Abstract

Plastic tanks and water tanks store substances utilized in industrial processes, such as water,
sewage, petroleum and chemicals. They are utilized in numerous industrious, such as the
agricultural, oil/gas, water, waste treatment, medical, scientific and pharmaceutical industries.
Plastic tanks have several advantages over the traditional steel tanks. Their seamless construction
provides them with greater impact strength and superior resistance to rust, corrosion and fuel
additives. These virtually indestructible tanks have a longer lifespan than steel tanks, which can
fracture and leak. Plastic tanks can easily be molded to fit tank compartments, unlike metal tanks,
and are simple to install. This characteristic provides savings in size, weight and cost. Plastic tanks
also cost less overall than steel tanks.
PVC Pipes and fittings are made from the polyvinyl chloride material. PVC pipes and fittings are
manufactured by heating plastic resins and the molten resins are set to make desirable shapes and
sizes. The PVC pipes and fittings are widely used in the various applications such as irrigation,
building & construction, water supply, sewage management and others. PVC pipes and fittings are
of various types such as rigid pipes and flexible.
PVC piping systems are used in several areas for the transport of water - from delivery of drinking
water over the removal of sewage or waste products to drainage of water from the ground or roof.
SWR pipes also known as PVC SWR Pipes are available with one end as plain and other ends as
self-socketed with an integral groove to hold the rubber gasket. When joined with a rubber ring,
the joint formed is a water tight. This rubber ring joint takes care of thermal expansion/contraction
in the pipes.

•    These Pipes are Lead Contaminant Free leading to superior quality

•    These Pipes is a fully backward integrated manufacturer with complete control of raw material
used to generate unbeatable quality
HDPE pipe is a kind of flexible plastic pipe that is extensively used for gas and fluid transfer. It is
also used to replace the ageing concrete or steel pipelines. This type of pipe is well suited for high
pressure pipelines. These pipes are extensively used for various applications such as drainage pipes,
storm-water pipes, rural irrigation, slurry transfer lines, electrical and communications conduit,
and few more. 
 
Introduction
1) Water Tanks
Polyethylene water storage tanks are ideal for economic and hygienic storage of potable water in
residential buildings, industrial units, business complexes, in fact anywhere and everywhere. These
tanks are moulded in one piece. Water storage tanks are without any seams, joints or welds.

Because of their light weight, these tanks are easy to install and are extremely mobile. They are very
light for the volume of water stored. A tank capable of storing 2000 litres of water weighs only 65 kgs.
as against 0.5 MT in case of M.S. tank and 2 MT in case of RCC tank of a similar capacity. These tanks
are rust proof and leak proof. Hence they practically require little or no maintenance. These tanks
have double the life than that of RCC tanks and three to four times than that of M.S. tanks. The
temperature of water inside is maintained for a considerable longer time than an M.S. tank because
polyethylene is a bad conductor of heat

PRODUCTS AND ITS APPLICATION

A water tank is a container for storing water. The need for water tanks is as old as civilization. Tanks
were used to provide storage of water for use in many applications, drinking water, irrigation
agriculture, fire suppression, agricultural farming, both for plants and livestock, chemical manufacturing,
food preparation as well as many other uses.

MARKET POTENTIAL AND MARKETING ISSUES, IF ANY

Rotational moulding is new to the plastic industry because of its importance as processing method.
Though the art is an old one but technological advancement during the last twenty years has caused
growth of several sizeable industries and is rapidly gaining interest on a widespread basis. Root-molded
Plastic Water storage tanks being lighter in weight are easy in handling and can be easily fitted at any
desired place, and are hence preferred and practically replacing the conventional tanks of steel, cement
concrete or stone.

These tanks are available in market in various sizes and shapes. The prices of these tanks are at the rate
of Rs. 3 per liter of water capacity approximately. The demand of plastic water storage tanks is
increasing day-by-day. They are not only installed in the individual houses and flats but are also fitted in
factories, group housing schemes and multistoried buildings as well. Field investigations have revealed
that due to increase in the house building activities and preference given by the Government to provide
homes to the homeless people, the demand for plastic water storage tanks is likely to increase in the
years to come. Hence there is a good scope for establishing a few units for the manufacture of water
storage tanks by rot Molded process.

RAW MATERIAL REQUIREMENTS

 LLDPE

 Master batch black

 LPG Industrial gas

MANUFACTURING PROCESS
Rotational Moulding is a process for producing hollow seamless containers of all sizes and shapes. The
process does not involve high injection pressure or high shear rates. Black polyethylene powder of 35
mesh is weighed and charged in the mould. The mould is heated while it is being rotated about two
perpendicular axes. Simultaneously a porous skin is formed on the mould surface which gradually melts
as the heating cycle progresses. At the end of heating cycle a layer of homogenous uniform thick wall is
formed. The mould then enters a cooling station where forced air/water spray cools the mould. It is
then positioned in a work zone where the mould is opened, the tank is removed and the mould is
recharged for next cycle.

