why pvc tape producing is so economical now

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A Review of the Conventional A Review of the Conventional method of PVC Tape production method of PVC Tape production v/s the Latest one v/s the Latest one with with bunch of advantages , low cost, high bunch of advantages , low cost, high speed, 100% eco green speed, 100% eco green 1 speed, 100% eco green speed, 100% eco green 19-02-2017 By Shrikant Athavale Shrikant Athavale Prathith Consultants Prathith Consultants Pune MS India Pune MS India website : http://www.psadhesive.com , http://www.adhesivelabtesting.com , Linkedin Profile : https://www.linkedin.com/in/shrikantathavale4adhesiveconsu

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Page 1: Why PVC Tape producing is so economical now

A Review of the ConventionalA Review of the Conventionalmethod of PVC Tape productionmethod of PVC Tape productionv/s the Latest onev/s the Latest one withwithbunch of advantages , low cost, highbunch of advantages , low cost, highspeed, 100% eco greenspeed, 100% eco green

1

A Review of the ConventionalA Review of the Conventionalmethod of PVC Tape productionmethod of PVC Tape productionv/s the Latest onev/s the Latest one withwithbunch of advantages , low cost, highbunch of advantages , low cost, highspeed, 100% eco greenspeed, 100% eco green

19-02-2017

ByShrikant AthavaleShrikant AthavalePrathith ConsultantsPrathith ConsultantsPune MS IndiaPune MS Indiawebsite : http://www.psadhesive.com , http://www.adhesivelabtesting.com,Linkedin Profile: https://www.linkedin.com/in/shrikantathavale4adhesiveconsu

Page 2: Why PVC Tape producing is so economical now

Back GroundBack Ground

This is a Innovative method of manufacturing , Insulation tape ,by coating PVC Film with , a specially compounded , NaturalRubber Based PSA , with superior Properties .The Product manufacturing process is extremely safe , easy tohandle and 100% eco friendly with no VOC concerns , nohealth or Fire hazard

2

Back GroundBack Ground

This is a Innovative method of manufacturing , Insulation tape ,by coating PVC Film with , a specially compounded , NaturalRubber Based PSA , with superior Properties .The Product manufacturing process is extremely safe , easy tohandle and 100% eco friendly with no VOC concerns , nohealth or Fire hazard

19-02-2017

Page 3: Why PVC Tape producing is so economical now

Advantages :Advantages :

Higher production speeds Compact Coating mc design. Very Cost effective. Lower Adhesive Cost

Process Cost , andCapital Investment

No Heat Treatment / Annealing No loss in Physical Properties of PVC Film The Product is Highly eco Friendly

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Advantages :Advantages :

Higher production speeds Compact Coating mc design. Very Cost effective. Lower Adhesive Cost

Process Cost , andCapital Investment

No Heat Treatment / Annealing No loss in Physical Properties of PVC Film The Product is Highly eco Friendly

19-02-2017

Page 4: Why PVC Tape producing is so economical now

Higher Production SpeedsHigher Production Speeds

Adhesive Coating is possible at speeds of 30-35 mtrs/ Min

In comparison with the conventional process cancoat at approx. 8-10 mtrs / min

In short you can produce 3 times the quanity

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Adhesive Coating is possible at speeds of 30-35 mtrs/ Min

In comparison with the conventional process cancoat at approx. 8-10 mtrs / min

In short you can produce 3 times the quanity

19-02-2017

Page 5: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

The Innovative design occupies just 1/3 the space , incomparison with the conventional PVC Tape ManufacturingPlant ,.

This is possibleNo separate primer coating station and the curing tunnel,No Accumulator,no Freezer zone…..

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The Innovative design occupies just 1/3 the space , incomparison with the conventional PVC Tape ManufacturingPlant ,.

This is possibleNo separate primer coating station and the curing tunnel,No Accumulator,no Freezer zone…..

