Roto – Molded Plastic Water Tank

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Uploaded on : September 2013

 

1. Product and Its Applications:

  • Rotational Moulding or Rotomoulding is a highly versatile process that allows unlimited design possibilities with the added benefit of lower production cost. The range of products being moulded is matched only by the innovative manner in which the moulders tackle new products lines and market. The product portfolio ranges from micro moulding of PVC ear pieces to large polythene tanks. Rotational moulding is an economically viable process to manufacture limitless range of products in all shapes and sizes, some of which would be difficult to produce by any other process. It is also possible to give special effects like texturised grain , leather finish etc. in the moulds. The benefits of rotomoulding are varied. Regulated DC power supplies provide accurate DC voltage which is derived from AC Design and process benefits can be enumerated as :-

  • Flexibility-from small and intricate to large and complex products.
  • Seamless construction and virtually stress free products.
  • Easy to vary thickness and uniform wall distribution- no thinning round the corners.
  • Double wall products.
  • Multi layer or multi material products.
  • Products with undercuts and metal inserts.
  • Foamed products.
  • Products with mould on or mould- in graphics.
  • Products with different surface texture and colours.

 

2. Industry Profile and Market Assessment:

Indian Rotomoulding industry started in early 70’s with a focus on water tanks and containers. Rotomoulded water tanks became very popular due to their light weight, durability, hygienic & easy installation and maintenance, easy availability, and low cost. Since then, the industry has grown by leaps and bounds, both in number of rotomoulders and plastic consumption. Today, there are more than 200 rotomoulders spread across the country consuming tonnes of different grades of polymers. The annual growth rate of the industry is around 20% and the robust growth is likely to continue in years to come.

Water tanks have been traditionally the main segment for the Indian Rotomoulding industry and more than 95% of rotomoulders depend on this segment. Today water tanks constitute 80% of the market share and would continue to be the major segment due to scarcity of water and increasing building and construction activity.

With increased awareness and access to the global market, many of the moulders have started venturing into custom madr/industrial products like fuel tanks, chemical tanks, material handling products, solid waste management products, etc. these products though they are at nascent stage should register higher growth rate. Awareness within design community about the process and products is fast growing and this will further fuel growth in the industry as new and innovative design products are developed.

Rotomoulding is one of the fastest growing sectors and its developmental activities are good in emerging markets like Asia and particularly in India. The growing Indian economy will open new avenues for Rotomoulding industry. Thr Government emphasis on development of infrastructure will generate growth potential and opportunities for this Industry. The Indian Rotomoulding industry is at an exciting stage with the development of a wide range of products such as automotive components like bumpers, crash guards, air ducts, engine covers, three wheeler bodies, seating systems, under ground tanks, manholes, garbage bins, portable toilets, traffic and safety barriers, kiosks, indoor/outdoor furniture etc.

Easy availability of raw material technical support from machinery and raw material suppliers gives further impetus to the industry.  


3. Manufacturing Process & Know How:

 

Roto moulded plastic water Storage Tanks are made from Linear Low Density Polythene/Low Density polythene. These tanks are light in weight therefore it is easy to fix them. As rotational moulding does not require any injection pressure and high shear rates, this process offers certain basic advantages over other processes and techniques of plastic processing. These tanks keep water clean, odour free, and maintain the quality of water stored intact. These tanks are economical, practical, and hygienic alternative for storing potable water in residential buildings, industrial setups, commercial establishments etc. The rotomoulding process is simple in concept and consists of loading a known amount of plastic material in powder, micropellets, or liquid form into hollow shell like mould. The shell is then heated and simultaneously rotated about its two principal axis so that the material enclosed in the mould fuses and uniformly adheres to the surface. The mould is then cooled to solidify while rotating to retain the desired shape. The part is then de-moulded.

 

Rotomoulders currently use a variety of polymers. The most widely used are polyethylenes that include Linear Low density polyethylene (LLDPE), High Density polyethylene (HDPE), Low Density Polyethylene (LDPE), Cross- linkable polyethylene and PVC.

