A

REPORT

On

EXPANSION OF CURRENT FACILITY

Of

MAX SPECILAITY FILMS LTD
Bhai Mohan Singh Nagar, Rail Majra, Tehsil Balachaur, Distt. S.B.S. Nagar (Nawanshahr)
PUNJAB - 144533, India

1. Introduction :
Max Speciality Films Ltd (also known as MSFL) is a unit of Max India group which has operations in hospitality, healthcare and insurance. The company currently produces BOPP films, Metallized films. In this expansion project the company proposes to install the project of manufacturing of additional capacity of BOPP film, a Speciality Coated Film and Thermal Coated film.

2. Expansion Quantity :

The proposed Expansion is as under Sr. No | Product | Existing | Proposed | Total | 1 | BOPP | 210 TPD | 110 TPD | 320TPD | 2 | MET BOPP | 50 TPD | Nil | 50TPD | 3 | Coated Films | Nil | 8 TPD | 08 TDP | 4 | Thermal Coating | Nil | 48 TPD | 48 TPD |

3. Investment :

Sr. No | Plant | Investment | 1 | BOPP | 226 Crores | 2 | MET BOPP | 0 Crores | 3 | Coated Films | 18 Crores | 4 | Thermal Coating | 49 Crores | | Total | 293 Crores |

4. Likely date of Commissioning

Sr. No | Plant | Likely date of Commissioning | 1 | BOPP | Mar-17 | 5 | Coated Films | Oct-15 | 6 | Thermal Coating | Jun-16 |

5. Process Description and Raw materials to be consumed:

6.1 BOPP Production

The process for the manufacture of Biaxially Oriented Poly Propylene (BOPP) film is described below:

Polypropylene resins are melted and extruded through a set of electrically heated extruders and after filtration passed through a T-die with adjustable lips. The molten sheet of Polypropylene is taken on to a chilled & water bath, where chill water is circulated in closed loop for casting it into continuous polypropylene film. This film is then passed over oil heated rolls, where it is first pre-heated & then stretched in the machine direction. This process causes the film to thin down without reducing its width. At this stage, the film so obtained is monoaxially oriented.

For biaxial oriented, subsequent stretching in the transverse directions is accomplished on equipment known as stenter frame which consists of two endless chains equipped with gripping clips mounted on a frame. The final width of film will be 8700 mm.

The film produced is wound on steel cores at the winder. The roll thus produced is known as Mill Roll. These rolls are stored for 32 to 72 hours at ambient conditions in maturation area to facilitate stabilisation of physical properties.
The matured film on mill rolls is slit into various widths on a set of slitting machines comprising mechanical razors. The actual width & length of slit rolls depends upon the end use requirement.

The process of operation is purely physical by mechanical stretching and reorientation of molecules achieved under specific thermal conditions for achieving desired physical properties for packing, over-wrap and lamination. All the films are manufactured through co-extrusion process.

Raw Material details S. No. | Raw Material | | Quantity consumption /Daily | | | Unit | Existing | New | Total | 1 | Homopolymer | | 107 | 67.5 | 174.5 | | | MT | | | | 2 | Copolymer | | 9.7 | 8.2 | 18 | | | MT | | | | 3 | Additives | | 7.6 | 15.3 | 22.9 | | | MT | | | | 4 | RGG | | 8.7 | 9.4 | 18.1 | | | MT | | | |

