FLEXIBLE PU FOAM

[EIRI/EDPR/4033] J.C.: 2165XL

INTRODUCTION

Polyurethane foams are materials with a low weight-to-strength ratio, desirable

insulating properties and a strong tendency for energy absorption.
Broadly, foams come in three types – polyurethane (PU), memory foam and latex
rubber foam. PU foam and Memory foam both are polyurethanes but memory
foam has additional chemical composition to provide the contraction and
retention. So, it is important to understand Polyurethane Foams in detail and the
cost structure.

At its core, manufacturing polyurethane foam is similar to making a cake. You

have a batter and then you bake it (causing it to expand) and you get a fluffy cake.
Similarly, you have a chemical mix which when exposed to a blowing agent and a
catalyst causes the mix to expand and cool down to become foam.

Polyurethane foams are prepared by the reaction of a polyisocyanate with a polyol

in the presence of a blowing agent, a surfactant, and a catalyst without external
heating of the foaming system. The principle of preparation of urethane foams is
based on the simultaneous occurrence of two reactions, i.e., polyurethane
formation and gas generation in the presence of catalyst and surfactant, as shown
below. While polyurethane polymers are used for a vast array of applications, their
production method can be broken into three distinct phases. First, the bulk
polymer product is made. Next, the polymer is exposed to various processing
steps. Finally, the polymer is transformed into its final product and shipped.

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PU Foams come in two types – flexible and rigid PU foams. In flexible polyurethane
foams, the major blowing agent is water and, at the same time, auxiliary blowing
agents, i.e., low–boiling–point inert solvents such as CFC–11, methylene chloride,
can be used. But in the case of rigid polyurethane foams, the major blowing agent
has been CFC–11, which vaporizes due to the exothermic reaction of polyurethane
formation.

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 CONTENTS

INTRODUCTION
TESTING OF PU FOAM DENSITIES
PROPERTIES OF PU FOAM MATTRESS
RESILIENCE
SOLVENT RESISTANCE
ANTIBACTERIAL PROTECTION
YELLOWING AND DISCOLOURATION
LOW FIRE RETARDANCY
USAGE AND APPLICATION
ADVANTAGES AND DISADVANTAGES OF POLYURETHANE
ADVANTAGES
DISADVANTAGES
MARKET PROSPECTIVE
B.I.S. SPECIFICATION
PROCESS FLOW DIAGRAM
FOAMING PROCESS
FOAM CURING:
QUALITY CONTROL:
MANUFACTURING PROCESS DESCRIPTION:
MANUFACTURING PROCESS FLOW DIAGRAM:
PLANT AND MACHINERY
REQUIRED MACHINE FEATURES:
MARKET POSITION
MARKET OVERVIEW
FURTHER STUDY
U.S. POLYURETHANE FOAM MARKET REVENUE BY PRODUCT
2014-2024 (US$ MILLION)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE
ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:

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8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF FLEXIBLE PU FOAM
SUPPLIER OF RAW MATERIALS
SUPPLIER OF CHEMICALS
SUPPLIER OF PLANT AND MACHINERY
SUPPLIER OF PRODUCTION LINE
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EXHAUST FAN
SUPPLIERS OF TESTING EQUIPMENTS

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 1.20 MT/Day

Land & Building (1000 sq.mt.) Rs. 3.84 Cr
Plant & Machinery Rs. 82 Lac
Working Capital for 2 Months Rs. 1.10 Cr
Total Capital Investment Rs. 5.96 Cr
Rate of Return 19%
Break Even Point 62%

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