1. Steps in Setting Up an SSI
Step 1 : Know Yourself
Step 2 : Training
Step 3: Project Identification Selection
Step 4: Location of the Enterprise
Premises Owned Vs Hired
Typical Question
Step 5: Preparation of a Project Report
Typical Questions
How is the cost project report calculated?
What is meant by 'contingencies'?
What are the expenses included under preliminary and preoperative expenses?
How does one calculate the amount of margin on Working Capital?
Step 6: Arranging Technical know how
Step 7: Constitution of the firm
Step 8: Registration
Step 9: Arranging Finance
Other Sources
Need for Planning
Margin Money
I Needn't Be Rich
Step 10: Statutory Licences/Approvals/Clearances26
Step 11: Arranging Land & Building
Step 12: Procuring Plant & Machinery
Step 13: Utilities: Power Connection/Water Supply35
Step 14: Recruitment of Personnel
Step 15 : Procurement of Raw Materials
Step 16 : Registration with Excise/Sales Tax Authorities
Step 17 : Trial Production
Step 18 : Commercial Production
Step 19 : Marketing
Step 20: Accountants and Record-Keeping
Step 21: Market Research
Step 22: Quality Control
Step 23: Updating Yourself
Step 24: Growth
Step 25: Avoiding Typical Pitfalls

2. Registration/Licences for SSI
Special Approvals
Pollution Control Board

3. Resourcing
(A) Non-Financial
I. National Level
II. State Level
(B) Financial

4. Plastic Spectacle Frames
Introduction
Uses and Applications
Raw Material Required
B.I.S. Specifications
Frame Spectacle Glossary
Market Survey
Demand Supply Gap
Major Buying Countries
Quality Control and Standatd
Process of Manufacture
Sheet Cutting
Forming and Welding
Wire Insertion
Assembling & Buffing
Packing and Despatching
Raw Material Suppliers
Cellulose Acetate Sheet
Steel Wire or Rod
Suppliers of Plant Machineries
Forming and Welding Machine
Drilling Machine
Compression Moulding Machine
Plant Economics

5. P.V.C. Rexine Cloth
Introduction
Polyvinyl Chloride (P V C)
Common Name - P V C
Characteristics
Uses and Applications
Market Survey
Manufacturing Process
Pigment Titanium Dioxide
Supply of Raw Material PVC Resins
Titanium Dioxide
Lead Stearate
Plastic Colours & Pigments
Suppliers of Plant & Machinery
Plant Economics

6. Plastic Granules from Scraps/Waste
Introduction
Plastic Classification
Uses and Applications
Resources of Plastic Waste
Foreign Suppliers of plastic Waste
Waste Raw Materials Suppliers
B.I.S. Specification
Process of Manufacture to Produce Colourless Transparent Plastic Granules from Waste
Sorting
Smashing
Washing
Concentration of Blending
Solvent Addition
Removal of Colour to Obtain Transparent
Granules by Activated Carbon Treatment
Filtration
Distillation
Cooling and Dehumidifying
Granulation
Manufacturing Process Flow Sheet for Plastic Granules from Plastic Scrap
Suppliers of Plant & Machinery
Reaction Vessel
Granulators
Mixer
Distillation Units
Rotary Drum Filters
Grinder
Plastic Waste Grinder & Cutter
Dryer
Baby Boilers
Tanks
Storage Tank
Packaging Machinery
Pipe & Fitting
Motors & Pumps
Suppliers of Raw Materials Dimethyl Phthalate
Ethanol
Toluene & Xylene
Activated Carbon
Plant Economics

7. P.V.C. Hand Gloves
Introduction
Properties
Uses
B.I.S. No. of Hand Gloves
Manufacturing Process
Packing Process
Process Flow Diagram
Market Survey
Production of Hand Gloves
Present Manufacturers
Plant & Machinery Suppliers
Raw Material Suppliers
Plant Economics

8. H.D.P.E. Tarpaulins
Introduction
Properties of HDPE
Uses and Application
B.I.S. Specifications
Market Survey
Export Potential
Lamination (or Sealing) By Hot Rolling
Process Flow Diagram for HDPE Woven Tarpulines
Suppliers of Raw Materials
H.D.P.E. Granules
Plasticizers
Stabilizers
Colours
Printing Inks
Suppliers of Plant & Machinery
Plain Looms
Warping Machine
Flexographic Printing Machineries
Present Manufacturers
Plant Economics

9. Tooth Brush
Introduction
Properties of Tooth Brush
B.I.S. Specification
Uses and Application
Market Survey
Manufacturers of Tooth Brushes
Handle Making
Fibre Dressing
Filling
Trimming
Embossing of the Mark etc.
Packing
Process Flor Sheet for Tooth Brush Making
Suppliers of Raw Materials
Polystyrene
Colour
Packaging Materials
Sheets for Tooth Brush Handles
Suppliers of Plant and Machinery
Moulding Press (Hand Operated)
Other Machinery
Moulds & Dies
Plant Economics

10. H.D.P.E. Films/Sheets
Introduction
Uses & Applications of High Density
Polyethylene Sheets or Films
Properties of High Density Polyethylene Sheet
B.I.S. Specification
Market Survey
Demand Supply Gap
Manufacturing Process
PLant & Machineries Suppliers
Suppliers of Raw Material
Plant Economics

11. Fibre Reinforced Plastics
Introduction
Properties
Uses and Applications
Market Potential
Present Manufacturers
Formulation & Process of Manufacture
Catalysts and Accelerators
Colouring material & Pillers
Processing Conditions
Flow Sheet for Fibre Reinforced Glass Moulded Products
Raw Materials Suppliers
Fibre Glass
Polyester Resin
Calcium Carbonate
China Clay
Hydrated Lime
Calcium Stearate
Methyl-Ethyl Ketone Peroxide
Plant and Machinery
Plant Economics

12. Polyester Resin
Introduction
Properties and Uses
Indian Standard Specifications
Market Survey
Estimated Demand for Polyester Film
Process of Manufacture
Blending Operation
Packaging
Suppliers of Plant and Machinery
Present Manufacturers/Suppliers
Raw Materials
Maleic Anhydride
Phthalic Anhydride
Styrene
Propylene Glycol
Plant Economics

13. Plastic Cooler Body
Introduction
Blow Moulding Machine
Extrusion
Properties
Uses
B.I.S. Specification
Manufacturing Process
Manufacturing Flow Sheet
Market Survey Report
Uses of coolers in India as Follows
Suppliers of Plant and Machineries
Injection Moulding M/c.
Raw Material Suppliers
Plant Economics

14. Disposable Plastic Cups and Glass Etc.
Introduction
Market Survey
Manufacturing Method
Thermoforming
Machine Type
Moulds
Glass
Cups
Plates
Spoons
Printing on Cups, Glasses and Plates
Roto Gravure Printing
Suppliers of Machine
Forming Machine Suppliers
Sealing Machine
Moulding Dies
Suppliers of Raw Material
Polypropylene
L.D.P.E. Film
Ethylene Oxide
Present Manufacturers
Plant Economics

15. Electroplating of Plastics
Introduction
Properties
Uses and Applications
B.I.S. Specification
Market Survey
Present Electroplaters
Pre-Plating Treatments
Plastic Moulding
Cleaning
Solvent Treatment
Conditioning
Sensitizing, Nucleation
Sensitizing
Conditions of Use
Nucleation
Electroless Plating
Operating Conditions
Electroplatings
Electroplating Process
Manufacturing Process Flow Diagram
Raw Material Suppliers
Suppliers of Plant and Machinery
Plant Economics

