor
Skilled Worker
Semi-Skilled worker
01
04
04
06
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20.MULTILAYER BLOWN FILM
INTRODUCTION
Multilayer blown film material is comparatively stronger than two layer and mono
layer blown films. It is widely preferred in packaging industry as this product bears
multiple protection properties including puncture and heat resistant, less or zero
attraction to moisture and oxygen, etc. Multilayer Blown Film Plant is suitable for
producing high barrier wrapping and stuffing material for packing food products,
processed fluid consistency food items, etc.
Three layers blown film extrusion (also known as blown film co-extrusion) is a
process of simultaneously extruding in molten stage three polymers or a single
polymer with modified properties or colour which adhere to each other through a
common die to form an integral film of unique strength and barrier properties. The
selection of layers depends upon end properties required as well as items to be
packed. Now-a-days three Layers Coextruded blown film is playing a major role in
the packaging industry. It is replacing the conventional packing materials like
paper, aluminium foil, tin, glass etc. These films are considered for packing purpose
because of specific requirement of shelf-life and protection to product. The other
advantages are excellent resistance to puncturing, heat sealability, gas barrier, high
mechanical property high bursting strength etc.
USAGES/APPLICATIONS
Sl
Combination of
NO. layers
1
PP/Low Density
Polyethylene (LDPE)/PP
3
PP/High Density
Polyethylene (HDPE)/
PP
3
4PP/SCRAP/PP
4
PP/ Linear Low density
Polyethylene
(LLDPE)/PP
Applications
Heavy-duty bags
Industrial base food oil, backed
confectionary,
Dry vegetables,hydrogenated oil,lube oil
Garbage bags.
Industrial base food oil, backed
confectionary,
dry vegetables, hydrogenated oil, lube oil
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MARKET POTENTIAL
India’s flexible packaging industry anticipates strong growth but remains challenged
by negative perceptions about the use of plastics. India’s flexible packaging market
is growing 14 percent a year, currently accounts for 24 percent of the consumer
packaging market, and is expected to be a $32 billion industry in 2020. India’s
consumption of polyolefins for film and sheet is projected to increase from 2.5
million metric tons in 2014 to 4.2 million tons in 2020, an average annual growth
rate of 9.4 percent. The two fastest growing areas are in lamination for food
packaging and shrink film.
Packaging has a massive upside in the country because basic household items like
flour, rice, sugar and tea are still being sold unpackaged in the country’s interior,
where organized retailing has yet to make its presence felt. The global packaging
film market is expected to register decent growth during the coming decade driven
by middle class of China and India. With rapid urbanization and increasing
disposable income, demand for packaged food and pharmaceutical products are
rising in China, India and other emerging nations. Growth in such emerging nations
is expected to impact the packaging films industry positively. Polyethylene is the
mostly used material for packaging film; however, in flexible packaging PP is used
as the preferred material for film formation. Specialty films such as water soluble
and high barrier films are gaining importance in matured economies of North
America and Europe. Food packaging industry is the major consumer for packaging
films. However, pharmaceutical and personal care packaging is increasingly finding
application of packaging films.
Geographically, Asia-Pacific is the major segment in packaging film market with
around 35% of the market share in 2012. North America and Europe held market
shares of 25.3% and 24.1% respectively. The global packaging film consumption is
expected to grow at a CAGR of 4.5% from 2013 to 2018. In Terms of value the
market is expected to grow at a CAGR of 5.8% from 2013 to 2018. China and India
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are expected to drive the global market in the coming future. Increasing demand
for packaged food and improving healthcare infrastructure is the major reason for
growth in China and India. However, PP films demand is growing at a faster rate
than polyethylene films. BOPP is the mostly preferred raw material for flexible
packaging films in the recent past and expected to report higher growth as
compared to the cast PP.
FLOW CHART
1a
1b
1. Extruder-1,1 a-Extruder-2,1b-Extruder-3
2. Die Head
3. Rotary Die Device
4. Air Ring
5. Water Ring
6. Cooling System
7. 1st Take Up Unit
8. 2nd. Take Up Unit
9. Dry System
10. 3rd Take Up Unit
11. Winder
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12. Control Panel
MANUFACTURING PROCESS

Three types of resin from PP, LLDPE, LDPE and HDPE along with additives
and colour master batches to be used are selected depending on the
properties required on each layer.

The resin is first melted by
barrel of three extruders and
a circular die. The resulting
“bubble” (blown film). As the
rolled up on a core.

Air is introduced in the center of die to blow up the tube like a ballon.

Air ring blows onto the hot film to cool it from inside and outside of the tube.

The tube passes through nip rolls where it is flattened.

Collapsed tube is taken back down the extrusion tower via idler rollers.

