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A Review of the Conventional

method of PVC Tape production


v/s the Latest one with
bunch of advantages , low cost, high
speed, 100% eco green

By
Shrikant Athavale
Prathith Consultants
Pune MS India
website : http://www.psadhesive.com , http://www.adhesivelabtesting.com,
Linkedin Profile
: https://www.linkedin.com/in/shrikantathavale4adhesiveconsu
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Back Ground

This is a Innovative method of manufacturing , Insulation tape ,


by coating PVC Film with , a specially compounded , Natural
Rubber Based PSA , with superior Properties .
The Product manufacturing process is extremely safe , easy to
handle and 100% eco friendly with no VOC concerns , no
health or Fire hazard

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Advantages :

Higher production speeds


Compact Coating mc design.
Very Cost effective.
Lower Adhesive Cost
Process Cost , and
Capital Investment
No Heat Treatment / Annealing
No loss in Physical Properties of PVC Film
The Product is Highly eco Friendly

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Higher Production Speeds

Adhesive Coating is possible at speeds of 30-35 mtrs


/ Min

In comparison with the conventional process can


coat at approx. 8-10 mtrs / min

In short you can produce 3 times the quanity

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Compact Coating Mc Design.

The Innovative design occupies just 1/3 the space , in


comparison with the conventional PVC Tape Manufacturing
Plant ,.

This is possible
No separate primer coating station and the curing tunnel,
No Accumulator,
no Freezer zone
..

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Compact Coating Mc Design.

No Primer Coating

Yes

No more primer coating necessary

The job is done online with help of corona treater,

Online treatment is possible because the adhesive is


Water borne

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Compact Coating Mc Design.

The Electrical Connected load is also reduced to approx.


35 HP .

This is possible because


There is no need
Of Rubber Mixing Mill, Sigma Mixer
A saving of
Nearly 40 Hp connected load

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Compact Coating Mc Design.

No need of Freezer Zone

Yes

Since the PVC film is exposed to a lower temp like


75-80 deg C

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Compact Coating Mc Design.

No need of Accumulator

Yes

Because now jumbo rolls can be coated , without frequent


stoppage of coating . Log roll rewinding is possible due to the
new technology developed.

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Compact Coating Mc Design.

Very low Maintenance

Due to a simple and innovative design.

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Very Cost effective.

No Primer required
Adhesive is , Natural Rubber Latex based , its Water
borne . The properties of dry adhesive film at par with the
conventionally used Rubber Based adhesive

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Lower Manufacturing Over Heads

Lower Electrical energy cost

Connected load will be reduced to just approx. 35 hp from


approx. 80 hp ( for the conventional design + Rubber
processing equipment load )

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Lower Manufacturing Over Heads

Lower Fuel cost

This is possible due to the fact that


The drying / curing temp is down from 110-120 deg c to
just 75-80 deg C

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Lower Manufacturing Over Heads

Lower Manpower cost

Due to innovative design


No Rubber Processing equipment

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Lower Adhesive Cost

The Adhesive is water borne , but Rubber based with


suitable compounding, hence matches with the
Physical properties of solvent dissolved Rubber
Based adhesive .

Lower Adhesive Manufacturing cost.

Adhesive is 100% Eco Friendly.

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Lower Adhesive Manufacturing cost.

Regular Solvent Dissolved Rubber Adhesive


manufacturing process involves , a long time cycle ,
and a lot of Electrical energy.
The Flow chart for the same follows the next slide

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Dry Rubber Adhesive Manufacturing
Process Flow Chart
filtered Water and
Natural
purified and rubber
Rubber Latex
coagulated separated

Masticated on
Two Roll Mill This is Dry Rubber sheets
For about 30-
30- Natural Rubber are then dried
40 minutes

At this stage The mixture is Ready


Resins+ A/O + charged to a sigma Adhesive is
Plasticizer mixer and solvent stored in
Added to Toluene is added barrels
Rubber gradually with Before
For about 40 continuous mixing Coating
minutes For about 3-
3-4 hours
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The Electrical Load required for Solvent dissolved
Natural Rubber Adhesive

Mastication on Mixing of Resins /


Rubber Mill A/O , other raw mat. Mixing of Dry Rubber
Connected Load : on Rubber Mill compound with
15 HP = 11.25 Connected Load : 15 Solvent Toluene
Kw HP = 11.25 Kw Connected Load : 35
Mastication Time Mixing Time : 90 HP = 26.25 Kw
: 30 minutes minutes Mixing Time : 240
Rubber Quantity : Total Quantity : 24 minutes
12 kgs kgs Total Solution
Quantity : 48 kgs