16. Bakelite Electrical Accessories
Introduction
Properties of Electrical Accessories
Uses & Applications
Raw Materials Required
Plant & Machine Required
Process of Manufacture
Compression Moulding
Transfer Moulding
Injection Moulding Thermoset
Manufacture of Handles for Iron
Cost Economics

17. Bleaching, Dyeing & Finishing of Textiles
Introduction
Marker Survey
Raw Material Required
Plant & Machinery Required
Description of Textile Fibres
Name of Acrylic Fibres
Bleaching of Cotton Textiles
Cellulose Dyeing with Procion (Reactive) Dyes
Winch Dyeing of Cotton Knit Goods
with Procion M Dyes
Modified Methods for "Difficult" Cotton Materia7
Modified Methods for Dyeing of "Difficult"
Cotton Materials with Procion H Dyes
on winch Machine
Procion M dyes
Jig Dyeing of Woven Cotton Piece Goods
Dyeing of cotton Piece Goods with
Procion M Dyes
Pad Jig Developed Method
Development
Pad Jig Developed Method
Dyeing of Cotton Piece Goods with
Procion H Dyes
Dyeing of Cotton & Loose Fibre
Dyeing with Procion M Dyes
Dyeing with Procion H Dyes
Dyeing of Ribbons, Tapes & Narrow
Fabric with Procion Dyes
Use of Wetting Agents in Procion H Dye
Baths for Cellulosic Materials
Wet Fastness Properties of Procion Dyeing
Dyeing of Cotton Textiles with Sulphur Black
Wash & Wear Finishes
Cost Economics

18. Acid Slurry
Introduction
Properties
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Process of Manufacture
Cost Economics

19. Ceramic Industries
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulations
Raw Materials Required
Plant & Machinery Required
Manufacturing Process
Manufacturing of Wares (White, Sanitary & Art)
Jiggering
Castings
Finishing
Glazing & Firing
Decoration
Manfacturing of Structural Ceramics
Manufacturing of Refractories
Drying
Burning
Manufacturing of Glass
Melting
Shaping & Forming
Annealing
Finishing
Cost Economics

20. Adhesives (Fevicol and Vamicol Etc.)
Introduction
Phenol Formaldehyde Resin
Urea Formaldehyde Resin
Thermoplastic Resin
Market Survey
Process of Manufacture
Composition of Phenol Formaldehyde Adhesive
Urea Formaldehyde Adhesives
Process Manufacture
Process
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

21. Computer Ribbons
Introduction
Uses & Applications
Market Survey
Formulation of Inks
Raw Material Required
Plant & Machinery Required
Manufacturing process
Application of Ink to the Tape
Cost Economics

22. Coir-Foam
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulation
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

23. Cosmetics
Introduction
Classification
Properties and Characteristics
Uses & Application
Market Survey
Raw Material Required
Plant & Machinery
Manufacturing process
Formulations
Antiperspirant & Deodorants
Deodorant Liquid Formulation
Baby Cream
Baby Oil
Dry Skin Cream
Moisturising Cream
Enamel Remover
Process of Manufacture
Depilatories
Hair Dyes
Lead Dye
Black Silver Dye
Copper Hair Dye
Hair Fixers
Lipsticks
Nail Lacquers
Talcum Powders
Shampoos
Powder Shampoos
Shampoo Sulfonated Oil-Soapless
Tooth Paste & Powder
Herbal Formulations
Extracted Flavour for Herbal Tooth Paste
Flavour Used for Tooth Paste
Herbal Tooth Powder
Herbal Hair Oil
Herbal Shampoo
Cost Economics

24. Electric Mixer
Introduction
Market Survey
Raw Material Required
Plant & Machinery Required
Testing Instruments
Process of Manufacture
Cost Economics

25. Hawai Chappal
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulations
Raw Materials
Plant & Machinery
Manufacturing Process
Manufacture of Straps
Manufacture of Sole Surface
Manufacture of Sole
Cost Economics

26. Greases
Introduction
Properties
Mechanical Properties
Loss of Evaporation
Oxidation Stability
Heat Stability
Uses & Applications
Market Survey
Formulation of Greases
Raw Materials
Plant & Machinery
Process of Manufacture
Principles
Processing
Manufacturing Process of Greases in General
Cost Economics

27. Ferric Alum
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

28. Hosiery Industry
Introduction
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Manufacture of Banyans & T-shirts
Manufacture of Underwears
Manufacturing of Sweaters
Cost Economics

29. Leather Garments
Introduction
Uses & Applications
Market Survey
Raw Materials
Plant & Machinery
Manufacturing Process
Vests
Caps
Cost Economics

30. Fruit Drinks
Introduction
Properties
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery
Manufacturing Process
Cost Economics

31. Ice Cream and Ice Candy Industry
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulations
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

32. Mushrooms (Dehydration & Pickling of Oyster and Paddy Straw Mushroom)
Names of Some Common Mushrooms
Properties
Analysis of Some Common Edible Mushrooms
Button Mushroom
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Processing of Mushrooms
Cleaning
Blanching
Canning
Sterilization
Cooling
Pickling & Preservation
Cost Economics

33. Match Box and Fire Works Making Industry
Introduction
Uses & Applications
Market Survey
Match Works
Formulation
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

34. Naphthalene Balls
Introduction
Properties & Characteristics
Physical of Naphthalene
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

35. Paints Industry
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Paint Formulae
Manufacturing Process
Ready Mixed Paints
Raw Materials for the Manufacture of Paints
Manufacture of Paint
Cost Economics

36. Reclamation of Used Engine Oil
Introduction
Uses
Market Survey
Raw Materials
Plant & Machinery
Process of Manufacture
Cost Economics

37. Pencil Making Industry
Introduction
Properties & Characteristics
Uses & Application
Market Survey
Formulation
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Finishing Process
Cost Economics

38. Room Cooler (Desert Type)
Properties & Characteristics
Uses & Applications
Market Survey
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

39. Soap Industry
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulations for Toilet Soaps
Raw Materials
Machinery Required
Manufacturing Process
Cold Process
Semi-Boiled Process
Full Boiled or Grain Process
Cost Economics

40. Electronic Toys
Introduction
Uses & Applications
Market Survey
Plant & Machinery Required

Process of Manufacture
Cost Economics

41. Engine Coolant
Introduction
Properties & Characteristics
Uses & Applications
Market Survey
Formulations
Raw Material Required
Plant & Machinery Required
Manufacturing Process
Cost Economics

^ Top

Steps in Setting Up an SSI

      To set up an SSI is not difficult if you know the methods, start­ egies and operations In this chapter this task is explained as a simple, step by step process. Figure (1) gives a diagrammatic overview. You would do well to give careful thought to each of the steps and considerations imperative in each such step. This will help you to successfully set up a business venture of your own and avoid costly mistakes, which other entrepreneurs have made.

      The list of steps is designed to focus your thought, to help you climb the ladder for searching the role of having your own suc­cessful business enterprise. The list does not cover every thing: no list coult. It is, at best, a good guide. Consider other aspects also that may be relevant. Possibly certain considera­tions may not be relevant; before ignoring any such aspect com­pletely satisfy yourself that it does not apply to your business.

