1. Innovative Method 4
PVC Tape Manufacture
with
17% Cost Saving
Author :
Shrikant Athavale
Prathith Consultants
Pune - MS . India
e-mail : psatechno@gmail.com
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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.
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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
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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
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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
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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
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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.
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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
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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
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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
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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
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12. PVC Tape Log
rolls after
Hear
Treatment for
a min of 24 hrs
Next stage
of
Production
i.e. Slicing
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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
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15. Our Innovative Coating plant
Much compact and easy to operate
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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
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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
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18. Further Process :
Rewinding Machine:
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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
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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
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21. Packing Machine :
Shrink Wrapping
Box Sealing
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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
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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
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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
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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.
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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
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