5.2 Coated Films: WHAT IS COATING | Coating is process of covering of substrate plastic films like BOPP, BOPET etc (of thickness 12 µ to 75 µ) with lacquer and inks such as Acrylic, PVDC, and Polyurethane as per the end application, using gravure technology. The purpose of coating may be decorative, functional or both. Some of the main application of the Coated films are Pressure sensitive label application , Over wrapping , high barrier packaging( like snacks ,baked goods ,tea , coffee ,pet foods & agarbattis ) ,Adhesive Lamination (book covers ,Invitation cards ,Cosmetic Box covers , menu cards) and fresh foods , salads etc packaging | MSFL Is planning to put up a coating plant wherein BOPP and BOPET film is coated with Inks and Lacquers such as Acrylic and PVDC so as to give following properties to the film : 1. Barrier against Water vapor 2. Barrier against oxygen to preserve foods 3. Aesthetically pleasing properties 4. Printing properties 5. Adhesive/Label properties | PROCESS DESCRIPTION: | * Raw Materials:
Basically two raw materials are required for coating process: Substrate and Lacquer/Inks (like Acrylic, PVDC). Substrate is a plastic film on which coating is done.
Lacquer used for coating can be water based or solvent based chemical. Chemical used depend upon type of application of finish product, substrate and process capabilities. | * Mixing of Raw Materials:
Two or more materials are mixed as per the required proportions. | * Coating Process it consists of Unwinder, 2 coating stations, drying units & winder. Lacquer is coated on the substrate through gravure. Roll is loaded at machine at Unwinder and Lacquer/Ink is coated on the substrate through gravure (as per product). Gravure cylinder is immersed with Ink tray for coating and extra ink is cleaned by blade mounted on cylinder. Coated film then passes though a drying chamber for drying and film is collected at winder station. Scrap of sample checking, uncoated film, coated film and waste lacquer is generated and it can be reused. Sample of the produced film is inspected on the basis of some given quality specifications and after approval final jumbo roll goes to slitting machine. | * Slitting & Rewinding
Slitting is process of cutting big jumbo rolls into smaller rolls of desired length and width as per Market demand. |

* Packing
Packing is done as per the customer orders. Rolls are packed in fiber drums or wooden pallets/ corrugated boxes for dispatch.Raw Material details | S. No. | Raw material details | Unit | Proposed Quantity consumption /Daily | | | | Existing | Proposed | Total | 1 | BOPP Film | MT | 0 | 6.667 | 6.667 | 2 | Pet Film | MT | 0 | 0.5 | 0.5 | 3 | Misc. (Polymeric Film) | MT | 0 | 0.067 | 0.067 | 4 | Solid resins | MT | 0 | 0.003 | 0.003 | 5 | Water Based lacquers/ Emulsion | MT | 0 | 2.267 | 2.267 | 6 | Solvent based lacquers | MT | 0 | 0.233 | 0.233 | 7 | ETHYL | MT | 0 | 0.007 | 0.007 | 8 | TOULENE | MT | 0 | 0.007 | 0.007 | 9 | Iso Propyl Alcohal | MT | 0 | 0.007 | 0.007 | 10 | Misc. | MT | 0 | 0.003 | 0.003 |

5.3 THERMAL COATING WHAT IS THERMAL COATING : | Plastic film is coated with a material named EVA for this Firstly, EVA is fed into an extruder which melts it and extrudes it onto surface of a plastic film running below it. Output from this process is called thermal lamination film. This film is then slit and packed according to various customer requirements and shipped. * Customers then apply the coated film onto Books, Posters, Presentation Folders, Labels, Shopping Bag, POP Signs, Document, Book Covers, ID Cards, License, Passports , Board making,
Write on/wipe off Calendars, Photographs, Albums etc. | PROCESS DESCRIPTION: | * RAW MATERIALS:
Basically two raw materials are required for coating process: Plastic film and EVA (Ethylene-vinyl acetate).Substrate is a plastic film on which coating is done.
Coating material is (Ethylene-vinyl acetate). | * MIXING OF RAW MATERIALS:
Ethylene-vinyl acetate (EVA) is soft granules in shape as raw material, a material mixer is used that mixes Eva and additive in an in very small ratio, it is fed into an extruder that heats it to its processing temperature making a paste. Which is then extruded directly on to the plastic film, In case of BOPET, a material mixer is used that mixes Eva and additive in an in very small ratio. | * COATING PROCESS
It consist of Unwinder, primer application unit and dryer , Casting and coating section, | * SLITTING & REWINDING
Slitting is process of cutting big jumbo rolls into smaller rolls of desired length and width as per Market demand. | * PACKING
Packing is done as per the customer orders. Rolls are packed in fiber drums or wooden pallets/ corrugated boxes for dispatch. |
Raw Material details S. No. | Raw material details | Unit | Quantity consumption /Daily | | | | Existing | Proposed | Total | 1 | BOPP film | KG | 0 | 27072 | 27072 | 2 | EVA | KG | 0 | 29328 | 29328 | | | | |