Step 1 : Know Yourself

Behind every successful project there is a strong entrepreneur. It is this person who is the key to success of the business. Any product/project that you see under the sun is technically feasible and economically viable. If this were not so, the item would not have been manufactured and would not continue to be availa­ble. Simple, but then why one project is more profitable than another. It is the man behind the project who brings the di­fference by using certain methods and management techniques. He matches his qualities with the resources and requirements of the environment. Therefore, know your qualities, strengths and weak­nesses as an entrepreneur.

Fig. Steps in Setting up an Enterprise

      It is elementary that you shall succeed in a business where you have strengths and likely to fail where you have weaknesses. Your strengths could be your qualifications, training, experience, upbringing, personality traits, family background, exposure, knowledge etc. The lack of such factors would be your weaknesses. If you do not posses the strong points you need not get dismayed: still you can become a successful entrepreneur. Only thing is to know such strengths, which you do not possess, or the weaknesses in you. Remember no man, not even the greatest (including the likes of Swami Vivekananda and Mahatma Gandhi), was ever perfect. Once you realize your weaknesses, take care to choose a business which will not be harmed by them and adopt suitable strategies.

      Thus, if a non-technical entrepreneur takes up a hitch electron­ic project he should have on hand ready, sound technical advice. This can be arranged by hiring a good consultant on retain ship or having a qualified electronic engineer as partner. Similarly, if one is shy or introvert it is a weakness in business, which can be taken care of by choosing an ancillary industry where not many customers have to be dealt with. It is a good idea to constantly strive to acquire such strengths, which are not possessed but essential for smooth running of business. Over a period of time Šit is possible. Neither Birla, Tata nor any of the country’s big industrialist was an engineer but with constant efforts they have built up an excellent reservoir of technical knowledge. Nothing impossible (The word IMPOSSIBLE is I’M POSSIBLE).

      Every person, even the poorest, possesses sufficient strengths to become an entrepreneur. If you do not hail from a monied family, start with a low investment enterprise and slowly build it up. Do not start big just because money (bank loans etc.) are easily available. If you fail (or fall) investment (or injury) should be such that you are not hurt but instead can get up and spring back into action with victory (over your adversaries or adverse fac­tors). If you do not come from a business family background still you can be like any successful entrepreneur. Only thing is recognize this weakness and start building a circle of friends, relatives and business associates who will be helpful to you in one way or the other in any of the business obligations, presently or at any time in future.

      Once you are clear that you can build yourself to become an entrepreneur, set your goal and objectives. Acquaint yourself as to why you wish to have your own venture. Setting up a business is no child’s play. Therefore, you have to be clear on what, why and how. During the course of planning, organizing and running an enterprise there will be many distractions, adverse circumstanc­es, critical relatives, discouraging advisers and jeering friends. But once you are clear on your goal and objectives the going is smooth as nothing shall deter you. Remember all toes who plunge in water do not sink, with a little bit of efforts they swim ashore. So also in business with some efforts, real enthu­siasm and hope for the best, things take to an even word missing. Have you noticed in the Indian environment that those in business are more successful (in money terms) than those in employment? And this is when most people prefer a job as first choice failing which they are pushed into business. For you, business is by choice and not compulsion; so success is certain. Just keep trying with a clear goal.

      It is advisable to consult your near and dear ones: wife (or husband) children, parents, friends, relatives, well wishers, teachers, peer groups, gurus etc. Those around you will have to sacrifice a lot when you undertake the business endeavor. Dis­cussions with them will hold you in good stead later on. Even if their views, you know, are going to be negative and discouraging, consult them. At least some will encourage and later support. Those who are known for their negative views can be suitably discounted for the bias. Besides, the negative factors pointed out can be kept in mind and taken care of to ensure your success. Some excellent ventures have failed because the entrepreneur never bothered to take the people around him into confidence and had ultimately to succumb to their negative ways and means. A little bit of help, encouragement and support from well wishers goes a long way in ensuring enterprise success.

      Lastly, discuss your decision to become an entrepreneur with the support system. Fortunately, a number of organizations have been set up by government, central in state, to help people like you to take the entrepreneurial decision. Such assistance and advice is rendered absolutely free of charge. Such organizations of support system are, Small Industries Service Institute (SISI), District Industries Centre (DIC), Institute of Entrepreneurship Develop­ment, Directorate of Industries, Entrepreneurship Development Cells in schools, colleges, universities, banks, financial insti­tutions etc.

      Once you have decided to become an entrepreneur, know your strengths and weaknesses and are familiarized with the pros and cons of an entrepreneurial career, the next step is to gear yourself for the endeavour. Possibly there is need for training.

Step 2 : Training

      Over 700 Organizations provide different types of training to potentia entrepreneurs. Most provide such training free of charge. Some may even give you a stipend for attending their courses. Now, this is quite encouraging and may motivate anyone to become an entrepreneur.

      Such training that may be relevant for you could be Entrepreneur­ship development:

1. Technical

2. Managerial

      Entrepreneurship development training is conducted by over 700 organizations all over the country by SISIs (Small Industries Service Institutes), District Industries Centres (DICs) Banks, State Financial Corporations, Institute or Centres of Entrepre­neurship Development, Technical Consultancy Organizations, Small Industries of Entrepreneurs Association, Chambers of Commerce & Industries and, others. Such courses are usually advertised as EDPs (Entrepreneurship Development Programmes) in prominent local papers or one can contact the concerned EDP organization and register the name. Such training is usually given free and in certain cases you may even get a stipend particularly when EDPs are conducted by the SISIs.

      As for technical training SISIs conduct trade and shop oriented training courses of short duration lasting a couple of weeks. The addresses of SISIs and other institutions providing technical training, workshop and laboratory facilities is given in Annexure A. Such training can also be had from the ITIs (Industrial Train­ing Institute) which you shall find in every district; the poly­technics; PTDCs (Prototype Training and Development Centres) which operate under the NSIC at New Delhi, Rajkot, Howrah, Madras and Hyderabad; PPDCs (Product and Process Development Central Electronic Engineering Research Institute) at Pilani in Rajas­than, CECRI (Central Footwear Training Centres at Agra and Ma­dras; IIP (Indian Institute of Packaging) at Bombay and Delhi; Electronic Service & Training Centre at Ramnagar in UP: Central Machine Tool Institute at Bangalore for Machine Tools; Central Machine Tool Institute at Julandhar in Punjab; State Electronics Development Corporations in various state capitals and other centres; National State and district productivity Councils for productivity and energy saving techniques; Oils Technological Research Institute at Anantpur in Andhra Pradesh; Integrated Training Centre at Nilokheri in Haryana for bakery, carpet wea­ving, electric motors, diesel engine repair etc; Training cum production centres in Coir set up by State Government at Varsa­puram, Pothavaran and Gannavaran in Andhra Pradesh; National Design Institute at Ahmedabad for Industrial DEsigning; National Institute at Ahmedabad for Industrial Designing; National Insti­tute for Forgoing Technology at Ranchi; National Institute for Fashion Technology at New Delhi for readymade garments; Radio, Television and electrical appliance repair, air conditioning/ refrigeration at Society for Self-employment, New Delhi; Press Tools, dies, jigs, fixtures, gauges etc. at Central Tool Room, Jalundhar; bakery and confectionery at Government Polytechnic, Coimbatore; and so on.