On winder the tube or film is wound into rolls.
subjecting it to heat and pressure inside the
finally forcing the melt through a narrow slit in
thin film has a form of a tube, also called a
film comes out of the die, it is cooled and then
A.PLANT & MACHINERY DETAILS
Model
Screw Dia(mm)
L/D Ratio
Lay Flat Width (mm)
Thickness (Microns)
Main Moto(Kw.)
Out Put (Kg/hr.)
Die Size(mm)
Take off width (mm)
Winder type
Total Machine
Connected
Load (KW.)
Dimensions (Mtr.)
45MM/50MM/45MM
45/50/45
30:1
1000
20-60
17/21/17
100-150
400
1100
CENTER
136 KW
65MM/65MM/65MM
65
30:1
1500
20-100
37/37/37
220-250
320
1600
CENTER
208 KW
30’L X 20’W X 35’ H
30’L X 25’W X 35’ H
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INDUSTRIES IN PP MOULDED PRODUCTS
B.MACHINERY COST :
1.45mmX 50mm X45mmExtruder : RS.65 – 80 Lakhs
2.65 mm X 65mm X 65mmExtruder : RS.90 – 100 Lakhs
C.UTILITY REQUIREMENT:
Sl. No.
Utility
45 X 50 X45 MM EXTRUDER LINE
1.
Electric Power Supply
2.
Electricity
3.
Electric Running Load
Air Compressor
4.
5.
Water Recirculation
system
Plat Dimensions
65 X 65 X65 MM EXTRUDER LINE
1.
Electric Power Supply
2.
Electricity
3.
Electric Running Load
Air Compressor
4.
Water Recirculation
system
5.
Plat Dimensions
6.
Land area Requirement
 2016 CIPET Bhubaneswar. All rights reserved
Quantity
415 V Ac / 3 Ph / 50
Hz ±5% / PE / N
(Three Wire + Earth,
Neutral)
connected load 136
KW
100 KW
5 HP with Air and OIL
Filter
7.5 TR
40 Feet Length X 30
Feet Height X 25 Feet
Width (Approx)
415 V Ac / 3 Ph / 50
Hz ±5% / PE / N
(Three Wire + Earth,
Neutral)
connected load 208
KW
128 KW
5 HP with Air and OIL
Filter
2
Hp
Pump
and
related
Piping
Arrangement
40 Feet Length X 30
Feet Height X 25 Feet
Width (Approx)
50MTR. X 50 MTR
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INDUSTRIES IN PP MOULDED PRODUCTS
D. MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled-workers
Semi-Skilled
workers
01
03
04
06
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PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
21. BLOW MOLDING CONTAINER
INTRODUCTION
PP can be blow molded into containers of different sizes and shapes. Some of the
common items that are produced include bottles & jerry cans.
CHARACTERISTICS

Light weight

Flexibility

Corrosion and chemical resistance have made these plastic products versatile
for storage and handling of water, petroleum products

Due to its transparency and high strength characteristics, PP bottles are used
for detergents, shampoos, motor oil, milk, drugs and cosmetic products.

Milk bottles are the single biggest PP packaging material. Most milk and
water bottles use a natural colored PP resin.
USAGES/APPLICATION

Fuel tanks in automotive vehicles

Laundry detergent bottles
 2016 CIPET Bhubaneswar. All rights reserved
Page 201 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
MARKET POTENTIAL
After the development of PP material in copolymer grades, these bottles are
cornering the market for packaging liquids such as detergents, cosmetics,
lubricants and dairy products, a market whose scope has opened up a multitude of
potential applications PP. At present, cartons, pouches and bottles made of HDPE,
PP, PET and PE compete for space on retailers’ shelves. Glass bottles have lost
market share and are now holding their own in just a few traditional segments.
The features which make PP the first choice are the following
• Highly cost-effective material
• Excellent fitness for use
• Wide-ranging design potential and processing flexibility. Thus, industry has
recognized PP as the plastic container of choice to ensure purity of its contents and
fuel tanks in automotive vehicles are also made of PP.
EQUIPMENTS AND ACCESSORIES LIST