19-02-2017

Page 6: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

No PrimerNo Primer CoatingCoating

Yes

No more primer coating necessary

The job is done online with help of corona treater,

Online treatment is possible because the adhesive isWater borne

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No PrimerNo Primer CoatingCoating

Yes

No more primer coating necessary

The job is done online with help of corona treater,

Online treatment is possible because the adhesive isWater borne

19-02-2017

Page 7: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

The Electrical Connected load is also reduced toThe Electrical Connected load is also reduced to approx.approx.35 HP .35 HP .

This is possible becauseThis is possible becauseThere is no needThere is no needOf Rubber Mixing Mill, Sigma MixerOf Rubber Mixing Mill, Sigma MixerA saving ofA saving ofNearly 40 Hp connected loadNearly 40 Hp connected load

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The Electrical Connected load is also reduced toThe Electrical Connected load is also reduced to approx.approx.35 HP .35 HP .

This is possible becauseThis is possible becauseThere is no needThere is no needOf Rubber Mixing Mill, Sigma MixerOf Rubber Mixing Mill, Sigma MixerA saving ofA saving ofNearly 40 Hp connected loadNearly 40 Hp connected load

19-02-2017

Page 8: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

No need of FreezerNo need of Freezer ZoneZone

Yes

Since the PVC film is exposed to a lower temp like75-80 deg C

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No need of FreezerNo need of Freezer ZoneZone

Yes

Since the PVC film is exposed to a lower temp like75-80 deg C

19-02-2017

Page 9: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

No need of Accumulator

Yes

Because now jumbo rolls can be coated , without frequentstoppage of coating . Log roll rewinding is possible due to thenew technology developed.

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No need of Accumulator

Yes

Because now jumbo rolls can be coated , without frequentstoppage of coating . Log roll rewinding is possible due to thenew technology developed.

19-02-2017

Page 10: Why PVC Tape producing is so economical now

Compact Coating Mc Design.Compact Coating Mc Design.

Very lowVery low MaintenanceMaintenance

Due to a simple and innovative design.

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Very lowVery low MaintenanceMaintenance

Due to a simple and innovative design.

19-02-2017

Page 11: Why PVC Tape producing is so economical now

Very Cost effective.

No Primer requiredAdhesive is , Natural Rubber Latex based , it’s Waterborne . The properties of dry adhesive film at par with theconventionally used Rubber Based adhesive

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Page 12: Why PVC Tape producing is so economical now

Lower Manufacturing Over HeadsLower Manufacturing Over Heads

Lower Electrical energy cost

Connected load will be reduced to just approx. 35 hp fromapprox. 80 hp ( for the conventional design + Rubberprocessing equipment load )

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Page 13: Why PVC Tape producing is so economical now

Lower Manufacturing Over HeadsLower Manufacturing Over Heads

Lower Fuel cost

This is possible due to the fact thatThe drying / curing temp is down from 110-120 deg c tojust 75-80 deg C

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Lower Manufacturing Over HeadsLower Manufacturing Over Heads

Lower Fuel cost

This is possible due to the fact thatThe drying / curing temp is down from 110-120 deg c tojust 75-80 deg C

19-02-2017

Page 14: Why PVC Tape producing is so economical now

Lower Manufacturing Over HeadsLower Manufacturing Over Heads

Lower Manpower cost

Due to innovative designNo Rubber Processing equipment

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Page 15: Why PVC Tape producing is so economical now

Lower Adhesive Cost

The Adhesive is water borne , but Rubber based withsuitable compounding, hence matches with thePhysical properties of solvent dissolved RubberBased adhesive .

Lower Adhesive Manufacturing cost.

Adhesive is 100% Eco Friendly.

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Lower Adhesive Cost

The Adhesive is water borne , but Rubber based withsuitable compounding, hence matches with thePhysical properties of solvent dissolved RubberBased adhesive .

Lower Adhesive Manufacturing cost.