      State government has set up training-cum productions centres for trades like soap, embroidery, pattern making, dress making, durry weaving, silk reeling, chalk crayon, textile printing and dyeing, automobile repairs, battery charging and repair, book binding and printing etc. The Khadi & Village Industries Commission organizing technical training through its state-level boards and train­ing institutions in 96 village industries that it promotes (e.g. Pulses, pattal dona, baan etc.) just in case technical training is not available for manufacturing any product one can negotite for it form the machinery manufacturer. For example, if you are setting up a project for industrial fasteners like screws, nuts, bolts etc. or flexograpic printing or wire drawing then, nego­tiate for technical training and machinery operations from their respective plant and machinery suppliers. This should be done before placing an order. Most machinery suppliers agree to it.

   Another solution can be to have in-plant training at an existisng SSI through your own contact or through the aegis of any govern­mental organisation like the SISI or any EDP Organisation.

PLASTIC SPECTACLE FRAMES

INTRODUCTION

      Spectacle frames are quite common and familiar production in all over the world. Spectacle frames are used by people with weak eyesight. These can be made of different material e.g. plastic, aluminium steel etc. most widely manufactured frames are of plastic materials because they are cheap comfortable and long lasting. Since the plastic technology development, spectacle frames are constantly produced in plastic through metallic frames, are also seen in the market. Metallic frames are more liked by youth as they give good look. Fashion conscious people also like them but with time as fashion changes their taste also changes. But plastic spectacle frames have regularly captured the market since the origin and still maximum sale as compared to other metallic frames.

      Spectacle is indispensable item for the people with eyesight weakness.

      The manufacturing process of plastic frames is very simple. The main raw materials in this industry are plastic sheets, requires thickness, wire for insertion, pins, hangs etc. and the plant and machineries are sheet cutting machine, shaping machine, drilling machine, wire insertion machine, buffering machine, dies etc.

USES AND APPLICATIONS

      1.   Plastic spectacle frames are very simple in processing and reprocessing.

      2.   They are very cheap and available in different sizes and qualities.

      3.   They are non breakable and long lasting whereas metallic frames easily get fatigue.

      4.   They normally don’t leave any impression on nose but in case of regular wearing of metallic frames, an impression may be seen on the nose.

      5.   Plastic spectacle frames are smoothened and friction less.

RAW MATERIAL REQUIRED

      There are different types of plastic material, which can be made from sheet, these sheets are Acrylic, cellulose acetate, cellulose nitrate, polypropylene etc. But generally cellulose nitrate sheets are only used for the manufacture of spectacle frames. The use from sheet, the spectacle frame manufacturing is only limited to the cellulose nitrate. Other raw material such as Acrylics polypropylene are used in the another from. These are either used in powder from or in pellet from, the use of Acrylic sheet or polypropylene sheet does not gives the required toughness of the frame, so the compression moulding or injection moulding is most efficient and          useful method in these cases.

      These days it is being seen that HDPE also used for the spectacle of children.

      The printing of frame can be done by Flexography printing or Gravure printing, Big and bold letters are printed by Flexography printing and small and brighting letter are printed by Gravure printing.

B.I.S. SPECIFICATIONS

Frame Spectacle Glossary

      IS: 8260 (Part II) - 1979 - It is a specification that the frame of spectacle should be complete specification of BIS. As it will be prescribed in BIS Specification. This BIS can be received from BIS. (Bureau of Indian Standard) but now a day there is no use of ISI because number of unit is manufacturing without BIS specification, they are selling in the market and facing no problem about product.

MARKET SURVEY

      Spectacle frames are manufactured in various shapes and sizes, so as to meet consumer’s choice. Spectacle particularly sun glasses are to day popular as fashion wear. So the design and size will change with change in fashion. The plastic frames are made either from cellulose acetate or cellulose nitrate. Manufacturing of spectacle frames are reserved for exclusive development in small scale sector. Most of the manufacturing units are established in Maharashtra and Gujarat and specifically in Mumbai, Ahmedabad and Baroda. More then 130 units are in Gujarat only. As all the firms comprising the industry are in small scale sector. The industry is understood to have grown at a rapid rate, trend rate of 14.26 percent p.a. The industry has not only grown in terms of production but also in terms of production but also in terms of quality, variety and Technical maturity. Increasing exports clearly indicates this the share of exports to total production is found almost 50.5 percent. Exports are being made to Russia and Iran mainly.

      The demand for spectacle frame will depend upon like requirement of glasses due to weak eye, number of blind, fashion and requirement of goggles etc. All these are long terms and qualitative factors, which can be described but not measured. So the demand is estimated by trend rate of growth of last several years. The demand thus estimated is found to be of the order of 33280.26 thousand numbers.

      Beyond this, some demand would arise from export market also. Prospects of exports are very good in the sense that India has good footing in international         market and India may have comparative advantages in manufacturing these products. The share of export demand to total demand may be estimated at 18 percent per annum 1993-94, 1994-95 and 1995-96.

DEMAND SUPPLY GAP

		(‘000 Nos.)
1.	Present Production (1996-97)	70313.73
2.	Estimated demand by (1999-2000)	73049.06
3.	Gap between present Production & future demand	-3736.33
4.	New capacity required for bridgingthe Gap.	5919.00
5.	Conclusion :- Good scope for many new units.

      Demand to indigenous demand, total demand for 1999-2000 may estimated to 73,049.06 thousand numbers.

      As this is reserved for small scale industries, it is different to estimate supply position. The gap between present production and future demand is very high.

MAJOR BUYING COUNTRIES

      France, Iron, Kenya, Kuwait. Lebanon, United Kingdom, USSR, Nigeria, Bangladesh.

Major Importers of Spectacle Frames: -

      M/s. I. Saka & Sons,

      54, Insabere Street,

      Lagoe, Nigeria.

 

      M/s. International Stationery Mark,

      Grand Shopping Circle,

      Main Bazar, P.O. Box No. 513,

      Greater 101, aden, P.O.r,. of Yeman.

 

      M/s. Ahmed A. Aziz Mirghani,

      P.O. Box No. 2655,

      Khartoum, Ludam.

QUALITY CONTROL AND STANDARD

      For the manufacture of high quality of spectacle frame it should keep in mind that the product should be according to standard specification. For further information please contact the following address, from where you can get the specification.

      BUREAU OF INDIAN STANDARDS

      Manak Bhavan

      9, Bahadurshah Zafar Marg,

      New Delhi - 110 002.

      From above address you can get the required specification.

PROCESS OF MANUFACTURE

      The complete manufacturing process of spectacle frames (Plastic) consists of following major steps: -

1.   Sheet Cutting.

2.   Forming and Welding.

3.   Wire Inserting.

4.      Assembling.

5.   Packing and Despatching.

1. Sheet Cutting

      The plastic are available in the form of sheets of big lengths, it is for the requirement of length and size of frame.

      Cutting operation is done in a cutter especially applicable for cutting of plastics.

      Three length are cut for one spectacle frame. One for the main front portion of the frame and the other two for ear resting (Kamani). Sizes cut are, of course, different from the front portions. Now the length are sent for forming.

2. Forming and Welding

      Both the operation of forming and welding of  plastic frames are done in a single automatic machine. First of all, bigger length for front portion of frame of                    is fed inside the machine where it is formed in die and pushed forward where it is welded. Plastic welding joints are so perfect that one cannot differentiate between            moulded and welding, but in case of metallic welding, one can easily differentiated between moulded and welded joints. One the front portion is formed, the            smaller length for the ear resting are also fed to the machine one by one with different set of dies where the length are also formed.