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This means that

The Electrical Energy consumption of


Rubber Mill : 11.25 kw x 120 minutes = 11.25 kw X 2 hrs =
22.5 Units
Sigma Mixer : 26.25 X 240 minutes = 26.25X 4 hrs = 105
units
Total Electrical Units = 127.5 , for 24 kgs of dry adhesive
= 5.31 units / kg = INR 37.18 / Kg

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This means

The Man Power cost of


On Rubber Mill : 1+1 person x 120 minutes = 2 men X 2 hrs =
2 X ( (10000/25 = 400 / day/person = 50/hr/person x2= INR
100 / 24 kg of adhesive = INR 4.00 / kg )

On Sigma Mixer : 1 person X 240 minutes = 1 manX 4 hrs =


1 X ( (10000/25 = 400 / day/person = 50/hr/person x1X 4 hrs =
INR 200 / 24 kg of adhesive = INR 8.00 / kg )
Total Manpower cost = 300 , for 24 kgs of dry adhesive
= INR 12.50 / Kg

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Adhesive is 100% Eco Friendly.

No solvent used
Hence no solvent vapors after drying

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No loss in Physical Properties of PVC Film

The Film is exposed to a Temperature of about 75-


80 deg C .
hence very good retention of the Physical Properties

There is no shrinkage of Film

There is no stretching on Film

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The Product is Highly eco Friendly

Its water Borne system


Hence
There are No Solvent Vapors
No Health Hazard
No Fire Hazard
No worries at all

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NO Heat Treatment on Log Roll Necessary
And

Slicing
can be done
Immediately after Log Roll winding

This results in lot of Saving in Precious Production


Time

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Conventional
PVC Tape Coating Plant

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Conventional
PVC Tape Coating Plant

The primed PVC Film is then PVC Film is coated with


coated with Solvent dissolved Solvent dissolved Natural
Natural Rubber Adhesive Rubber Primer
+ Isocyanide X Linking
For Curing the Temp inside the Agent
Tunnel is again 110-120 deg C
For Curing the Temp inside
the Tunnel is 110-120 deg C

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In short the PVC film is exposed to higher temperature like
110-120 deg c , two times
And
That too at a slow speed of 8 10 mtrs a minute.

This results in developing un wanted stresses in the PVC


film.

and to compensate/ remove these stresses , the log rolls


need to be exposed to annealing stage.

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Our Innovative Coating plant
Much compact and easy to operate

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Our Innovative Coating plant
Much compact and easy to operate

The PVC Film is then coated with Latex based Natural Rubber
Adhesive
For Curing the Temp inside the Tunnel is again 75-80 deg C

In this method the PVC is exposed to a lower temperature of


approx. 75-80 deg C , and that too , only once , and at higher speed
like 30-35 mtrs. per minute.
Hence there is no inbuilt stress in the Film. This helps us in
eliminating the annealing process
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Flow Chart for
existing Process of PVC Tape
Manufacture

Primer Coating Adhesive Curing


at 110-120 deg C

Primer Curing at
110-120 deg C Annealing
Process

Adhesive Coating Ready


Slicing

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Flow Chart for
existing Process of PVC Tape Manufacture :

Heat Treatment on Log Roll


And Slicing after a minimum of 24 Hrs.

PVC Tape
PVC Tape Log rolls under
Log rolls Heat Treatment

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PVC Tape Log rolls after
Hear Treatment for a min of
24 hrs

Next stage of
Production
i.e. Slicing

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50 mm
1250 mm

ID. 38 mm
ID. 38 mm

Log Roll of 1250 mm width X


Finish Roll of 50 mm width X
10 Mtrs length
10 Mtrs length

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Flow Chart for

Invented Process of PVC Tape


Manufacture

Carona Adhesive Curing


Treatment at 75-80 deg C

Adhesive Coating Ready


Slicing

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Rewinding Log rolls of required length , from the Jumbo rolls made as
above.

1250 mm
1250 mm

ID. 76 mm ID. 38 mm

Jumbo Roll of 1250 mm width Log Roll of


X 500/1000 Mtrs length 1250 mm X 10 Mtrs length

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The Product Construction is given Below.

Natural Rubber
Latex Based PSA

Adhesive

PVC
Film
PVC Film
Magnified
View

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Further Process :

Rewinding into 8 mtrs:

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Further Process :

Slicing in to 18 mm

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Packing Machine :
Shrink Wrapping

Box Sealing

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The Product Cost Analysis
Conventional Method

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The Product Cost Analysis
New Method

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Conclusion

The Invented Method of Producing Electrical


Insulation Tape by very Cost Effective.
There is a net saving of at least 15 % ,
which sizable by any standards.

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Thank
You
Please feel free to contact us
For more Information

Our website : www.psadhesive.com


Personal Email : psatechno@gmail.com
Cell : 00 91 9850242282
00 91 7588288204
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