Adhesive is 100% Eco Friendly.

19-02-2017

Page 16: Why PVC Tape producing is so economical now

Lower Adhesive Manufacturing cost.

Regular Solvent Dissolved Rubber Adhesivemanufacturing process involves , a long time cycle ,and a lot of Electrical energy.The Flow chart for the same follows the next slide

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Page 17: Why PVC Tape producing is so economical now

Dry Rubber Adhesive ManufacturingDry Rubber Adhesive ManufacturingProcess Flow ChartProcess Flow Chart

This is DryThis is DryNatural RubberNatural Rubber

Masticated onMasticated onTwo Roll MillTwo Roll MillFor about 30For about 30--

40 minutes40 minutes

NaturalNaturalRubber LatexRubber Latex

filteredfilteredpurified andpurified andcoagulatedcoagulated

Water andWater andrubberrubber

separatedseparated

Rubber sheetsRubber sheetsare then driedare then dried

19-02-2017 17

Masticated onMasticated onTwo Roll MillTwo Roll MillFor about 30For about 30--

40 minutes40 minutes

At this stageAt this stageResins+ A/O +Resins+ A/O +

PlasticizerPlasticizerAdded toAdded toRubberRubber

For about 40For about 40minutesminutes

The mixture isThe mixture ischarged to a sigmacharged to a sigmamixer and solventmixer and solventToluene is addedToluene is addedgradually withgradually with

continuous mixingcontinuous mixingFor about 3For about 3--4 hours4 hours

ReadyReadyAdhesive isAdhesive is

stored instored inbarrelsbarrelsBeforeBefore

CoatingCoating

Page 18: Why PVC Tape producing is so economical now

The Electrical Load required for Solvent dissolvedThe Electrical Load required for Solvent dissolvedNatural Rubber AdhesiveNatural Rubber Adhesive

Mastication onRubber MillConnected Load :15 HP = 11.25KwMastication Time: 30 minutesRubber Quantity :12 kgs

Mixing of Resins /A/O , other raw mat.on Rubber MillConnected Load : 15HP = 11.25 KwMixing Time : 90minutesTotal Quantity : 24kgs

Mixing of Dry Rubbercompound withSolvent TolueneConnected Load : 35HP = 26.25 KwMixing Time : 240minutesTotal SolutionQuantity : 48 kgs

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Mastication onRubber MillConnected Load :15 HP = 11.25KwMastication Time: 30 minutesRubber Quantity :12 kgs

Mixing of Resins /A/O , other raw mat.on Rubber MillConnected Load : 15HP = 11.25 KwMixing Time : 90minutesTotal Quantity : 24kgs

Mixing of Dry Rubbercompound withSolvent TolueneConnected Load : 35HP = 26.25 KwMixing Time : 240minutesTotal SolutionQuantity : 48 kgs

19-02-2017

Page 19: Why PVC Tape producing is so economical now

This means that

The Electrical Energy consumption ofRubber Mill : 11.25 kw x 120 minutes = 11.25 kw X 2 hrs =22.5 UnitsSigma Mixer : 26.25 X 240 minutes = 26.25X 4 hrs = 105unitsTotal Electrical Units = 127.5 , for 24 kgs of dry adhesive

= 5.31 units / kg = INR 37.18 / Kg

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This means that

The Electrical Energy consumption ofRubber Mill : 11.25 kw x 120 minutes = 11.25 kw X 2 hrs =22.5 UnitsSigma Mixer : 26.25 X 240 minutes = 26.25X 4 hrs = 105unitsTotal Electrical Units = 127.5 , for 24 kgs of dry adhesive

= 5.31 units / kg = INR 37.18 / Kg

19-02-2017

Page 20: Why PVC Tape producing is so economical now

This means

The Man Power cost ofOn Rubber Mill : 1+1 person x 120 minutes = 2 men X 2 hrs =2 X ( (10000/25 = 400 / day/person = 50/hr/person x2= INR100 / 24 kg of adhesive = INR 4.00 / kg )