3. Wire Insertion

      At this stage, to make the ear rest more rigid and strong, steel wire is inserted in middle of it with half of wire inserting machine and ends are closed. Steel wire is of 1 mm. diameter and 3 inches long. At times half of the portion of steel wire fattened before being inserted to give extra strength.

4. Assembling & Buffing

      Once the lengths are formed, metallic hinges are fixed no both sides of ear rest to enable them to fold when not in use. The second portion of hinge is fixed on front portion of the frame and finally pins are inserted to give the folding action. Pins should be hammered at one end to form a rivet or they will come cut end the frame will be disassembled.

            After assembling frames which are polished by buffering and sent for packing.

P.V.C. REXINE CLOTH

INTRODUCTION

      For many years a range of leather like materials has been in use for sockings, linkings and uppers. They are all made of fabrics, usually woven and mainly of cotton. These base cloths should be carefully selected to give the requisite physical properties for shoe uppers and they may be coated with oil or PVC or rubber compound, Cellulose derivatives or synthetic resin (plastics). The surface may be smooth, with high polish or matt effect, or embossed with designs, many of which simulate leather or fabrics. All these coated materials are totally impermeable to air and water, ventilation must therefore achieved by suitable shoe design.

      PVC leather cloth is also known in other words as artificial leather, which is becoming increasingly popular all over the world because of shortage of actual leather and high cost of the same. Artificial leather is specially suitable for upholstery, shoe upper, attachi cases, brief cases and all kinds of bags. It is water repellent and is chemically inert. Present inductions show that artificial leather goods have good export potential.

POLYVINYL CHLORIDE (P V C)

Common Name - P V C

Characteristics

      Flexible and rubber like, or rigid according to grade, flexible type has considerable elongation and good recovery, high tensile and tearing strengths, inert to oxidation and weathering with freedom for cracking in use, negligible water absorption good electrical properties, noncracking at temperature down to -30oC, resistant to most erosive liquids and inert to most organic solvent great resistance to abrasion non-flammable and low specific gravity. P V C has low thermal conductivity and thus suitable as an insulating materials. P V C has a softening point ranges from 80 - 140oC. It has not exceptional chemical resistance. It decomposes rapidly at 140oC liberating HCl. It can be stabilized at lower temperatures with acid neutralizers such as alkali metal salts. Normal PVC is hard tough polymer soluble in most solvents.

USES AND APPLICATIONS

      The prime use of PVC leather cloth is in the manufacture of heavy duty upholstry for seats, cushions backs and facings. It is used for wall covering and decoration of house furniture, auditorium and theater seats. Thin coated fabric is used in book binding and other decorative purposes.

MARKET SURVEY

      The PVC leather cloth is being manufacturing in India by 15-16 firms, most of them located in Maharashtra. Their installed capacity is not well known, however the present production is quite in sufficient to need the growing demand. Manufacture of PVC goods began in India in 1958 with the establishment of imperial chemical industries. However it was only in 1960 after establishment of petrochemical complexes near, Mumbai the rapid progress was made which facilitated the greater availability of petroethylene to produce PVC. The coming up of plastic machinery manufacture and the availability of improved technical know-how gave further fillup to the industry progress. At present there are 5,089 plastic processing units in India providing employment to 3.89 lacs workers.  The plastic industry is now operating with a capital investment of Rs. 3,802 million.

MANUFACTURING PROCESS

      The manufacturing of PVC leather cloth has been divided into four categories. (i) PVC paste making (ii) Coating of PVC paste on the fabric (iii) Gelling and embossing and (iv) Winding.

      For PVC paste, it is noted that the fresh paste is made in every batch of cloth coating. The pre-prepared paste is not preferred.

      Dye pigment, titanium dioxide and lead stearate are mixed with 10% of DOP, which are ground and mixed in ball mill preferable porcelain lined. The dispersion is added to PVC (Paste grade) 90% dioctyl phthalate and trioxylenyl phosphate in a pug mill. Mixing is started at slow speed for one hour or so followed by medium speed and finally high speed for 3 hours. A free flowing paste composition thus obtained is left to stand overnight to allow entrapped air to escape. Now the paste is ready for coating.

      The coating is carried out in the reverse roll coater or knife roller coated head. First the cloth is stretched between rolls so as to be wrinkle free and a thin coating of PVC paste 1/32 is spread by means of a straight edge, evenly over the cloth.

      Both knife and roll coaters are used for the process. After spreading is required in usual way. Force more procure coating roll coaters are preferred to doctor blade coaters. All system employ three or four rolls and there are various ways in which they may be arranged. The paste reservoir can be arranged above two of them. The paste is transferred to the fabric passing through one feed and one idler roll.

          In the latter case, the coated material is passed over the steam chest in the usual way with a bank of infrared heaters above. In special PVC equipment only infrared heaters or conventional oven are used. It is essential that the getting temperature is reached and it will be between 160 and 200oC, therefore the heating equipment must be set much higher. The gelation may be checked by wrapping specimen round a material and immersion in ethyl acetate. After gelling or drying the coated cloth is embossed by embossing machine.

PLASTIC GRANULES FROM SCRAPS/WASTE

INTRODUCTION

      A plastic is one of a large and varied group of materials, which consists of an essential ingredient combinations of carbon with oxygen, hydrogen, nitrogen and other organic and inorganic elements. While solid in the finished state, at some stage in its manufacture it has been or can be formed into various shapes by flow-usually through the application singly or together of heat and pressure.

Plastic Classification:

      Plastics are classified in several ways. The most     accepted division that covers the entire field is by the behaviour pattern.

(1)      Thermoplastic

(2)      Thermosetting plastics

      Plastics today have a prominent place in the spectrum of materials frequently used by materials engineers and designers. Engineering properties as contrasted with data sheet properties. Needed are engineering criteria for rigidity, strength, endurance and temperature range, which are common to nearly all plastic applications, as well as more specialized performance characteristics that are       important only in certain types of special product (e.g. electrical properties).

      Among the plastics the various industrial grade plastic waste available, the following are the materials like A.B.S. (Acrylonitrite Butadiene Styrene), polypropylene, H.D.P.E., H.I.P.S., L.D.P.E. Polystyrene and Acrylic. By above polymers plastic granules will be prepared.

USES AND APPLICATIONS

      Plastic have many applications, it can do a better job at a lower cost then other materials. Each plastic should be selected on the basis of its properties. It is used for the following purposes.

1.   Injection Moulding purposes.

2.   Extrusion Purposes.

3.   Extruded Sheets.

4.   Extruded Pipes.

      Mechanical engineering applications like gears, cans bearings, brushes and valve seats.

      Industrial applications like various components for Textiles, Transport Containers, Storage Containers, Tool Boxes, Bottle crates, Galvanised components for Automobiles and plumbing, woven sacks for packing a variety of products like fertilizers, powdered chemicals, pesticides, etc. Sheet linking of Tanks/Vessels for               chemicals.

RESOURCES OF PLASTIC WASTE

      Out of the whole spectrum of commercially available material the thermo plastics predominate and of these ten major polymers i.e. HDPE - High Density Poly Ethylene and LDPE-Low Density Poly Ethylene, Polystyrene, ABS, PP, HIPS, LDPE, OPP, OPS, Acrylic and mostly used for packaging and other different products.  Their unique combination of properties e.g. their durability and resistance against a wide variety of environments, use in different ways and different products.