Process:
The rotational moulding process for manufacturing water storage tank consists of the following major
process steps.

• Loading of raw material

• Moulding of the part

• Cooling or curing

• Unloading of finished part

Cycle time generally varies from 6 to 10 minutes. Cycle as low as 2 minutes can be achieved and
extremely large part with heavy wall requires 15 minutes for each moulding cycle.

 Loading: Raw material in the form of powder (35 to 40 mesh) or liquid state is loaded into the mould
or cavities and mould halves are mechanically locked together. Loading is generally accomplished before
the machine has completed its previous cycle and ready to accept the mould.
 Moulding the part: The prepared mould is next placed in a closed chamber where it is subjected to
intense heat up to 400oC while rotating the mould biacially. Rotation is at low speed generally in the
range of 1 – 40 rpm on the minor axis and 1 – 12 rmp on the major axis. A 4:1 rotation is common
however both variable speeds and variable ratios are used for moulding unusual configuration.

 Cooling or curing: The mould containing formed part is then transferred to a second enclosed chamber
where it is subjected to a combination of water spray a dforced air cooling while continuing to rotate
biaxially. This causes the part to cure evenly and mould to reach handling temperature.

 Unloading: Like loading this can be accomplished manually by simply opening the mould and physically
removing the parts or automatically by using forced air to facilitate the ejection of the part.

2) PVC Pipes & Fittings

Rigid PVC Pipes are fast replacing the conventional metal pipes in many applications. The conventional
metal pipes are already started replacing by PVC pipes. Use of PVC pipes as electrical conduits is well
accepted in household and industrial activities. PVC conduits have been accepted by all Electricity
Boards. PVC pipes of different diameters have gained wider acceptance for water supply. Their light
weight, low cost, easy installation, non-corrosiveness, high tensile strength to withstand high fluid
pressure make them ideal for number of purposes. They also offer resistance to most of the chemicals
and have excellent electrical and heat insulation properties. Due to the chemical resistant properties
the PVC pipe fittings are widely used in these areas. The most commonly used PVC fittings are Sockets,
T’s, Elbows, Bends and Joints. Most of these fittings are manufactured by injection moulding in
different sizes corresponding to the size of PVC pipes

PRODUCTS AND ITS APPLICATION

PVC pipes and fittings are mainly used in all sectors but the major usages are in household water supply,
electrification in houses and industries, and irrigation facilities in agriculture.

MARKET POTENTIAL AND MARKETING ISSUES, IF ANY

In view of the priorities to rural water suppliers, irrigation facilities in the national planning and rapid
rural electrification, the demand for rigid PVC pipe and fittings is growing regularly. The PVC pipe fittings
are widely used in the housie constructions and commercial constructions.60% of the total demand of
PVC pipe and fittings exist today is up to 110 mm outer diameter which is very much suitable for small
scale sector industries.

RAW MATERIAL REQUIREMENTS

 PVC Resin
  D.O.P.

 Stabilizers

 Lubricants

 Colors

 Fillers

MANUFACTURING PROCESS
The basic material which on Polymerization produces P.V.C. Pipes is Polyvinyl chloride which in resin
form is hard and rigid. The rigidity can be controlled by controlling the percentage of plasticizer at the
time of compounding. Production of Rigid PVC pipe is based on plasticizing and homogenizing PVC
compound and then passing the compound through an extruder. The hot molten PVC compound is
extruded through a circular slit. Circular slit governs the size of pipe to be extruded. Different dies are
used for manufacturing different size of pipes.

The Pipes thus extruded through the die is then passed through a vacuum sizing tank wherein the
dimensions of the pipe can be accurately set. It also helps in surface finish of the pipes. Vacuum sizing
reduces the percentage of wastage considerably.

As the pipe being extruded is rigid in form they cannot be wound into coils. So an inline motorized
cutting device should be provided for cutting the pipes into required sizes. For ascertaining the
consistency in product quality the unit should be equipped with process control laboratory for
preliminary testing of raw materials. The unit may also have arrangement for quality testing of finished
products.

PVC fittings are made on the injection moulding machines. The PVC compound is fed into the hopper of
the injection moulding machine which essentially has a mould locking and injection arrangements. The
mould is held in-between the platens which are kept closed by the locking pressure and the materials
which get plasticized by the heating arrangements, is injected under this pressure into mould which
results into a molded and high quality product. Mould should have proper injection arrangement for
consistent high production.

