Project Report On Silicone Foam Manufacturing For Railway

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Additional Details

SILICONE FOAM MANUFACTURING FOR RAILWAY [CODE NO.3509]  

Silicone foam is a synthetic rubber product used in gasketing, sheets and restops. It is
available in solid, cured form as well as in individual liquid components for eld
installations.

Silicone foams are lightweight products derived from liquid silicone ingredients that are
cast onto a liner and cured in an oven. Low density silicone foams have open cell
structure that may allow moisture to pass through the cell structure. Open cell silicone
foam can be compressed to collapse the cells o ering a water tight seal. In contrast,
higher density silicone foam products will have a higher proportion of closed cells
compared with medium or low density grades. As with all gaskets, with the proper
de ection, a good long term weather seal can be achieved.

What is Silicone Foam?

Silicone foam products are manufactured from platinum cured, liquid silicone rubber.
The raw compound is expanded and dispensed on a continuous casting line, then heat
cured. The expansion process is controlled to create a range of products having di erent
densities, softness/ rmness and cell structures. Silicone foam materials typically have a
smooth skin on one or both sides due to the casting process. Open cell silicone foams
are widely used for cushioning, dust sealing or light water sealing. Closed cell silicone
foam materials are used for outdoor gaskets, wash-down gaskets and resilient
cushioning pads. Expanded silicone foam products have a rmness range from Ultra
Soft to Extra Firm, allowing engineers to select the best product for their application.

COST ESTIMATION

Plant Capacity                                           0.50 MT/day       

Land & Building (4000 sq.mt)                Rs. 4.07  Cr
Plant & Machinery                                    Rs. 51.00 Lacs
Working Capital for 2 Months                Rs. 86.44 Lacs
Total Capital Investment                        Rs. 5.73  Cr
Rate of Return                                        21%
Break Even Point                                    66%

INTRODUCTION    
WHAT IS SILICONE FOAM?    
PROPERTIES OF SILICON FOAM    
ADVANTAGES    
USES AND APPLICATION    
USES    
APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUCACTURING PROCESS    
RAW MATERIAL    
(1) POLYSILOXANES AS A RUBBER POLYMER    
(2) FINALLY DIVIDED SILICA FILLERS AGENT    
(3) AZODICARBONAMID FOAMING AGENT    
(4) DIACYL PEROXIDE VULCNISING AGENT    
PEROXIDE VULCANIZATION    
EXAMPLES OF CO-VULCANIZATION AGENTS USED DURING
   PEROXIDE VULCANIZATION    
(A) SLABSTOCK    
(B) MOULDING    
THE PROCESS OF FOAM PRODUCTION CAN BE DIVIDED INTO THE FOLLOWING STEPS:    
1) COMPOUNDING AND MATURING    
COMPONENT (A) IS AN ORGANOPOLYSILOXANE HAVING THE
    GENERAL FORMULA:    
2) FOAMING AND GELLING    
3) VULCANISATION    
4) WASHING AND DRYING    
MANUFACTURERS/SUPPLIERS OF SILICON FOAM    
MARKET POSITION    
GLOBAL OPEN CELL SILICONE FOAM MARKET SEGMENTATION    
THE TOP LEADING MARKET PLAYERS:    
IMPORT DATA OF SILICONE FOAM SHEETS    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
LIST OF APPROVED VENDOR FOR SUPPLIER OF SEAT AND BEARTH
   IN INDIAN RAILWAY    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF POLY SILOXANE    
SUPPLIERS OF DIACYL PEROXIDE    
SUPPLIERS OF AZODICARBON AMIDE    
SUPPLIERS OF SILICA FILLER    
SUPPLIERS OF COMPLETE RUBBER    
PROCESSING PLANT    
SUPPLIERS OF RUBBER CURRING OVEN    
SUPPLIERS OF BOILERS    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF RUBBER TESING EQUIPMENTS    
SUPPLIERS OF MOLDS    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
JIGS AND FIXTURE    
SUBMERSIBLE WATER PUMP    
                
  
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      

 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET      
 

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