      It has been noted that at times when the quantity becomes beyond the storage capacity they are crushed and dumped in the ocean, if the same is imported/ procured from these sources processed in India the project becomes highly viable. In India the big sources of high quality industrial plastic waste are:

      1.   Maruti Udyog.

      2.   ONGC

      3.            Electronics Corporation of India.

      4.            Hindustan Motors.

      5.   I.P.C.L.

      6.            Various Docks and Inland Containers Depots.

      7.            Ordinance Depots.

      8.   Food Corporation of India

      9.            Fertilizer Plants

    10.   All Plastic Units where Plastic Products are Manufactured.

FOREIGN SUPPLIERS OF PLASTIC WASTE

1.   M/s. G.K. Sun International  Trading Co. Ltd.,

      410, Lafleur, Suite 33, Lasalle

      Montreal, P.Q.,

      Canada  H 8R 3 H6.

 

2.   M/s. Rank Trading Company,

      2260, W. Pioneer Pkwy,

      suite ‘D’,

      Pantego, Texas 76013,

      U.S.A.

 

3.   M/s. Bright Flax Co. Ltd.,

      Ching Shiao East Road,

      Sec. 4, Lane 194, Alley - 1,

      No. 10 - 5, 6th Floor,

      Taipei,

      Taiwan.

 

4.   M/s. Inter Plast Inc.

      6821, Jetport Industrial Blvd.

      Tempa, Fl. 3343,

      U.S.A.

 

5.   M/s. Jackstone &Johnson Inc.

      E-385 Enford Road,

      Richmond Hill, Ontario

      Canada L 8C 3 G8.

 

6.   M/s. Hongkong Plastic Co. Ltd.,

      C9, 6/F Hongkong Industrial Centre,

      Kowloon,

      Hongkong.

WASTE RAW MATERIAL SUPPLIERS

1.   M/s. Malvan Bio-Food & Chemicals

      6, Shiv Darshan,

      VG Pingle Marg,

      Parel, Mumbai - 400 012

      Tel. : 022-3756305

 

2.   M/s. IBEX Overseas Pvt. Ltd.

      182/B, Bhandarkar Bangalows,

      15th Road, Chembur,

      Mumbai - 400 071

      Tel. : 022-5244450

      Fax : 91-22-5564675

 

3.   M/s. Marathe Engineering Industries,

      Industrial Estate, Plot No. 7 & 8,

      Miraj - 416 410 (Maharashtra)

      Tel. : 023382, 822087

      Fax : 91-23382-77236

 

4.   M/s. Maruti Udyog Limited,

      Jeevan Prakash, IInd Floor,

      25, K.G. Marg,

      New Delhi - 110 001.

      Tel. : 011-3316831, 3354831

      Fax : 91-11-3318754

 

5.   M/s. Indian Petrochemicals Corporation Limited,

      P.O. Petrochemicals,

      Distt. Vadodara - 391 346.

      Tel. : 0265-72411, 72611

      Fax : 91-265-73164

B.I.S. SPECIFICATIONS

      There is no specific Indian Standard (I.S.) on Plastic Recycling but regarding the thermoplastic based products, I.S. Specifications are there. Some of them are

    IS  :  938    -    Moulded Briefcase

    IS  :  10106    -    Packaging Material

    IS  :  3287    -    Reflectors, Lighting - Fittings.

    IS  :  3730 - 1965   -    Polythene Buckets.

 

PROCESS OF MANUFACTURE TO PRODUCE COLOuRLESS TRANSPARENT PLASTIC GRANULES FROM WASTE 

SORTING

      The plastic waste is taken for granules manufacture off contains many impurities like dust, mud, wires and vains. First of all the scrap is sorted out and the wire and nail are removed by a magnetic separator.

SMASHING

      Then the plastic scrap is crushed by means of a scrap grinder or pulverizer small pieces of desired size.

WASHING

      The crushed material is then fed to the washing unit where it is washed with water and detergent solution and oil HCL under this process, the scrap is cleaned and is ready for the next process.

CONCENTRATION OF BLENDING

      After washing, the clean scrap is melted in a venal by direct firing. Now add DMPC (Dimethyl Phthalate) or DOP (Dioctyl Phthalate) or any other plasticizer. The           ingredients are thoroughly mixed.

SOLVENT ADDITION

      The above mass is taken to a mixer, where  solvent is xylene, toluene, ethanol, cresol, Butanol etc. may be added and diluted thoroughly with the above solvents till the desired consistency of mass is obtained.

REMOVAL OF COLOUR TO OBTAIN TRANSPARENT

GRANULES BY ACTIVATED CARBON TREATMENT

      The mass is treated with activated carbon to adsorb all the dyes, pigments, colours owing to the scrap.

      This treatment of adding solvent and activated carbon is repeated two to three times till all the colour is removed.

FILTRATION

      Now, the above mixture is filtered by passing through a rotary drum filter where the melted scrap is totally cleaned, the impurities being retained on the filter.

DISTILLATION

      After the removal of colours, it is introduced into a distillation column (Tray Type) to remove the solvent and when a particular viscosity of the molten mass is attained, it is withdrawn out of the distillation column by means of vier- jorew type pump.

COOLING AND DEHUMIDIFYING

      The molten mass is sent to the cooling unit and at the same time it is dehumidified from its moisture contents. The cooling is done to a temp of 60oC before it enters the granulator.

GRANULATION

      The molten mass cooled to 60oC is passed through the granulator (with cutting arrangement) to obtain desired size granules.

P.V.C. HAND GLOVES

INTRODUCTION

      The use of plastics of all types is increasing and will almost certainly continue to increase. Different kinds of plastics, being processed into numerous items by three different processes.

      Injection Moulding are designed for moulding thermoplastic materials such as Polystyrene, Polyethene, High Density Polyethene, Polypropylene, Cellulose            Acetate, Butyrate, P.V.C. Nylon. These machines are comparatively cheap, simple in operation, have high production capacity and require less overheads & space.

      Following are a few of the hundreds of items produced on this machines : Fountain and ball pen  bodies, Radio knobs, Push button-keys, Automobile parts, Nylon gears, Wheals and pulleys, Camera parts, lenses, Film spools, Textile accessories, Cosmetics and Pharmaceutical Containers, Caps and Stoppers, Plugs, Spoons and Measures, Buttons and Combs, Clothes line, Grips, Beads Hairlides, Buckles, Earrings, Toys, Coat Hangers, Small glasses and plates, Tumbler mats, Watch and Jewellery cases, Paper knives, Cigarette cases and Soap cases etc.

      Hand gloves is the smallest safety appliance, which is widely used in the industries. In the electrical industry there is special type of hand gloves widely used in the field work. Gloves are manufactured from various raw materials like rubber, PVC, Cotton etc.

      P.V.C. hand gloves is prepared basically from PVC resin. It is inert in water, it is non-toxic, light and non-corrosive material. It is ineffective towards acids and alkalies.

      There is a several methods of manufacturing of hand gloves.

