BLOWN FILM MAKING MACHINE, MONO LAYER, MULTI LAYER, ABA – INDIA

BLOWN FILM MAKING MACHINE

<s0″>pan style=”font-size: xx-small;”>CO-EXTRUDED MULTILAYER FILM

Location of the unit:

         Location of the unit must be based on availability of infrastructural facilities such as electricity, water, transport & communication, bank etc. are also available. 900 ft² additional shed making a total plinth area of 1800 ft². to accommodate the project.

Plant & Equipment:

         Principal items of plant and equipment needed for the manufacture of co-extruded blown film is as follows: –

i) Co-extrusion film plant
ii) Corona surface treating equipment
iii) Rotogravure printing machine
iv) Co-extrusion film plant

         Co-extrusion means, combining more than one material by means of plasticizing extrusion into a unit structure in such a way that the materials will constitute distinct layers. As the co-extrusion technique is relatively a new one, special care is to be taken in the selection and procurement of the plant.

The plant essentially consists of two single screw extruders, a control panel with separate thyrister control panel for each drive motors and a heating panel for all zone heaters, film die assembly, air cooling ring and blowers, an oscillating platform which can oscillate through 300 each way, take off tower unit, trimming attachment, a two station surface winder having a roller width of 800 mm. The machine and equipment are suitable for operation on 400/440volts, 3 phases with neutral 50 cycles AC supply. All electrical heaters are single phase but the load is distributed for 3-phase supply through control cabinet. Total power load required is 85 KW.watch The Magnificent Seven 2016 film now

Corona Surface treating equipment:

         Plastics in general and polyolefin’s in particular have got a tendency to reject printing inks from their un-polarized surfaces. Hence it is necessary to polarize the surface of the film by this pre-treatment so that during printing the necessary level of adhesion is achieved.
This equipment consists of a solid-state theater, HT transformer, and special oil for above transformer, enclosed type roller assembly, an extra pair special dielectric sleeve, one extra zone extraction unit etc/

Rotogravure printing machine:

         The printing machine is specially designed in such a way that all the printing units are identical with the possibility that additional color can be attached. The machine is equipped with DC motor coupled to a thyrister converter to operate on AC mains.

Raw materials:

         Plastic raw materials such as LDPE, LLDPE, HDPE, PP, and Nylon etc. can be used for the manufacture of co-extruded film depending upon the end use of the product. Since milk pouches are generally a two-layer film (LDPE/LDPE) and the project envisages production of plastic film for milk pouches, the requirement is only LDPE. The other important raw materials required are butanol, solvent IPA and gravure printing ink.

Marketability and Scope:

         Co-extruded films find extensive use in the manufacture of pouches for packaging of various edible consumer items like milk, ghee, oils, snacks etc. It is estimated that in India about 80% of co-extruded films are being consumed for milk pouches and ghee pouches. The market for blown films is expanding and it is envisaged that more and more items would be brought under this material for packaging purposes.

Basis and Presumptions:

        The efficiency of the unit is calculated at 80% of the total production capacity.
The unit will work 25 days in a month of 3 shifts and 300 days in a year.
The time period for achieving the full envisaged capacity utilization is one year.
The labor wages are as per the prevailing rates in the market.
The rate of interest for fixed and working capital is taken @ 14%.
The margin money requirement for this project is 25%.
The pay back period of this project is 5 years.
The land area is 500m and the constructed area is 250 m.

Implementation Schedule:

Preparation of project report
2 months
Selection of site
1 months
Registration as SSI
1 weeks
Acquiring loan
3 months
Machinery procurement, erection and commissioning
2 months
Recruitment of labors etc.
1 months
Trial runs
1 months

Process of Manufacture:

        Raw materials are fed into the hopper, which gets heated in the barrel with the help of the heater
The melt in the extruders is conveyed forwarded by the screw rotation
The 2 extruders individually feed the 2 channels within the die
All the flow channels coverage into a single flow channel, just a little distance before the material is blown out from the annular die orifice
The rotating die ensures even distribution of the melt flow while coming out of the die orifice
The rotating die ensures even distribution of the melt flow while coming out of the die orifice
The bubble is cooled by means of air circulation arrangements
The pre-determined size of the blown film is obtained by inserting compressed air through the die.
Iris rings, flattering boards, counter rotating nip rolls draw the film upwards and flatten it into a two layer lay flat film, which is wound on the winder.
The film is also treated with corona discharge equipment and then printed in rotogravure printing machine in desired colors.

Quality Control and Standards

         IS 10141: 1982/1997 or as per customers specification

Production Capacity (per annum)

        a)         Quantity      630 MT
b)         Value         441.00 lakhs

Motive Power

         The total connected load of the unit is 150 KWH. Assume 60% utilization of the connected load.

Pollution control:

         This unit has not been identified on the pollution making industry. However, proper ventilation of the working shed may be assured.

Energy Conservation

         Production by proper planning may save the energy.