Extruder
Mould
 2016 CIPET Bhubaneswar. All rights reserved
Page 202 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
FLOWCHART
Extruder
Parison
Blowing air
Cooling
Product
MANUFACTURING PROCESS
PP granules are fed in to an automatic extrusion blow moulding machine and is
subjected to heat and pressure in an extruder. The semi-molten plastic in extruder
is passed through the nozzle and air is blown into the mould to force the molten
plastic against the sides of the mould. The final product is then cooled before
removal from the mould. The article is then trimmed to remove flashes.
 2016 CIPET Bhubaneswar. All rights reserved
Page 203 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
Blow Moulding Techniques
Blow moulding is a method of fabrication in which a warm plastic (hollow tube) is
placed between the two halves of a mould (cavity) and forced to assume the shape
of that mould cavity by use of pressure. Pressurized air is introduced through inside
of the parison and thereby forces the plastic against the surface of the mould that
defines the shape of the product. Blow moulding offers a number of processing
advantages, such as moulding of irregular (re-entrant) shapes, low stresses.
Variable wall thickness, the use of polymers with high molecular weight and
economical processing cost.
Extrusion blow molding
In Extrusion Blow Moulding (EBM), plastic is melted and extruded into a hollow
tube (a parison). This parison is then captured by closing it into a cooled metal
mold. Air is then blown into the parison, inflating it into the shape of the
hollow bottle, container, or part. After the plastic has cooled sufficiently, the mold is
opened and the part is ejected.
 2016 CIPET Bhubaneswar. All rights reserved
Page 204 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
A.PLANT & MACHINERY DETAILS:
TECHNICAL DATA FOR MACHINES 500 ml/3 Litre/10 Litre.
A) Extruder
1. Screw and Barrel
PARAMETERS
1.Screw
Screw dia
Screw length
L/D Ratio
2.Barrel
Barrel dia
Barrel length
3.Material
4.Gear Box
5.Motor
6. Heat Zone
7.Die Head
500 ml
3 litre
10 litre
40 mm
1035 mm
21
65 mm
1430 mm
21
75 mm
------21
110 mm
1110 mm
41-B with nitriding
and screw hard
chrome
140 mm
1275 mm
41-B with nitriding
and screw hard
chrome
---------------41-B with nitriding
and screw hard
chrome
Variable A/C Drive
Electric Motor
,500ml 7.5 Hp
motor, Variable
speed a/c motor
Hydraulic motor
5 heaters
Max container dia/
size = 80 mm
Variable A/C Drive
Electric Motor, 15
Hp motor, Variable
speed a/c motor
Variable A/C Drive
Electric Motor, 25
Hp motor, Variable
speed a/c motor
8 heaters
Max container dia/
size = 200 mm
8 heaters
Max container dia/
size = 250 mm
200 mm
X175mm X
260mm
320mm X
260mm X 28mm
175mm
360 mm X 410mm
X 305 mm
500 mm X
400mm X 380
mm
B) Locking Unit
1. Mould
mounting
2. Platen size
3. Minimum
mould opening
4.
300mm.
500mlMaximum
mould opening:
5. Tie Rod
40mm .
6. Cutter:
automatic cutter
for parison tube
515mm X 440mm
X 40mm
150mm
150mm
350mm
650mm
60mm
automatic cutter
for parison tube
75 mm
automatic cutter
for parison tube
 2016 CIPET Bhubaneswar. All rights reserved
Page 205 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
7.Oil tank
capacity
8.Hydraulic
motor
9. Machine
dimension
LxWxH
cutting
150 litres,with oil
cooler
5 HP, double
pump
72’’x45’’x75”
cutting
300 litres, with oil
cooler
7.5 HP, double
pump
96’’x54’’x92’’
cutting
450 litres, with
oil cooler
10 HP, double
pump
12x8x10 ft
A. Machinery & Mould Cost
Machinery Cost
Sl. No.
1.
2.
3.
Size
500 ml
3 Litre
10Litre
Sl. No.
1.
2.
3.
Size
500ml
3Litre
10Litre
Cost in (Lacs.)
10-13
20-28
30-37
Mould Cost
Cost in (Lacs.)
5-7
10-12
15-18
Total Machinery & Mould Cost for 500 mL container: 15- 20 Lacs
Total Machinery & Mould Cost for 3 L container: 30 – 40 Lacs
Total Machinery & Mould Cost for 10L container: 45 – 55 Lacs
 2016 CIPET Bhubaneswar. All rights reserved
Page 206 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
C.UTILITY REQUIREMENT
Sl. No.
Utility
Size
01.
Power
500ml
3Litre
10Litre
Quantity
15HP
02.
Electricity
28HP
45HP
Connected load 120 KW
03.
Water
20TR/hr.
04.
Air Compressor
05.
Machine output
rate
06.
500ml
3Litre
10Litre
500ml
9CFM
12CFM
15GM
10 Kg/hr
3Litre
10Litre
20 Kg/hr
35 Kg/hr
Land area
Requirement *
10,000 – 12,000 sq.ft
* 70 – 80 % is required for Machineries and Utilities
D.MANPOWER REQUIRMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory Cadre
 2016 CIPET Bhubaneswar. All rights reserved
Designation
Manager
Supervisor
Skilled -Worker
Semi-Skilled
Worker
01
03
9
12
Page 207 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
22. DISPOSABLE CUPS
INTRODUCTION
The disposable plastic cups are manufactured by thermoforming technique. They
are fast replacing conventional cups. Drinking water, Ice-cream and other dairy
products are packed in disposable cups. Besides Ice-cream industry, hotels,
restaurants, canteens etc. have been increasingly using disposable cups as against
conventional glass-wares or ceramic cups. Disposable cups are mainly used for food
items and are made out of polypropylene sheets. Thermoforming is a process of
heating sheet between glass transition temperatures and softening point of the
material and then forming into the desired shape with the help of air pressure,
vacuum or aided with plugs. Sheets having thickness 0.35 mm to 2 mm is used for
these items in thermoforming machine. The disposable cups are gaining popularity
due to attractive look, light weight for container, ease of transportation and low
impermeability.
Now-a-days
organizations
like
railways,
airlines
are
using
disposable cups for serving water, coffee, tea etc.
USAGES / APPLICATIONS



In restaurant
In Wedding parties
In offices
 2016 CIPET Bhubaneswar. All rights reserved
Page 208 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
MARKET SURVEY / POTENTIAL
Due to the recent change in the life style of urban class the demand for disposable
cups is increasing at a rapid rate. Apart from being used at home, they also come in
handy during parties, picnics and other functions and get-togethers. Plastic
disposable cups are also used by Ice-cream industry, hotels, restaurants, canteens
etc. but the major customer of disposable cups is ice-cream industry and they have
started using plastic cups instead of paper ones that were being used earlier. The
main advantage of these plastic cups is that they are completely leak proof. Plastic
cups can be made up of different sizes and they can hold bulk material easily in
comparison to the traditional paper cups. Besides organization like Railways,
Airlines are using a good quantity of plastic disposable cups. Considering the above
factors, demand of disposable cups is expected to increase faster in future.
EQUIPMENTS AND ACCESSORIES LIST





Thermoforming machine
Thermoformed article cutting press
Air Compressor
Vacuum pump
Scrap grinder
 2016 CIPET Bhubaneswar. All rights reserved
Page 209 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
FLOW CHART
CLAMPING
HEATING
PRE-STRETCH
VACUUM
PLUG ASSISTED
WASTE
COLLECTION
COOLING &
RELEASING
TRIMMING &
FINISHING
MANUFACTURING PROCESS
Thermoforming is the process of converting a thermoplastic sheet into a threedimensional.
 2016 CIPET Bhubaneswar. All rights reserved
Page 210 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
Basic steps of thermoforming