PROPERTIES

1.   It should be easily handleable.

2.   It should be leak proof.

3.   It should be fit to the hand.

4.   It should not be corrosive.

5.   It should be acid and alkali proof.

6.   It should be heat resistance at 50oC.

USES

1.   It is used in the electrical work.

2.   It is used for lifting acid or alkali.

3.   It is used for handling of hot material.    

4.   It is used in pickup of surgical materials.

5.      It is used in the food industry for sorting of treated sterilized can.

H.D.P.E. TARPAULINS

INTRODUCTION

      High density polyethylene oriented tarpaulins are becoming increasingly popular all over the world. Tarpaulin is used for water proofing, for protection of food grains and other materials, which are stored in bulk.

      HDPE Tarpaulin involves woven cloth of HDPE, over which thin layer of foam or film of HDPE, LDPE for restricting the flow of water.

      The most important is the method of applying the film or foam over the woven HDPE base. The latter is done in two ways. In first type material is used as a solution in a suitable solvent or mixture of solvents either above or with added resins, colours and plasticizers. The material is applied by brushing, centrifuging, dipping, gasket coating, roller coating, rubbing, spraying or tumbling. The second type employs a very viscous “Dough” of the plastics together with plasticizers and other agents, and supplying by rollers or otherwise coating on fabrics, paper sheets, iris etc. in continuous lengths.

      The coating material is generally thermoplastic like HDPE or LDPE or may be thermosetting resin compared with pigments, colourents, fillers and other ingredients. In the extrusion process soften material is passed through orifice by applying a continuous pressure.

PROPERTIES OF HDPE

      HDPE is a type of most widely used thermoplastic polyethylene (polythene). It is non toxic & resistant to solvents and corrosive solutions. The other properties are listed below:

1.   Specific Gravity      0.945 - 0.965

2.   Water Absorption      0.01% - 0.03%

3.   Tensile Yield strength (100 psi)      3 - 5.5

4.   Ultimate Elongation      100 - 1000 %

5.      Compressive St. at yield 1000 psi      3.2

6.   Rockwell hardness      45 - 70

7.   Deflation Temperature (oF)

      (at 66 psi fiber stress)      140 - 185

      The advantages of HDPE over other thermoplastics includes cost, transparency, temp. resistance, impact strength, and moisture and chemical resistance. Among its disadvantages are poor grease resistance, permeability to odour, and gases, poor weatherability, flammability & poor resistance to high temperature.

USES AND APPLICATION

      The tarpaulin finds following uses in general: -

   1.   It is most commonly used for covering the food grains & other products, which are stored in open and in bulk.

   2.   Tarpaulin is also used to make the temporary sheds for tenting purposes.

   3.   Largest use is in defence department where it is used for temporary shed tents.

   4.   HDPE tarpaulins are used widely in number of other places, like making of holdalls, covering on fruit & vegetable shops, shop front so to save from rains and sun.

   5.   They are used widely for tenting purpose in marriage parties, puja festivals other functions and occasions.

B.I.S. SPECIFICATIONS

      The bureau of Indian Standards has published two specifications for the HDPE tarpaulins which are as under :

1.   IS : 2789 - 1972, Specification for special purpose paulins (Tarpaulins).

2.   IS : 7903 - 1984, Specification for Tarpaulins made from HDPE woven fabric.

MARKET SURVEY

      Indian plastic industry made a widest start in 1926 with imported materials. Later in 1958 first plant was  established in plastic & petrochemicals sector by ICI               England.

      The tarpaulins in India is being manufactured by about 120 units few of them being in organized sector. The installed capacity of units is estimated around 1130 millions meters and production is 1110 million meters. The demand was around 1150 millions meters. The  demand is increasingly continuously due to rapid                 consumption of tarpaulin end use industries and in  domestic life.

      The HDPE has large number of uses and since it is produced and consumed by a very large number of industries.

      Tarpaulins has a number of end uses and is consumed in bulk hence this industry has a good scope at present and in future. They are resistant to damage by tear water and acids. They have excellent chemical  resistance and are light in weight with high strength and can withstand such higher impact loads. Their Elongation at break is 15 to 25 %. They are much cleaner.

EXPORT POTENTIAL

      There is a lot of export potential for this product now a days. It is required by various countries in large increasingly amount.

      The statistical report is shown as :

Year	Quantity
1990-91	2,015 MT
1991-92	2,850 MT
1992-93	3,100 MT
1993-94	3,600 MT
1994-95	3,800 MT
1999-2000 (Estimated)	5,600 MT

      From the above statistics it can be judged that there is ample scope of export of this product due to its rapidly increasing consumption.

PROCESS OF MANUFACTURE

      High density polyethylene granules of extrusion grades are being used as a basic raw material manufacture of the tarpaulins.

      HDPE granules are fed to the hobby of machine. It passes through barrel of extruder which is covered by a number of heaters working at different temperatures. The material is moved forward and passed on various temperatures. It starts melting and becomes in viscous form or semi liquid form. This semi liquid form of plastic is must for purpose of processing. Here it is completely plasticized and comes in molten stage. To control constant heating of the barrel and to prevent damage to barrel by way continuous heating water (cool) is circulated with help of pipeline fitted inside the barrel.

      Molten material is then passed through cross head. Here it is filtered with help of fine sieve to remove foreign particles like dust, impurities etc. This filtered plasticized and molten material is then passed through the die-head and die which is attached just adjacent to cross head. Plasticized HDPE comes out in form of tape fabric from the die. The dimensions of tape can be controlled with the help of using different type of dies. The tape line is passed through water tank for the purpose of static formation of tape which is stretched by stretching unit which is just adjacent to water tank. The stretched tape is then reeled on bobbins giving Ist grade tapes that is used for weaving of fabric.

Lamination (or Sealing) By Hot Rolling

      Lamination of HDPE woven fabrics coming out of plain looms are to sealed to make the fabric impermeable to the water. This can be done by passing the HDPE           woven fabric and layer lamina of required material and thickness over the heated rolls to just plasticize them and then following it they are passed simultaneously through a pair of rolls which presses the heated layers to the required thickness. The thickness is controlled by adjusting the clearance between two rolls. Further the layers are cooled down and laminated fabric comes out which can be used as excellent tarpaulin.

P.V.C. BOTTLES FOR MINERAL WATER

INTRODUCTION

      The use of plastics of all types is increasing and will almost certainly continue to increase. The development of existing plastics and possibly the discovery of new materials will mean that in the future plastics will be used for even more purposes than they are used today. Different kinds of plastics, being processed into numerous items by different processes.

INJECTION MOULDING MACHINES

      Injection Moulding Machines are designed for moulding thermoplastic materials such as well Polystyrene, Polyethene, High Density Polyethene, polypropylene, Cellulose Acetaters, Butyrate, P.V.C Nylon. These machines are comparatively cheap, simple in operation, have high production capacity and require less overheads & space.

      Moulding Machines are the backbone of the Plastic industry organized on small as on medium scale. Many machines are in operation throughout the country and are engaged in the economical production of industrial and utility items. Following are a few of the hundreds of items produced on the machines. Fountain and Ball pen bodies, Radio knobs, Push button-keys, Automobile parts, Nylon gears, Wheals and pulleys, Camera parts, lenses, film spools, Textile accessories, Cosmetic and pharmaceutical containers, caps and stoppers, plugs, spoons and measures Buttons and Combs, clothes line, grips, beads hairlides, buckles, Earrings, Toys, Coat Hangers, small glasses and plates, Tumbler mats, watch and jewellery cases, paper knives, cigarette cases and soap cases etc.