Financial Aspects

A. Fixed Capital
i) Land and Building

Area
Rate Rs. / m
Value (Rs.)
Land
500
Working Shed
250
Offices and Stores
100
Rented
15,000

         ii) Machinery and Equipments

Sl.No.
Description
Qty. (Nos.)
Values (Rs.)
1
Co-extrusion Blown film plant
1
28,00,000
2
Corona surface treatment plant
1
2,50,000
3
Rotogravure machine
1
6,00,000
4
Slitter-cum- re-grinder machine
1
1,50,000
5
Testing equipment
LS
50,000
6
Electrification and Installation charges @ 10% of cost
3,85,000
7
Total cost of machinery and equipment
42,35,000
8
Cost of office equipment, working table etc.
50,000

         iii) Pre-operative Expenses: 20,000
Fixed Capital = 43, 20,000/-

B. Working Capital (per month)

i) Personnel

Designation
Nos.
Salary (Rs.)
Total (Rs.)
Manager
1
12,000
12,000
Machine Operator
2
6,000
12,000
Skilled Workers
3
3,000
9,000
Clerck-cum-Accountant
1
5,000
5,000
Unskilled Workers
3
1,500
4,500
Peon
1
1,500
1,500
Total
44,000
Perquisites @ 15% of salaries
6,600
Total
50,600
Or
Say
50,000

ii) Raw materials including Packaging requirement (PM)

Particulars
Qty.
Rate / Kg.
Values (Rs.)
LDPE
52,500
50
26,25,000
Printing Ink
50,000
Packaging Material
5,000
Total
26,28,000

iii) Utilities (per month)

        Power 96 KW x 500 hrs. x Rs.4 x 0.6 utilization———- 1,15,200
Water —————————————————–2,000
        Total —————————————————————-1,17,000

iv) Other Expenses (per month)

Other contingent expenses (per month)
Rs.
Rent
15,000
Postage and Stationery
10,000
Telephone
2,000
Consumable Store
1,000
Repair and Maintenance
1,000
Transportation Charge
10,000
Advertisement and Publicity
1,000
Insurance
4,000
35,000

v) Total Recurring Expenditure

Staff & Labor
Rae Material
Utilities
Other expenses
Total
For 3 Months

C. Total Capital Investment

        1. Fixed Capital —————–43, 20,000
2. Working Capital ————–86,46,000
Total —————————-1,29,66,000

Machinery Utilization

        Co-extrusion process will be the bottleneck operation for this project. The production capacity is 105 kegs. /hr.

i) Cost of Production (per year)

Cost of Production (per year)
Rs.
Total recurring cost
3,45,84,000
Depreciation on machineries @ 10%
4,23,500
Depreciation on office equipment @ 20%
10,000
Interest on total capital investment @ 14%
18,15,240
Total
3,68,32,740
or
Say
3,68,33,000

ii) Turnover (per year)

Item
Qty.(MT)
Rate / Kg.
Value (Rs.)
Co-extruded film
617
70,000
4,31,90,000
Scrap
13
20,000
2,60,000
4,34,50,000

iii) Net Profit (per year)

        Turn over – cost of production = 4,34,50,000 – 3,68,33,000
= 66,17,000

iv) Net Profit Ratio

        Net Profit per year x 100 / Turnover

        = 66, 17,000 x 100 / 4,34,50,000

        = 15.23 %

v) Rate of Return

        Net profit per year x 100 / Total Investment

        = 66, 17,000 x 100 / 1,29,66,000

        = 51.03 %

VI) Breakeven Point (% of Total Production Envisaged)

1
Fixed Cost
Rs.
a)
Depreciation on machinery and equipment
4,23,500
b)
Depreciation on Office Equipment
10,000
c)
Rent
1,80,000
d)
Interest on Capital Investment
18,15,240
e)
Insurance
48,000
f)
40% of Salary and Wages
2,40,000
g)
40% of other expenses
1,68,000
Total
28,84,740
or
Say
28,85,000

B.E.P. = Fixed Cost x 100 / Fixed Cost + Profit

        = 28,85,000 x 100 / 28,85,000 + 66,17,000

        = 28,85,000 x 100 / 95,01,740

        = 30.36 %

 

Blow extrusion of plastic film

The manufacture of plastic film for products such as shopping bags and continuous sheeting is achieved using a blown film line.

This process is the same as a regular extrusion process up until the die. There are three main types of dies used in this process: annular (or crosshead), spider, and spiral. Annular dies are the simplest, and rely on the polymer melt channeling around the entire cross section of the die before exiting the die; this can result in uneven flow. Spider dies consist of a central mandrel attached to the outer die ring via a number of “legs”; while flow is more symmetrical than in annular dies, a number of weld lines are produced which weaken the film. Spiral dies remove the issue of weld lines and asymmetrical flow, but are by far the most complex.

The melt is cooled somewhat before leaving the die to yield a weak semi-solid tube. This tube’s diameter is rapidly expanded via air pressure, and the tube is drawn upwards with rollers, yielding the plastic in both the transverse and draw directions. The drawing and blowing cause the film to be thinner than the extruded tube, and also preferentially aligns the polymer molecular chains in the direction that sees the most plastic strain. If the film is drawn more than it is blown (the final tube diameter is close to the extruded diameter) the polymer molecules will be highly aligned with the draw direction, making a film that is strong in that direction, but weak in the transverse direction. A film that has significantly larger diameter than the extruded diameter will have more strength in the transverse direction, but less in the draw direction.

In the case of polyethylene and other semi-crystalline polymers, as the film cools it crystallizes at what is known as the frost line. As the film continues to cool, it is drawn through several sets of nip rollers to flatten it into lay-flat tubing, which can then be spooled or cut.

Sheet/film extrusion

Sheet/film extrusion is used to extrude plastic sheets or films that are too thick to be blown. 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 achieved by pulling through a set of cooling rolls (calender or “chill” rolls). In sheet extrusion, these rolls not only deliver the necessary cooling but also determine sheet thickness and surface texture.[6] 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.

A common post-extrusion process for plastic sheet stock is thermoforming, where the sheet is heated until soft (plastic), and formed via a mold into a new shape. When vacuum is used, this is often described as vacuum forming. Orientation (i.e. ability/ available density of the sheet to be drawn to the mold which can vary in depths from 1 to 36 inches typically) is highly important and greatly affects forming cycle times for most plastics.

Tubing extrusion

Blown Film Plant