Plastic sheet is heated in an oven

Hot sheet is then transported to a moulding area and draped over a cool
mould

Vacuum is drawn through the mould, pulling the hot sheet onto the mould

Hot sheet takes the shape of the mould

Plastic cools and is transported to a trimming station where the formed part
is trimmed out of the full-width sheet
THERMOFORMING PROCESS
Thermoforming is the process of heating a thermoplastic sheet, to its softening
point, stretching it over or into a single-sided mould, and holding it in place while it
cools and solidifies into the desired shape. The thermoplastic sheet is clamped into
a holding device and heated by an oven using either convection or radiant heat
until it is softened. The sheet is then held horizontally over a mould and pressed
 2016 CIPET Bhubaneswar. All rights reserved
Page 211 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
into or stretched over the mould using vacuum pressure, air pressure, or
mechanical force. The softened sheet conforms to the shape of the mould and is
held in place until it cools. The excess material is then trimmed away and the
formed part is released. Excess material can be reground, mixed with unused
plastic, and reformed into thermoplastic sheets, which is done using scrap grinder.
There are different methods of forcing the thermoplastic sheet to conform to the
mould.
Vacuum forming
A vacuum is formed between the mould cavity and the thermoplastic sheet.
Vacuum forming is a thermoforming process involving forming thermoplastic sheets
into three-dimensional shapes through the application of heat and pressure. During
vacuum forming processes, plastic material is heated until it becomes pliable, and
then it is placed over a mould and drawn in by a vacuum until it takes on the
desired shape.
Pressure forming
This process is similar to vacuum forming, except with the addition of pressure,
which pushes the sheet into the shape of the mould. This additional force allows the
forming of thicker sheets and creating finer details, textures, undercuts, and sharp
corners.
This process is mainly used for parts requiring styling and aesthetic
qualities because pressure forming creates greater detail, allowing for textured
 2016 CIPET Bhubaneswar. All rights reserved
Page 212 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
surfaces, undercuts and sharp corners, which are not as easily created with vacuum
forming.
Mechanical forming
The thermoplastic sheet is mechanically forced into or around the mould by direct
contact. Typically, a core plug will push the sheet into the mould cavity and force it
into the desired shape. The sheet is heated until it is soft, and then both mould
halves clamp together to form the part. Used with parts those do not have large
draws.
RAW MATERIAL