On Sigma Mixer : 1 person X 240 minutes = 1 manX 4 hrs =1 X ( (10000/25 = 400 / day/person = 50/hr/person x1X 4 hrs =INR 200 / 24 kg of adhesive = INR 8.00 / kg )Total Manpower cost = 300 , for 24 kgs of dry adhesive

= INR 12.50 / Kg

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This means

The Man Power cost ofOn Rubber Mill : 1+1 person x 120 minutes = 2 men X 2 hrs =2 X ( (10000/25 = 400 / day/person = 50/hr/person x2= INR100 / 24 kg of adhesive = INR 4.00 / kg )

On Sigma Mixer : 1 person X 240 minutes = 1 manX 4 hrs =1 X ( (10000/25 = 400 / day/person = 50/hr/person x1X 4 hrs =INR 200 / 24 kg of adhesive = INR 8.00 / kg )Total Manpower cost = 300 , for 24 kgs of dry adhesive

= INR 12.50 / Kg

19-02-2017

Page 21: Why PVC Tape producing is so economical now

Adhesive is 100% Eco Friendly.

No solvent usedHence no solvent vapors after drying

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Page 22: Why PVC Tape producing is so economical now

No loss in Physical Properties of PVC Film

The Film is exposed to a Temperature of about 75-80 deg C .hence very good retention of the Physical Properties

There is no shrinkage of Film

There is no stretching on Film

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No loss in Physical Properties of PVC Film

The Film is exposed to a Temperature of about 75-80 deg C .hence very good retention of the Physical Properties

There is no shrinkage of Film

There is no stretching on Film

19-02-2017

Page 23: Why PVC Tape producing is so economical now

The Product is Highly eco FriendlyThe Product is Highly eco Friendly

It’s water Borne systemHenceThere are No Solvent VaporsNo Health HazardNo Fire HazardNo worries at all

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The Product is Highly eco FriendlyThe Product is Highly eco Friendly

It’s water Borne systemHenceThere are No Solvent VaporsNo Health HazardNo Fire HazardNo worries at all

19-02-2017

Page 24: Why PVC Tape producing is so economical now

NO Heat Treatment on Log Roll NecessaryAnd

Slicingcan be doneImmediately after Log Roll winding

This results in lot of Saving in Precious ProductionTime

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NO Heat Treatment on Log Roll NecessaryAnd

Slicingcan be doneImmediately after Log Roll winding

This results in lot of Saving in Precious ProductionTime

19-02-2017

Page 25: Why PVC Tape producing is so economical now

ConventionalPVC Tape Coating Plant

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Page 26: Why PVC Tape producing is so economical now

ConventionalConventionalPVC Tape Coating PlantPVC Tape Coating Plant

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PVC Film is coated withSolvent dissolved NaturalRubber Primer+ Isocyanide X LinkingAgent

For Curing the Temp insidethe Tunnel is 110-120 deg C

The primed PVC Film is thencoated with Solvent dissolvedNatural Rubber Adhesive

For Curing the Temp inside theTunnel is again 110-120 deg C

19-02-2017

Page 27: Why PVC Tape producing is so economical now

In short the PVC film is exposed to higher temperature like110-120 deg c , two timesAndThat too at a slow speed of 8 – 10 mtrs a minute.

This results in developing un wanted stresses in the PVCfilm.

and to compensate/ remove these stresses , the log rollsneed to be exposed to annealing stage.

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In short the PVC film is exposed to higher temperature like110-120 deg c , two timesAndThat too at a slow speed of 8 – 10 mtrs a minute.

This results in developing un wanted stresses in the PVCfilm.

and to compensate/ remove these stresses , the log rollsneed to be exposed to annealing stage.