PROPERTIES OF P.V.C. RESIN

      P.V.C. versatility, durability and economics has made it one of the most popular plastic all over the world. A synthetic thermoplastic polymer, which with heat, can be easily moulded, blown and formed in to almost any shape and size desired. It offers rigidity/flexibility, hardness, corrosion resistance, colour in wide range so as to substitute or complement steel, rubber, tin, jute, cotton wood and many other natural materials in an ever increasing number of applications. Advanced technology has given nontoxicity, light weight with high strength and non-contaminating properties which adds to its growing popularity.

USES

      1.   It can be used for filling of mineral water.

      2.   It can be used for filling vegetable oil or other any liquid food material.

 

 

 

H.D.P.E. FILMS/SHEETS

INTRODUCTION

      H.D.P.E. is High Density Polyethylene by general agreement in the plastic industry, plastic films are any plastic materials (mainly low density polyethylene, medium density polyethylene films, High Density polyethylene films) made in flat form with a thickness of 10 mils or less.

      Flat stock with a thickness greater than 10 mils is referred to as sheet. This convention is not always strictly adhered to, however.

      Films or sheets are made from any of the commonly used polyethylene (mainly low density & high density), however, the majority of films are thermoplastics and can thus be easily produced by the common process of solvent casting, extruding/or calendaring.

      The base materials for the films are (with possible slight variations) identical to the materials used to make mouldings or extruders. The three most important of the special treatments are orientation, coating and lamination. In each cases, the special processing is used to obtain an improvement in some particular characteristic of the original material or in several related characteristics. In cases of lamination, the combination of two or more materials produces a synergistic effect, with the laminate properties superior to the properties of the original base films.

USES & APPLICATIONS OF HIGH DENSITY polyethylene SHEETS OR FILMS

      The most common uses of H.D.P.E. films are for various packaging applications:

      Heat-sealed bags for fresh produce and meet thermoformed skin packaging for meat, and thermoformed blister packages for dry goods, hardware items, and similar parts. The obvious advantages of visibility and reduction of pilferage as well as the light fit of the skin packages and will formed blisters, all add up to excellent acceptance by both commercial interest and the consuming public.

      H.D.P.E. films are also used for such diverse applications as electronic capacitors (in the form of metallized foils), high temperature wire insulator, thermal insulation of space craft, and in fabrication of high altitude balloons for research purpose. The diversity in applications is accompanied by a similar diversity in requirements for the various applications.

PROPERTIES OF HIGH DENSITY polyethylene SHEET

i.	Specific Gravity	0.941-0.965
ii.	Manufacturing method(extrusion, biaxial, orientation, casting, etc.)	extrusion, stress Calendering, relieving.
iii.	Availability(In sheets, rolls, tapes)	Steel, rolls, tapes, tubes.
iv.	Maximum width in	60
v.	Color ability	excellent
vi.	Clearity	good
vii.	Self life	indefinite
viii.	Flammability	slow burning
ix.	Maximum-minimum use	-
	temperature Range 0F	70 to 250
x.	Resistance to acids	excellent
xi.	Resistance to alkalies	excellent
xii.	Resistance to Greases and oil	good
xiii.	Tensile strength lbs sq. in @ RT	2,400-6,100
xiv.	Elongation (%)	10-650

 B.I.S. SPECIFICATION

      IS  : 10889 - 1984 High density polyethylene films

      IS  :   7328 - 1974 High density polyethylene materials for moulding and extrusion.

MARKET SURVEY

      High density polyethylene is one of the very popular thermoplastic materials, which has been introduced in India during late 1960. Polyethylene treated at high pressure level is known as HDPE.

      Production of HDPE was started in India by poly olefin industries limited in 1968. The technology was imported from Germany. The production has increased in last years. In 1994-95 it was 60,000 tonnes, which increased to 90,000 tonnes in 1995-96. The reason is non availability of high quality polyethylene and the scarcity of alcohol in indigenous market. The unit has installed capacity of 30,000 tonnes per annum.

      At present these are only one unit polyolefin industries limited whose installation capacity is 50000 tonnes of HDPE. But it is expected that M.G.C.C., Reliance, Haldia Petrochemical industries whose installation capacity by 1997-98 will be 80000, 55000, 85000 tonnes respectively. It is also expected that demand of the product is expected 3 times than the future production. It should be noted that Government has fully liberalized imports of HDPE recently.

DEMAND SUPPLY GAP

      There exists a certain demand supply gap. Due to higher consumption and lower production in our country, always a definite demand supply gap exists. So new entrepreneur can well venture in this field by installation one H.D.P.E. films and sheets unit to satisfy the peoples demand.

 

FIBRE REINFORCED PLASTICS

INTRODUCTION

      Fibre Reinforced plastics are essentially structural materials that belong to the larger family of composite materials. Fibre-Reinforced Plastics (FRP) have been               born out of sheer necessity imposed by the straight requirements of present day technology and in particular aerospace technology. Engg. materials for the present day high technology must combine very special mechanical, electrical, thermal, chemical properties etc. and at the same time have good aesthetic characteristic very often, the same material has to combine several desired quantities like light-weight, high strength, high stiffness, toughness, chemical resistance, electrical properties, aesthetic appeal etc.

      Firstly they have excellent engineering properties, which naturally are as competitive. Secondly FRP can be easily moulded into any size and shape, the property not so easily or cheaply achieved in other construction materials like metals stones, or timber. Finally FRP offers considerable flexibility in the design of structures.

      The current applications of FRP range from bathtubs, wash basins and suitcases to the heat shield of a satellite-launch vehicle, the nose cone of the SST concord and the hull of the mine sweeper HMS milder. About 60,000 different items have been identified that can be made out of FRP.

PROPERTIES

      Fibre glass Reinforced Thermoplastic Consists of a thermoplastic Polymer, often referred to as the base polymer, in which fibre glass has been dispersed.

      In FRP, the Fiberglass is the stronger and stiffer, although more brittle, material than the base Polymer which possesses less strength, the higher Co-efficient of thermal expansion and is tougher and more extensible.

USES AND APPLICATIONS

      Fibre Glass Reinforced Thermoplastics, because of their unique combination of properties, represents today one of the fastest growing segments of the plastics industry. It is used in Textile, Chemical, Food & Beverage, Dairy, Pharmaceuticals, Electrical and Electronic, Automobile and General Engineering Industries. FRP have various applications like Rigidity and smoothly finished surfaces, excellent corrosion resistance, Non toxic, Non corrosive, higher impact strength at low temp., high dielectric strength, low dielectric constant, High volume and Resistivity, Good Stiffness, strength & weatherability, Electrical insulation is very safe, its self lubricating.

MARKET POTENTIAL

      The average rate of growth of the glass fibre (and FRP) industry in India especially over the last few years has been in the range of 15%. This is much higher than the 4-5% average increase found in USA. Western Europe and Japan. The main reason for the higher rate of FRP in India compared to advanced countries is due to the continued efforts in the development and identification of new area of application. Over a decade back, the chemical and marine industries were considered to be the prime domain of FRP apart from its use in translucent roof light sheets by the construction industry. Presently FRP is finding increasing applications in the Transport (Road and Rail) Electrical/Electronic, Defence and Renewable Energy Sectors and that too with a great degree on success. These sectors have gradually began to realise the long-term benefits of FRP: in spite of its higher prime cost compared to conventional materials.

Consumption Pattern of FRP

      The consumption of FRP in India is thousand tonnes in 1995 and 1260 thousands tons in 1996, in Western Europe it is 1700 thousands tons