PP Sheet of desired thickness
 2016 CIPET Bhubaneswar. All rights reserved
Page 213 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
THERMOFORMING MACHINE SPECIFICATION
Sl. No
1
2
3
4
5
6
Injection Unit
Maximum Forming
Area
Maximum Product
Height
Thickness Range
Material Used
Electric Power
Product / Working
Speed
Unit
mm
Specification
760×600
mm
120
mm
00.2 to 1.5
PP,HIPS,PET,PVC,PE
20
3.0 / cycle, 20 / cycle (Min –
Max)
KW
Sec
SHEET EXTRUDER SPECIFICATION FOR THERMOFORMING
Sl. No
1
2
3
4
5
Injection Unit
Screw Diameter
L/D Ratio
Width of Die Head
Width of Finished Product
Thickness of finished
products
Unit
mm
mm
mm
mm
Specification
65
35:1
1500
700-1200
2 – 1.5
MACHINERY & MOULD COST
A. MACHINERY COST
Sl.No.
Machinery
Quantity
1 No.
2 Nos.
30-40
1 No.
10-15
2 Nos.
3-5
5.
Sheet Extruder (150250 Kg/hr)
Thermoforming
(Vacuum) Machine
Dry
offset
printing
machine
Packing
&
Sealing
Machine
Air Compressor
Cost
(in Lacs)
50-60
1 No.
2.5 - 3
6.
Water Pump
1 No.
0.5 - 1
1.
2.
3.
4.
 2016 CIPET Bhubaneswar. All rights reserved
Page 214 of 217
PROJECT PROFILES FOR DOWN STREAM
INDUSTRIES IN PP MOULDED PRODUCTS
7.
8.
Chilling Plant/Cooling
Tower
Scrap
Grinding
Machine
Total Cost
1 No.
8 – 9/3-5
2 Nos.
5-6
109 – 139
B.MOULD COST
Sl.No.
1.
Mould
Quantity
Mould (12 cavity)
1 Nos.
Total Cost
Cost
(in Lacs)
8 - 10
8 - 10
TOTAL COST (MACHINERY & MOULD): 117-149 lacs
C.PRODUCTION CAPACITY
Production
Capacity per day
@ 25 shots /minute
for 22 hours
3, 96,000
Production
Capacity per
annum (300 days)
Raw Material
Consumption
/ annum
11,88,00,000
~ 356 MT
@ 3 g / piece
D.UTILITIES REQUIREMENTS
Sl. No.
1.
2.
3.
4.
5.
Type
Electricity for Sheet Extruder
(150-250 Kg/hr)
Electricity for
Thermoforming (Vacuum)
Machine
Electricity for Dry offset
printing machine
Electricity for Packing &
Sealing Machine
Electricity for Air
Compressor
 2016 CIPET Bhubaneswar. All rights reserved
Requirement (approx.)
Connected Load – 75 KW
Connected Load – 25 KW
Connected Load – 8 KW
Connected Load – 4 KW
Connected Load – 5 KW
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INDUSTRIES IN PP MOULDED PRODUCTS
6.
7.
8.
9.
Electricity for
Electricity for
Plant/Cooling
Electricity for
Machine
Water
Water Pump
Chilling
Tower
Scrap Grinding
Connected Load – 2 KW
Connected Load – 8 KW
Connected Load – 3 KW
50 litre/min
Water will be circulated
through fixed tank capacity
is 15,000-20,000 litre
10.
Land Required *
15,000 – 20,000 sq. Ft.
* 70 – 80 % is required for Machineries and Utilities
E. MANPOWER REQUIREMENTS
Sl. No.
Manpower
1.
Supervisory Cadre
2.
Non-Supervisory
Cadre
Designation
Manager
01
Supervisor
03
Skilled - Worker
06
Non-Skilled
worker
12
DISCLAIMER
This report contains information about 20 Project Profiles for downstream Industries
in PP Moulded Products. The information is only a guideline as per the current
market scenario and not an advice, and should not be treated as such. CIPET does
not undertake any representations, warranties, undertakings and guarantees
relating to the report, thereby reporting; that the use of guidance in the report will
lead to any particular outcome or result or that by using the guidance in the report,
if the user does-not achieve success or the desired output, CIPET shall not be held
responsible. We will not be liable in respect of any losses arising out of any event or
events beyond our reasonable control. We will not be liable in respect of any
business losses, including without limitation loss of or damage to profits, income,
revenue, use, production, anticipated savings, business, contracts, commercial
opportunities or goodwill. We will not be liable in respect of any special, indirect or
consequential loss or damage.
 2016 CIPET Bhubaneswar. All rights reserved
Page 216 of 217
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 1 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 2 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 3 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 4 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 5 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 6 of 7
Annexure I
RAW MA
MATERIAL SPECIFICATIONS
 2016 CIPET Bhubaneswar. All rights reserved
Page 7 of 7
Annexure II
MACHINE MANUFACTURER
MANUFACTURERS
S DETAILS
INJECTION MOULDING MACHINE
1. Ferromatik Milacron India Pvt. Ltd.,
Plot No- 93/2 and 94/1, Phase – I, GIDC Vatva, AhmadabadAhmadabad 382445
Gujarat . E-mail: neeraj_sharma@milacron.com
2. Windsor Machines Ltd.,
Plot No- 5402-5403,
5403, Phase – IV GIDC Vatva Ahmadabad- 382445,
Gujarat. E-mail: ritesh.shah@windsormachine
ritesh.shah@windsormachines.com
3. Electronica Plastic Machine (P) Ltd.,
Gat No- 399, Hissa No 1 & 2, Bharetaluka Mulshi Dist.
Dist.- Pune
India-412115,
412115, Maharashtra. E
E-mail: epml@electronicapmd.com
4. Vishavakarma Hydrulics (P) Ltd.,
A-102/3 Wazirpur,
rpur, Industrial Area , Delhi
Delhi-110052,
110052, New Delhi.
E-mail: vhpl2012@gmail.com
5. Toshiba Machine (Chennai) Pvt. Ltd.,
P.O. Box No-5, Off--Chennai-Bangalore
Bangalore Highway, Chembarambakkam,
Chennai-600123. E--mail: sales@toshiba-machine.co.in
6. Husky Injection Molding System (P) Ltd.,
404, Awing, Delphi Building, Hiranandari, Powai, Mumbai (Maharashtra)
Pin-400076
7. S.G. Engineer, 68, Nawada Sheikhan, Baljati Well,
Old city, Bareilly, Uttar Pradesh, India.
