why pvc tape producing is so economical now
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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
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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
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
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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
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
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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
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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…..
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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
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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
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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
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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.
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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.
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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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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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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
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Lower Manufacturing Over HeadsLower Manufacturing Over Heads
Lower Manpower cost
Due to innovative designNo Rubber Processing equipment
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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.
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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.
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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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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
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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
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
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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
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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
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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
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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
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Adhesive is 100% Eco Friendly.
No solvent usedHence no solvent vapors after drying
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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
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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
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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
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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
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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
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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
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ConventionalPVC Tape Coating Plant
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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
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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.
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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.
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Our Innovative Coating plantMuch compact and easy to operate
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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
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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
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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
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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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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
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Flow Chart for
Invented Process of PVC TapeManufacture
CaronaTreatment
Adhesive Curingat 75-80 deg C
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Adhesive Coating ReadySlicing
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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
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The Product Construction is given Below.
Adhesive
Natural RubberLatex Based PSA
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PVCFilm
Adhesive
MagnifiedView
PVC Film
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Further Process :
Rewinding into 8 mtrs:
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Further Process :
Slicing in to 18 mm
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Packing Machine :Shrink Wrapping
Box Sealing
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Box Sealing
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The Product Cost AnalysisThe Product Cost AnalysisConventional MethodConventional Method
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The Product Cost AnalysisThe Product Cost AnalysisNew MethodNew Method
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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.
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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.
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ThankThankYouYou
Please feel free to contact usFor more Information
Our website : www.psadhesive.comPersonal Email : psatechno@gmail.comCell : 00 91 9850242282
00 91 75882882044319-02-2017
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