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Innovative method 4 pvc tape with wbpsa

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  • 1. Innovative Method 4 PVC Tape Manufacture with 17% Cost Saving Author : Shrikant Athavale Prathith Consultants Pune - MS . India e-mail : psatechno@gmail.com 1
  • 2. Back Ground This is a Innovative method of manufacturing , Insulation tape , by coating PVC Film with , a specially compounded water Borne acrylic PSA , without compromising quality. 2
  • 3. Advantages :     Higher production speeds Compact Coating mc design. Very Cost effective. Lower Adhesive Cost Process Cost , and Capital Investment  No Heat Treatment / Anneling  No loss in Physical Properties of PVC Film  The Product is Highly eco Friendly 3
  • 4. Higher Production Speeds Adhesive Coating is possible at speeds of 3035 mtrs / Min In comparison with the conventional process can coat at approx. 6-10 mtrs / min In short you can produce 3 times the quanity 4
  • 5. Compact Coating mc design. In comparison with the conventional PVC Tape Manufacturing Plant , the Innovative design occupies 1/3 the space. The Electrical Connected load is also reduced to approx. 35 HP per plant . No need of Freezer Zone No need of Accumulator Very low Maintenance Hence a big Saving in terms of Rent / Fixed Asset Investment , as well as Equipment Cost 5
  • 6. Very Cost effective. No Primer required Adhesive is Water borne , suitably compounded Lower Manufacturing Over Heads Lower Electrical energy cost Lower Fuel cost Lower Manpower cost 6
  • 7. Lower Adhesive Cost The Adhesive is water borne Acrylic with suitable compounding, hence matches with the Physical properties of Rubber Based solvent borne. Lower Adhesive Manufacturing cost. Adhesive is Eco Friendly. 7
  • 8. No loss in Physical Properties of PVC Film The Film is not exposed to higher Temperatures hence retails the Physical Properties There is no shrinkage of Film There is no stretching on Film 8
  • 9. The Product is Highly eco Friendly It’s water Borne system Hence There are No Solvent Vapors No Health Hazard No Fire Hazard No worries at all 9
  • 10. Flow Chart for Invented Process of PVC Tape Manufacture NO Heat Treatment on Log Roll Necessary And Slicing can be done Immediately after Log Roll winding This results in lot of Saving in Precious Production Time 10
  • 11. Flow Chart for existing Process of PVC Tape Manufacture : Heat Treatment on Log Roll And Slicing after a min . of 24 Hrs. PVC Tape Log rolls PVC Tape Log rolls under Heat Treatment 11
  • 12. PVC Tape Log rolls after Hear Treatment for a min of 24 hrs Next stage of Production i.e. Slicing 12
  • 13. Details are as follows The Product Construction is given Below. PS Adhesive , Compounded Water Borne , Acrylic Adhesive PVC Film PVC Carrier Film Magnified View 13
  • 14. Conventional PVC Tape Coating Plant 14
  • 15. Our Innovative Coating plant Much compact and easy to operate 15
  • 16. Flow Chart for existing Process of PVC Tape Manufacture PVC Film Primed PVC Film Primed PVC Film Primer Rubber Based Adhesive Adhesive coated PVC 16
  • 17. Flow Chart for Invented Process of PVC Tape Manufacture PVC Film PVC Film Carona PVC Film CARONA tREATMENT Carona PVC Film Rubber Based Adhesive Adhesive coated PVC 17
  • 18. Further Process : Rewinding Machine: 18
  • 19. Rewinding Log rolls of required length , from the Jumbo rolls made as above. 1250 mm 1250 mm ID. 76 mm Jumbo Roll of 1250 mm width X 500 Mtrs length ID. 38 mm Log Roll of 1250 mm width X 10 Mtrs length 19
  • 20. Slicing / Slitting Machine : 50 mm 1250 mm ID. 38 mm Log Roll of 1250 mm width X 10 Mtrs length ID. 38 mm Finish Roll of 50 mm width X 10 Mtrs length 20
  • 21. Packing Machine : Shrink Wrapping Box Sealing 21
  • 22. The Product Cost Analysis : PVC Tape ( Conventional ) Sr.No. Ingredients Thickness in Microns GSM Price/ Kg or Sq.Mtr Cost/ Sq.Mtr in INR in USD 90 135 140 18.90 0.30 5 5 200 1.30 0.02 35 35 240 8.40 0.13 Manufacturing OH 2.00 0.03 5 Packaging Cost 2.00 0.03 6 Net Cost 32.60 0.52 in Euro 0.22 0.02 0.10 0.02 0.02 0.38 5.28 0.08 0.06 1 PVC Film 2 Primer 3 Adhesive RB Solvent 4 Width/ MM Length/ Mtr 6 Cost per roll 18 9 22
  • 23. PVC Tape ( Invented ) Sr.No. 1 Ingredients Thickness in Microns GSM Price/ Kg or Sq.Mtr Cost/ Sq.Mtr in INR in USD 90 135 140 18.90 0.30 30 30 164 4.92 0.08 in Euro 0.22 3 PVC FILM Adhesive WB PSA ( Compounded ) 4 Manufacturing OH 1.00 0.02 5 Packaging Cost 2.00 0.03 6 Net Cost 26.82 0.43 0.06 0.01 0.02 0.32 4.34 0.07 0.05 Width/ MM Length/ Mtr 7 Cost per roll 18 9 23
  • 24. Saving in Cost Per Sq. Mtr. Per Roll of 18 mm X 9 Mtr Saving % In INR in Euro In USD 5.78 0.94 17.73 0.09 0.01 17.73 0.07 0.01 17.73 Updated as per Exchange Rate till 24/12/2013 24
  • 25. Conclusion The Invented Method of Producing Electrical Insulation Tape by very Cost Effective. There is a net saving of at least 17.70 % , which sizable by any standards. 25
  • 26. Thank You Please feel free to contact us For more Information Our website : www.psadhesive.com Personal Email : psatechno@gmail.com Cell : 00 91 9850242282 00 91 7588288204 26