8. Kapsun Resources Corporation,
Shed No- 5, Raj Estate, B/H. Vallabh Dining Hall,
JP Compound, Sarkhej Char Rasta, Sarkhej, Ahmadabad, Gujarat.
9. Alfa Polymers Pvt. Ltd.,
154/597, Village Pooth Khurd, Next to Tulip Pub
Public
lic School,
Near Bawana Indl, Area, Delhi.
10.Electronica
Electronica Hitech Machine Tools (P) Ltd.,
44, Elektra Chambers, Mukund Nagar, Pune, Maharashtra.
 2016 CIPET Bhubaneswar. All rights reserved
Page 1 of 5
Annexure II
MACHINE MANUFACTURER
MANUFACTURERS
S DETAILS
11.H.K.
H.K. (HIKON) Industries ,
3/23 Kirti Nagar, Indl. Area, New Delhi
Delhi- 11005
E-mail: hikonindus@yahoo.co.in , surmit@hirkonindia.com
12.Polymech
Polymech Plast Machines Ltd.,
Gold Coin House 775, G.I.D.C , Makarpura, Vadodara
Vadodara- 390010 , Gujarat,
India. E-mail: goldcoin@polymechplast.com
Ph- 0091-265-2632210,2631211
2632210,2631211
13. Patel Plast, Vivek Indl. Estate, Gala No
No-18,
18, Walbhat Road, Goregaon
(East) Mumbai-400063
400063 (Maharashtra).
14.Haitian
Haitian Huayuan Machinery (India) Pvt. Ltd.
Survey No.543 (P) 2, of Irana, Chadasana Chokadi, Near Ratnamani Metal
& Tubes Pvt Ltd., Chhatral Mehsana Highway, Irana, Kadi, Mehsana (NG),
Gujarat. -382715
Phone: +91 9920022688
9920022688（IN）
Email: info@haitian.in , lm@mail.haitian.com
 2016 CIPET Bhubaneswar. All rights reserved
Page 2 of 5
Annexure II
MACHINE MANUFACTURER
MANUFACTURERS
S DETAILS
BLOW MOULDING MACHINE
1. Central Machinery & Plastic Products
B-3,
3, Aristocrate Building, Ground Floor, Laiya Compound, Mogra Road,
Andheri East, Mumbai
Mumbai- 400069, Maharashtra. E-mail: cmp@cmppin.com
2. Rana & Sons
Plot No- 28-A,
A, Khandivali Industrial Estate, Shri Hanuman Mandir Road,
Charkop, Kandivali West, Mumbai, Maharashtra – 400067.
3. Jagmohan Pla-Mach
Mach (P) Ltd.,
901-B,
B, Filix Complex , L.B.S. Marg, Near Asia. Paints, Bhandup (W),
Mumbai-400078
E-mail: info@jagmohan.com
4. Shree Siddhi Vinayak Engineers,
Plot No- 3001, Phase
Phase- 4, GIDC Vatva, Ahmedabad- 382445, Gujarat.
 2016 CIPET Bhubaneswar. All rights reserved
Page 3 of 5
Annexure II
MACHINE MANUFACTURER
MANUFACTURERS
S DETAILS
EXTRUDER MACHINE
1. Kabra Extrusion Technik Ltd.,
Kolsite House , P.O. Box No
No- 11902 , Dattaji Salvi Marg, Off-Veera
Off
Desai
Road, Andheri West, Mumbai
Mumbai-400053, Maharashtra.
E-mail: marcom@kolsitegroup.com
2. J.P. Extrusion Tech Ltd.,
1701, GIDC Industrial Estate, Ankaleswar – 393002, Gujarat.
E-mail: info@jpel.in
3. Lohia Corp Ltd.,
D-3/A,
3/A, Panki Industrial Estate, Kanpur
Kanpur- 208022, U.P. ,
E-mail: sales@lohiagroup.com
4. Sai Machine Tools (P) Ltd.,
Plot No- 23, Sector – ‘A’ Sanwer Road, Industrial Area. IndoreIndore 452015,
M.P. E-mail: mail@saimachinetools.com
 2016 CIPET Bhubaneswar. All rights reserved
Page 4 of 5
Annexure II
MACHINE MANUFACTURER
MANUFACTURERS
S DETAILS
THERMOFORMING MACHINE
1. Mlew Eng. Pvt. Ltd.
24/63, Nabalia Para Road, Behala Chowrasta, Kolkata - 700 008
Phone : (033) 494-7888
7888 / 494
494-8504, Fax : (033) 494-8504
e-mail : info@mlew.in
info@mlew.in, Website : www.mlew.in
2. Rajoo Engineers Ltd.,
.,
Rajoo Avenue, Survey No
No- 210, Plot No-1,
1, Industrial Area, Veraval (Shaper)
Rajkot-360024,
360024, Gujarat. E
E-mail: marcom@rajoo.com
3. Machine Craft
505, Palm Spring, Above Croma, Link Road, Malad West, Mumbai – 400064
Maharashtra. E-mail:
mail: sales@machinecraft.org
4. R.R. Plast Extrusions (P) Ltd.,
Corporate office B-3,
3, Nand Jyot, Industrial Estate. Safed Pool, Sakinka,
Andheri (E), Mumbai
Mumbai-400072, Maharashtra. E-mail: info@rrplast.com
5. Elpie Enginering pvt. Ltd.
Survey No-170,Plot
,Plot No
No-G-12, Chandra Indl. Estate,
Gondal chokdi gondal Road, Kothariya, Rajkot-360004(Gujarat)
360004(Gujarat)
6. Samarpan Fabricator pvt. Ltd.,
Plot No-A/182, Road
oad No
No-16-Z,Wagle Indl. Estate, Mumbai400604,
Maharashtra. Ph. No--+91-844756310
 2016 CIPET Bhubaneswar. All rights reserved
Page 5 of 5
Annexure III
AUXILIARY EQUIPMENT
MANUFACTURERS DETAIL
DETAILS
Chilling Plant
1. Prasad Group of Companies
Companies, Plot No- 14 & 16,
GIDC Estate, Phase
Phase-1, Vatva, Ahmadabad – 382445, Gujarat.
E-mail: plastics@prasadgroup.com
2. Renold India (P) Ltd.,
C-38/39, Sector--2, Noida-201301, U.P.
E-mail: chiller@reynoldindia.com
3. Air-Tech
Tech Cooling Process (P) Ltd.,
145, Type-A,
A, HSIDC, Sector – 31, Faridabad-121003, Haryana, Head
Office, B-93,
93, Okhla Industrial Area, Phase
Phase-II,
II, New Delhi-110020.
Delhi
E-mail: info@airtechengineers.com
4. Crescent Refrigeration (P) Ltd.,
49/H-32,
32, Sector
Sector-3, Rohini 85, Delhi- 110085, New Delhi.
E-mail: crescentrefrigeration313@gmail.com
 2016 CIPET Bhubaneswar. All rights reserved
Page 1 of 3
Annexure III
AUXILIARY EQUIPMENT
MANUFACTURERS DETAIL
DETAILS
Scrap Grinder
1. Plmco Machines (P) Ltd.,
A-28,
28, Nanddham Industrial Estate, Marol Maroshi Road, Marol.
Andheri East, Mumbai
Mumbai-400059, Maharashtra.
E-mail: sales@pimcomachine.in
2. Ploneer Engineering Corporation
Corporation, 218, Veera Dalvai Indl. Est.,
Oshiwara, S.V. Road, Jogeswari (W), Mumbai
Mumbai-400102,
400102, Maharashtra.
E-mail: dinesh@piocomachines.com
3. Dollplast Machinery Inc. , Plot No- 496, Bhagyalaxmi Indl. Estate,
B/H, Manpasand Weigh Bridge, Sola
Sola-Science, City-Santej
Santej Road, West
Ahmadabad, Rakanpur
Rakanpur-382721, Gujarat.
E-mail: dollplast@dollplast.com