Globally Roto Moulding industry uses fabricated sheet metal moulds for simple designs or for very large products like Tanks. For complex designs and for specific surface finishes/textures, rotomoulders prefer cast aluminum moulds or CNC machined aluminum moulds, which offer a very high degree of design flexibility and consistency.  For manufacturing LLDPE granules are mixed with granules of black colour concentrates. These are extruded and strands are chopped as granules so as to achieve uniform distribution of carbon black. The granules are pulverized ina special pulverization system from 30 to 40 mesh powder. This powder is fed in the mould in the required quantity. The burners of the rotomoulding machine are fired with the help of LPG/Diesel and the moulds are heated to 3000 C. Molten powder when rotated in the heated mould form hollow storage tank. White liner inner coating is given for better finish. After due time when the tank is ready the mould is cooled and opened and the tank taken out. Finishing of tank is done manually.


Roto moulded tanks are manufactured as per IS: 12701. This standard covers the requirement of materials, dimensions, construction shape, tolerances on dimensions, fittings, workmanship, performance requirement, inspection and Testing of the product.    


Production capacity of the unit per annum is envisaged as 3000 nos per annum of storage tanks of various capacities from 100 litres to 5000 litres on single shift basis. The plant will work for 24 hrs.
Know how is available indigenously with machinery suppliers.
The unit will require a total connected load of 145 H.P.

 

  • 4. Plant and Machinery:

  • Since the manufacturing process involved is basically plastic moulding the unit will require the following machinery:-

  • Biaxial rotation moulding plant 3 arm, 1000 lit capacity with accessories and electrical.                    1 nos.
  • Rock-N-Roll moulding machine with electricals and accessories for for 6 nos.                                   1 nos.
  • Pulverising machine                                                                 1 nos.
  • Extruder machine 1000 mm with electrical and accessories, reduction gear etc.                                 1 nos.
  • Heavy duty grinding machine 18” with motors etc.        1 nos.
  • Moulds of various capacities.
  • Chain pulley blocks, weighing machine etc.
  • Miscellaneous equipment furniture and fixture.

The total cost of plant and testing equipment etc. is estimated to be approx. Rs. 90, 00,000/-.

 

  • 5. Raw material and Components:

  • The basic raw material for this unit is LLDPE besides the unit will also require master batch black and Industrial LPG gas. The requirement of raw material per month at rated capacity is estimated as:-

  • LLDPE                     37400 kgs.
  • Master batch black       200 kgs
  • LPG                       500 cylinders

The total cost works out to Rs 476.16 lakhs.

 

6)   Land and Building:

For smooth operation of the unit it will require total area of 3000 sq.mts. and a built up area a  built up area of 1500 sq. mts. The cost of land and building is estimated to be Rs. 42.50 lakhs.

 

 7)  Manpower:


For smooth functioning of the unit the requirement of man power is expected to be around 10 persons.

Technical staff     self
Skilled & Semi skilled workers                      4
Office staff            2
Unskilled workers    4
The annual salary bill is estimated to be around Rs.12.72 lakhs

 

9. Cost of Project:

  Rs. lakhs
Land & Building                              42.50
Plant & Machinery                           90.00
Other assets                                        1.50
Contingencies          13.40
Pre operative Exp                               2.50
Margin money                                    54.75 
Total                                                 204.65

 

10. Means of Finance:


Term Loan                                       110.55   
Promoter’s  Contribution                   94.10
Total                         204.65

 

11. Profitability:

 

  Rs. lakhs
Sales                                                      637.50                        
Raw material   476.16                         
Salary 12.72
Utilities                                                 23.36
Rep.  & Mnt. Expenses                          4.50
Sales Expenses 32.00
Admn. Expenses.                                 15.94
Depreciation 8.70                       
Interest on W.C                                      7.74 
Interest on T.L                                      12.16
Cost of production                              572.42                            
Profit                                                    65.08nhh                          


12. Requirement of Working Capital

 

      W.C Margin Money
Raw material                                1mnth        30%           39.68  11.90
Work in process                               7days 25%          12.05           3.01          
Stock of finished goods             7 days       25% 12.91            3.22
Working expenses                      1 mnth       100% 28.66          28.66
Sale on credit            15days 25%         31.87            7.96
Margin money for W.C  54.75   

 

13. Break Even point:              


55% at installed capacity


14. Machinery Suppliers

  • M/S National Plastics.
    Plot no. 84, GIDC Odhav,,
    Ahmedabad.

     

  • M/S Jai Inmdustriual Works.
    Industrial Estate, 22 godam,
    Jaipur.

     

  • M/S Super India.
    Lawrence Road.
    New Delhi.

     

  • M/S Fixopan Machines Pvt. Ltd.
    71, Nehru Place,
    New Delhi.

For further information please contact

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com