3) High Density Polyethylene (HDPE) Pipes

 High Density Polyethylene (HDPE) Pipes are manufactured all over the world by extrusion technique.
Sizing methods still vary but the trend is the pressure sizing HDPE Pipes are generally manufactured on
single screw extruder. HDPE Pipes find application in a variety of fields in India and abroad. The most
important applications are as follows:

- Drinking water supply line

- Water lines in hilly areas. Here the property of flexibility of HDPE is exploited to the fullest extent
- Irrigation lines
- Industrial effluent disposal lines
- Sewage and gas lines
- Fuel gas line
- Mining Industry

MARKET POTENTIAL
There is a large market and very good scope envisaged for HDPE Pipes in the near future. Though some
units are already in the line, there is good demand with the increase in housing/building activities
spreading in rural and urban areas. Number of Chemical and Petrochemical plants are also being set up.
Therefore, the demand for HDPE Pipes is also likely to rise. One of the important applications is gas pipe
line. It has advantage over PVC pipe because it is unaffected even by temperature as high as 80 degree C
and is inert to almost all chemicals. These pipes are also used in the effluent treatment plants and line.

MANUFACTURING PROCESS
HDPE granules are fed into the hopper of the extruder which goes into the heated cylinder of the
extruder, where the granules melt and are conveyed (pumped) to the die exist. Now the melt passes
through the die and takes the shape of the die i.e. circular shape and emerges from the exit of the die. It
then passes through the calibrator and is forced to tale the shape of the inside of the calibrator which is
round in diameter by the inside air pressure. This melt solidifies and taken round shape in the calibrator,
which is cooled by passing chilled water through it continuously.

Now the solid pipe is taken out from the water and is drawn continuously from the die. The speed is
adjusted according to the thickness of the pipe required and extruder out put. The pipes is either cut
into 5 meters length or wound on the winder unit. Generally pipes upto 110 mm diameter can be made
on this extruder

Braided Hose Pipe & Hose Pipe

Braided Hose Pipe - PVC Braided Hoses made from high quality thermoplastic compound and reinforced
(braided) with high tenacity synthetic yarn (crosswise - lengthwise). The excellent ply adhesion and
bonding between the inner and upper layer of PVC ensures a durable pipe. The braiding gives the hose
high strength and resistance to withstand high pressure and elongation. Our production of hoses meets
the most stringent operational requirements. Transparent hoses facilitate the location of blockage in
use.

PVC Braided Hoses made from high quality thermoplastic compound and reinforced (braided) with high
tenacity synthetic yarn (crosswise - lengthwise). The excellent ply adhesion and bonding between the
inner and upper layer of PVC ensures a durable pipe. The braiding gives the hose high strength and
resistance to withstand high pressure and elongation. Our production of hoses meets the most stringent
operational requirements.

Transparent hoses facilitate the location of blockage in use. The smooth inner bore prevents any build -
up and offers minimum resistance to flow. The working pressure of the hose is dependent on
temperature and is lowered with increase in temperature. Available in various grades as Clear
Transparent, Super Spray (Car Washing), Agricultural Pesticide, Green Garden Water, Sanitary, Fire
Fighting, Rock Drill, Welding etc.

A hose is a flexible hollow tube designed to carry fluids from one location to another. Hoses are also
sometimes called pipes (the word pipe usually refers to a rigid tube, whereas a hose is usually a flexible
one), or more generally tubing. The shape of a hose is usually cylindrical (having a circular cross
section).

PRODUCT & ITS APPLICATION

 Braided pipes are tubes which can be utilized for the transfer of air, gases, and
fluid substances under low or high pressure. The presence of the wire on braided
pipes enhances the reliability of the hose and offers added strength. Braided metal
pipes are adopted in fields of applications such as hydraulic & pneumatic medium,
air-conditioning and heat techniques, technical gases, vacuum techniques, solar
techniques, and hot steam conveyance.
 Braided pipes are available in different sizes, material, and configurations. They
are available in both rigid and flexible form. Steel braided pipes are mainly used in
manufacturing facilities and for industrial purposes etc.

MANUFACTURING PROCESS:

1. Melting of the Raw plastic materials

The raw plastic materials such as beads, granules, pellets, or powder are loaded into
a hopper and then fed into a long heated cylindrical chamber called an extruder.

The plastic materials melted down is moved through this extruder by a spinning bolt.
It is important to note that some extruders can have either one or two spinning bolt.

2. Filtration of the melted plastic materials

The melted raw materials flow from the hopper down through the feed throat and
onto a large spinning screw operating within a horizontal barrel of the mini single
screw extrusion machine

Within the horizontal barrel, the melted raw materials are filtered to ensure a
uniform consistency.

3. Sizing of the molten plastic

The properties of plastic materials vary depending on the materials there are made
of. However, the raw materials are processed by subjecting it to heating at a
particular temperature with respect to the type of raw material being passed
through.

At the completion of the process, the molten plastic is pushed through a small
opening called a die. This allows the material to size or shape to the desired finished
product.

4. Workup Process

The die-cut for a particular plastic profile is designed to aid smooth and even flow
from the cylindrical profile of the extruder into the final profile shape.

Consistency in the plastic flow is crucial in achieving an end product with high quality
and reliability.

5. Cooling of the processed raw material

As the plastic is extruded from the die, it is fed onto a conveyor belt for cooling. The
finished product can be cooled either by air or water.

Note, this process is similar to the injection molding process except that the melted
plastic is forced through a die instead of into a mold.