4. Panchal Plastic Machinery (P) Ltd., Plot No- 127, GIDC,
Dist- Valsad, Gujarat
Gujarat, Umbergaon - -396171,
396171, Gujarat.
E-mail- info@panchal
info@panchal-plastic.com
5. Prasad Group Of Industries
Industries, Plot No- 14816, GIDC Estate,
Phase-I,
I, Vatva Ahmedabad
Ahmedabad-382445, Gujarat.
E-mail: plastics@prasadgroup.com
 2016 CIPET Bhubaneswar. All rights reserved
Page 2 of 3
Annexure III
AUXILIARY EQUIPMENT
MANUFACTURERS DETAIL
DETAILS
D
Dry Offset Printing Machine
1.Swastik techno Engineers Pvt Ltd.(Rs-5lakh)
Plot no-748,New
748,New G.I.D.C,gundlav,Valsad
G.I.D.C,gundlav,Valsad-396035,Gujarat,
396035,Gujarat,
Ph No- 9953360476
2.Pearl Printer Pack(Rs
Pack(Rs-3.5Lakh)
Plot No-124,Parvatiya
124,Parvatiya colony ,N.I.T.,Faridabad,Haryana
,N.I.T.,Faridabad,Haryana-121004,
Ph No-9953353608
9953353608
3.Winner Seveen Machines Pvt.Ltd,(Four Color)
W-372,TTC
372,TTC Ind.Area,MIDC,Rabel,Navi
Ind.Area,MIDC,Rabel,Navi-Mumbai-400701,Maharastra
400701,Maharastra
4.G.S Printographics machinery co
MCF 48/5A,Bhudatt Colony,Ballabgarh,Faridabad,Haryana
Colony,Ballabgarh,Faridabad,Haryana-121004
5.Ensure enterprises,(Six Color, Rs 7.5 Lakh)
Plot No-1b/138,NIT,Faridabad,
1b/138,NIT,Faridabad, Haryana-121001
 2016 CIPET Bhubaneswar. All rights reserved
Page 3 of 3
Annexure IV
MOULD MANUFACTURERS DETAILS
S
MOULD MANUFACTURER
1. Central Institute of Plastics Engineering & Technology ((CIPET
CIPET),
B/25, C.N.I.Complex , Patia, Bhubaneswar
Bhubaneswar-751024
E-mail: cipetbbsr@gmail.com
2. Central Tool Room Training Centre ((CTTC) ,
C.N.I.Complex, Patia, Bhubaneswar
3. Precision Moulds & Dies (P) Ltd.,
8/6-A-I,
I, Industrial Area, Site
Site-4, Ghaziabad - 201010. U.P.
E-mail: arjunk@pmd
arjunk@pmd-india.com
4. Tool Tech Moulds & Moulding (P) Ltd.,
Gala No-5,
5, Ground Floor, Bulding No
No-1,
1, Shivalay Industrial Estate.
Chinchpada, Vasasi (East) Dist
Dist- Thane-401208.
E-mail: tooltech97@yahoo.com
5. Sahil Enterprises
D-8,
8, Nanddham Industrial Estate, Moral Maroshi Road, Andheri (E),
Mumbai-400059,
400059, Maharashtra. E
E-mail: info@sahilmoulds.com
6. Vasantha Tool Crafts (P) Ltd.,
7-24/1,
24/1, Pipeline Road, Subhashnagar, Jeechimetia, Hyderbad
Hyderbad-500055,
Andhrapradesh. E-mail:
mail: info@vasanthatools.com
7. Daniel & Sons
1-3,
3, Vaibhav Industrial Estate, Mahakali Caves Road, Opp. Onida, House,
Andheri (East)
st) Mumbai
Mumbai-400093, Maharashtra.
E-mail: info@danielandsons.com
8. Devu Tools (P) Ltd.
A-44,
44, Nandjyot Indl. Estate. Safed Pool, Andheri, Kurla Road, Sakinaka,
Mumbai-400072,
400072, Maharashtra. E
E-mail: devugroup@vsnl.net
 2016 CIPET Bhubaneswar. All rights reserved
Page 1 of 2
Annexure IV
MOULD MANUFACTURERS DETAILS
S
THERMOFORMING MOULDS
1. Mould Craft Industries,
1,Damji Shamji Indl. Estate,L.B.S Marg., Vikhroli West,
Mumbati-4000083.
4000083.
Email: info@mouldcraftindust
info@mouldcraftindustries.com
2. Polyform Technologies,
A/24, Gate No-2,
2, Laghu Udyog Kendra, I.B. Patel Road, Goregaon,
(East) Mumbai-400063,
400063, Maharashtra.
Email: polyformtm@gmail.com
3. Team Thermoformings & Allieds,
No-09,1st Main
ain road, Doddanna Indl. Estate, Near Peenya 2nd
Stage, Bangalore
Bangalore-560091, Karnataka.
Email: info@thermoforming.com
4. Rajoo Engineers Ltd.
Rajoo Avenue, Survey No
No-210, Plot No-1,
Indl. Area Veraval(Shaper) , Ra
Rajkot-360024,Gujurat.
Email: macrom@rajoo.com
 2016 CIPET Bhubaneswar. All rights reserved
Page 2 of 2
FACILITIES IN PARADEEP PLASTIC PARK
PARADEEP PLASTIC PARK ODISHA
Asia has been world’s largest plastics consumer for several years, accounting for
about 30% of the global consumption. Global plastics and polymer consumption is
expected to grow at 5%. The growth rate of
Indian Plastics industry is one the highest in
the world.
Consumption of plastics is growing at more
than 16% per annum leading to tremendous
opportunities for plastic products as well as
plastics machinery manufacturer.
Odisha has a Plastic Polymer and Allied Cluster (PPAC) at Balasore which has 100
units operating in it. With reasonably good level of automation, abundant raw
materials and easy to access markets, the State has huge potential for production
and export of a wide range of products.
Department of Chemicals and Petrochemicals (DCPC), Ministry of Chemicals &
Fertilisers (MoCF), Government of India (GoI) has formulated the ‘Scheme for
setting up of Plastic Parks” with a view to synergise and consolidate the capacities
in Indian Plastic Industry through cluster development.
Paradeep Plastic Park Limited is a Public incorporated on 10 June 2013. It is
classified as State Govt Company and is registered at Registrar of Companies,
Cuttack. Its authorized share capital is Rs. 165,000,000 and its paid up capital is
Rs. 58,620,000. The project is developed jointly by IDCO and the Indian Oil
Corporation Ltd (IOCL), in which IDCO would be the nodal agency for development
of the Park.
Government of Odisha through its “Odisha Industrial Policy, 2007” has mandated
Odisha Industrial Infrastructure Development Corporation, (IDCO) with promoting
 2016 CIPET Bhubaneswar. All rights reserved
Page 1
FACILITIES IN PARADEEP PLASTIC PARK
the PCPIR at Paradeep on PPP mode. Govt. Of Odisha expects to attract
investments of Rs. 2.78 trillion with the Paradeep PCPIR and other related
proposals in the region.
KEY NOTES ON PARADEEP PLASTIC PARK:

Land: 120 acres of exclusive development near Indian Oil Corporation
Limited (IOCL) refinery.

Investment: USD 77.14 Million funds have been pumped in development of
Infrastructure.

Raw Material: Committed Feedstock of Polypropylene has been made by
IOCL, Paradeep

Common Machinery/ State-of-art Facility: Manufacturing industries having a
base with for the downstream plastic industry.

Production Units: Working Units who shall be engaged in Injection Moulding,
Blow Moulding and Extrusion Moulding shall be put up for installation and
commissioning with a view to capture the proposed market potential.
NATURAL
ADVANTAGES
AND
CONNECTIVITY
TO/
FROM
PARADEEP
PLASTIC PARK:

GEOGRAPHICAL
Logistics: Proximity to various medium of transport such as sea port (3
Kms), International Airport (150 Kms), Railway station (5 Kms) and raw
material linkages.
 2016 CIPET Bhubaneswar. All rights reserved
Page 2
FACILITIES IN PARADEEP PLASTIC PARK

AVAILABILITY OF FEEDSTOCK
Commitment of feedstock such as Polypropylene derivatives shall be
available from IOCL at a distance of 1.0 km and availability of raw materials
within a radius of 5 km.

EXPORT TRANSPORTATION CORRIDOR
Ease of export,from Paradeep Port, the main outlet and inlet for sea borne
trade in the eastern part of the country located at a distance of 3.0 km.

INDIAN RAILWAYS
The rail network from Cuttack-Paradeep double broad gauge line connects to
the National Rail Network. New railway line is being developed for fast
evacuation of materials.

NATURAL WATER
Commitment of 1.5 MLD of water has been available from the Water
Resources Department. Water makes a lot of facilities work, when operating
a
plant
with
sideways
other
residential
colony
with
small
localities
mushrooming nearby.
 2016 CIPET Bhubaneswar. All rights reserved
Page 3
FACILITIES IN PARADEEP PLASTIC PARK

UNINTERUPPED POWER:
The captive power plant of 500 MW has planning to be upgraded to 1000 MW
to ensure 24*7 availability of power. Two numbers of 400 KV transmission
lines also available through the same lines of Paradeep Plastic Park.
The Paradeep Plastic Park, is established near Indian Oil’s Paradeep refinery already
houses the frame towards the necessary state-of-the art infrastructure. These shall
further facilitate long term investments by Micro, Small, Medium and Large units in
the park. This is likely to create vast employment opportunities in this region. The
approximate investment is envisaged to be Rs 486 crore whereas the employment
 2016 CIPET Bhubaneswar. All rights reserved
Page 4
FACILITIES IN PARADEEP PLASTIC PARK
potential shall be close to 4,200 nos. of candidates. (Ref: News Article on “Plastic
park at Paradeep to be operational by mid-2016”, by Orissa Post Newspaper.)
PROJECT BRIEF
MASTER PLAN, INNER ROADS & CONNECTIVITY:
Paradeep Plastic Park Master Plan
The Park is connected with the following air/ rail and road connectivity:

Road connectivity to NH-5A 2.5 km.

Road connectivity to SH-12 3.0 km.

Nearest rail connectivity @ Paradeep 3.0 km.

Nearest Air Link (Bhubaneswar) 120 km.

Sea port @ Paradeep 10.0 km.
 2016 CIPET Bhubaneswar. All rights reserved
Page 5
FACILITIES IN PARADEEP PLASTIC PARK
TYPE OF MACHINERY INVESTMENT (IN NOS.)
The proposed Plastic Park will mainly consist of manufacturing units for plastic
products such as woven sacks, plastic pipes, injection moulded components, films,
pouches, packaging products and other consumer plastic products and supporting
infrastructure for producing various components and inputs that go into the
manufacture of plastic products, Plastic Products Evaluation Centre (PPEC) with
testing facilities, processing hall/ shop floor, tool room, design and product
development facility with simulation and evaluation support, training and skills upgradation facility, raw material stores, warehouses, logistics support facilities etc.
NUMBER OF PROJECTS/ ENTREPRENEURS:
Type of Unit No. of
INJECTION MOULDING
BLOW MOULDING
EXTRUSION
ACCESORIES
TOTAL
Units
29
26
21
4
80
All the participating entrepreneurs are those who are currently engaged in the
business of plastic products manufacturing and as on date 6 entrepreneurs
belonging to the plastic industry have evinced interest in participating in the
Project. Further, industry associations have also evinced interest in participation in
the proposed plastic park.
LAND AVAILABLE AND LAND TO BE UTILIZED
The proposed Plastic Park would be located on 120 Acres of land in Siju Village
carved out from the total 474 Acres of Land available with IDCO. The land currently
is in possession of IDCO which in turn has allotted to the SPV, Paradeep Plastic Park
Limited (PPPL). The land is contiguous and without any hindrances Land Cost – Rs.
21.60 crores.
 2016 CIPET Bhubaneswar. All rights reserved
Page 6
FACILITIES IN PARADEEP PLASTIC PARK
The land is proposed to be utilized as under:
Roads – 12.9% (15.43 Acres)
Common Infrastructure – 8.9 % (10.65 acres)
Common Amenities – 10.2 % (12.21 acres)
Industrial Plots – 58.1% (69.71 acres)
Open/ Green Spaces – 10.0% (12.00 acres)
COMMON INFRASTRUCTURE

Road Network – 5.5 km of 24/ 18 m ROW with street lighting at every 25 m
spacing

Storm Water Drainage – 9.4 km of storm water network

Water Supply - Storage and distribution network for supplying 1.49 MLD of
water for industrial and domestic uses

Sewerage & Effluent Treatment – 0.93 MLD STP with 3.3 km of Collection
network
PROPOSED BUSINESS BY THE PARK
The main objectives for promotion of the Plastic Park is to make it a state-of-art
manufacturing base for the downstream plastic industry comprising conversion of
polymers into plastic articles with support facilities ranging from warehouse for raw
material and finished products, simulation and testing facilities as well as finishing
and packing under one roof.
The Park would thus have units engaged in injection moulding, blow moulding and
extrusion moulding and shall cater to the requirements of a wide array of
applications like agriculture, infrastructure, automobile, construction, consumer
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Page 7
FACILITIES IN PARADEEP PLASTIC PARK
goods, telecommunication, packaging, healthcare etc., for export and domestic
market
The raw materials for the plastic processed articles are the polymers in the form of
granules made out of resins and compounds manufactured in the “upstream”
industry.
ESTIMATED PRODUCTION SALES (PARK OUTPUT):
The employment is estimated up-to:
Direct Employment - 4,170
Indirect Employment - 10,000
The investment now is routed as follows:
The combined sales turnover at full operational capacity of all the units in the Park
would aggregate to Rs. 1,146 crores per annum. The park invested approx 486
crores as an input to achieve an output for better annual revenue.
 2016 CIPET Bhubaneswar. All rights reserved
Page 8