19-02-2017

Page 28: Why PVC Tape producing is so economical now

Our Innovative Coating plantMuch compact and easy to operate

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Page 29: Why PVC Tape producing is so economical now

Our Innovative Coating plantMuch compact and easy to operate

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The PVC Film is then coated with Latex based Natural RubberAdhesiveFor Curing the Temp inside the Tunnel is again 75-80 deg C

In this method the PVC is exposed to a lower temperature ofapprox. 75-80 deg C , and that too , only once , and at higher speedlike 30-35 mtrs. per minute.Hence there is no inbuilt stress in the Film. This helps us ineliminating the annealing process

19-02-2017

Page 30: Why PVC Tape producing is so economical now

Flow Chart forexisting Process of PVC TapeManufacture

Primer Coating

Primer Curing at110-120 deg C

Adhesive Curingat 110-120 deg C

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Primer Curing at110-120 deg C

Adhesive Coating

AnnealingProcess

ReadySlicing

19-02-2017

Page 31: Why PVC Tape producing is so economical now

Flow Chart forexisting Process of PVC Tape Manufacture :

Heat Treatment on Log RollAnd Slicing after a minimum of 24 Hrs.

PVC TapeLog rolls

PVC TapeLog rolls underHeat Treatment

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PVC TapeLog rolls

PVC TapeLog rolls underHeat Treatment

19-02-2017

Page 32: Why PVC Tape producing is so economical now

PVC Tape Log rolls afterHear Treatment for a min of24 hrs

Next stage ofProductioni.e. Slicing

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Next stage ofProductioni.e. Slicing

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Page 33: Why PVC Tape producing is so economical now

ID. 38 mm

1250 mm

ID. 38 mm

50 mm

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Log Roll of 1250 mm width X

10 Mtrs lengthFinish Roll of 50 mm width X

10 Mtrs length

19-02-2017

Page 34: Why PVC Tape producing is so economical now

Flow Chart for

Invented Process of PVC TapeManufacture

CaronaTreatment

Adhesive Curingat 75-80 deg C

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Adhesive Coating ReadySlicing

19-02-2017

Page 35: Why PVC Tape producing is so economical now

Rewinding Log rolls of required length , from the Jumbo rolls made asabove.

ID. 76 mm

1250 mm

ID. 38 mm

1250 mm

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Jumbo Roll of 1250 mm widthX 500/1000 Mtrs length

Log Roll of

1250 mm X 10 Mtrs length

19-02-2017

Page 36: Why PVC Tape producing is so economical now

The Product Construction is given Below.

Adhesive

Natural RubberLatex Based PSA

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PVCFilm

Adhesive

MagnifiedView

PVC Film

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Page 37: Why PVC Tape producing is so economical now

Further Process :

Rewinding into 8 mtrs:

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Page 38: Why PVC Tape producing is so economical now

Further Process :

Slicing in to 18 mm

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Page 39: Why PVC Tape producing is so economical now

Packing Machine :Shrink Wrapping

Box Sealing

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Box Sealing

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Page 40: Why PVC Tape producing is so economical now

The Product Cost AnalysisThe Product Cost AnalysisConventional MethodConventional Method

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Page 41: Why PVC Tape producing is so economical now

The Product Cost AnalysisThe Product Cost AnalysisNew MethodNew Method

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Page 42: Why PVC Tape producing is so economical now

ConclusionConclusion

The Invented Method of Producing ElectricalInsulation Tape by very Cost Effective.There is a net saving of at least 15 % ,which sizable by any standards.

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ConclusionConclusion

The Invented Method of Producing ElectricalInsulation Tape by very Cost Effective.There is a net saving of at least 15 % ,which sizable by any standards.

19-02-2017

Page 43: Why PVC Tape producing is so economical now

ThankThankYouYou

Please feel free to contact usFor more Information

Our website : www.psadhesive.comPersonal Email : [email protected] : 00 91 9850242282

00 91 75882882044319-02-2017