innovative method 4 pvc tape with wbpsa

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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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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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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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Higher Production Speeds

Adhesive Coating is possible at speeds of 30-

35 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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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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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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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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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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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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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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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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PVC Tape Log

rolls after

Hear

Treatment for

a min of 24 hrs

Next stage

of

Production

i.e. Slicing

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Details are as follows

The Product Construction is given Below.

PVC Film

Adhesive

Magnified View

PS Adhesive , Compounded Water Borne , Acrylic

PVC Carrier Film

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Conventional

PVC Tape Coating Plant

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Our Innovative Coating plant

Much compact and easy to operate

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PVC Film Primer

Primed PVC Film

Primed PVC Film Rubber Based Adhesive

Adhesive coated PVC

Flow Chart for

existing Process of PVC Tape

Manufacture

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PVC Film

CARONA tREATMENT

Carona PVC Film

Rubber Based AdhesiveAdhesive coated PVC

PVC Film

Carona PVC Film

Flow Chart for

Invented Process of PVC Tape

Manufacture

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Further Process :

Rewinding Machine:

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Rewinding Log rolls of required length , from the Jumbo rolls made as

above.

ID. 76 mm

1250 mm

Jumbo Roll of 1250 mm width X 500 Mtrs length

ID. 38 mm

1250 mm

Log Roll of 1250 mm width X

10 Mtrs length

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Slicing / Slitting Machine :

ID. 38 mm

1250 mm

Log Roll of 1250 mm width X

10 Mtrs length

ID. 38 mm

50 mm

Finish Roll of 50 mm width X

10 Mtrs length

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Packing Machine :

Shrink Wrapping

Box Sealing

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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 in Euro

1 PVC Film 90 135 140 18.90 0.30 0.22

2 Primer 5 5 200 1.30 0.02 0.02

3 Adhesive RB Solvent 35 35 240 8.40 0.13 0.10

4 Manufacturing OH 2.00 0.03 0.02

5 Packaging Cost 2.00 0.03 0.02

6 Net Cost 32.60 0.52 0.38

Width/ MM Length/ Mtr

6 Cost per roll 18 9 5.28 0.08 0.06

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PVC Tape ( Invented )

Sr.No. Ingredients

Thickness in

Microns GSM

Price/ Kg

or Sq.Mtr Cost/ Sq.Mtr

in INR in USD in Euro

1 PVC FILM 90 135 140 18.90 0.30 0.22

3

Adhesive WB PSA (

Compounded ) 30 30 164 4.92 0.08 0.06

4 Manufacturing OH 1.00 0.02 0.01

5 Packaging Cost 2.00 0.03 0.02

6 Net Cost 26.82 0.43 0.32

Width/ MM Length/ Mtr

7 Cost per roll 18 9 4.34 0.07 0.05

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Saving in Cost In INR In USD in EuroPer Sq. Mtr. 5.78 0.09 0.07

Per Roll of 18 mm X 9 Mtr 0.94 0.01 0.01

Saving % 17.73 17.73 17.73

Updated as per Exchange Rate till 24/12/2013

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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.

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

Thank You