INTRODUCTION:

The advent of PVC pipes have relegated the use of metal pipes when it comes to conveying
water, sewer and even for protecting underground cables. Plumbing jobs have become easier
because of the introduction of PVC pipes to the market.

Polyvinyl Chloride (PVC) pipes are known to be highly durable, safer, and perhaps difficult to
damage and can last for a very long time simply because of its composition; it is made from the
combination of plastic and vinyl materials. With PVC pipes, and you wouldn’t have to bother
about rust and bacteria formation inside the pipes especially when it is used for water
distribution.

Therefore, If you are interested in a starting a manufacturing company that would provide
products that can be comfortably and effectively used for underground wiring, sewer lines and
water system in buildings, then you should consider starting your own Polyvinyl Chloride (PVC)
pipe manufacturing company to make the difference.

Starting your own PVC pipe manufacturing company would open you up to opportunities in the
construction industry, because there is hardly any construction job that is done without the use of
PVC pipes. No doubt establishing a PVC pipe manufacturing company may require huge capital
but the truth is that it is highly profitable especially if you know how to position yourself in the
market place.

If you have made up your mind to start your own PVC pipes manufacturing company, then the
following surefire tips should aid you.

Naming the company entity as “KSM INDUSTRIES”

1. Survey the Market

PVC pipe manufacturing company is not just any kind of company that you can start without due
preparation. The fact that it requires huge capital to establish a PVC pipe manufacturing
company means that you should do a proper research and feasibility studies before dabbling into
this type capital intensive business if you are concern about the safety of your investment.

2. Write a Comprehensive Business Plan

You are not expected to start your own PVC pipe manufacturing company without having in
place a comprehensive business plan that can serve as a blue print for your business. It is good to
get your business plan handy and review it over and over again before you start the process of
building your PVC pipe manufacturing company.
Even if you have started running your PVC pipe manufacturing company, you would still need to
continue to review your business plan. That is the reason why you must make your business plan
flexible so that you will be able to make adjustment when the need arises.

3. Raise Your Capital

If you have done your feasibility studies and have pooled the required capital to build your PVC
pipes manufacturing company; then good for you. On the other hand, if you don’t have the
required capital, then you should explore all the available means to raise the required capital.

You may consider getting a loan from the bank, or you can sell your business idea to investors,
and you can as well raise capital from your friends and family members. Your business plan is
one major tool you would need when you are out there trying to convince people to invest in
your business; if you business plan is well crafted, then the process of raising funds will be
easier.

4. Register Your Business and Obtain the Required License

If you have undertaken your research project and feasibility studies, written your business plan
and have the capital required to start your own PVC pipe manufacturing company, then your
next port of call would be that you approach the relevant authorities in your country to register
your business and obtain the required license and permission.

Furthermore, the authority regulating the industry would have to inspect your factory before you
can be issued a license and permission to start your own PVC pipe manufacturing company.

5. Choose a Suitable Location to Build your Factory

The location you choose to build your PVC pipe manufacturing company doesn’t really matter as
such, so you shouldn’t spend fortunes trying to get an expensive facility or location. You can
establish your PVC pipe manufacturing company in the outskirt of town since it is cheaper to do
so. The only drawback with establishing your PVC pipe manufacturing factory in the outskirt
town is the cost of transporting your goods and raw materials.

6. Enforce Safety and Quality

People that work in PVC pipe manufacturing factories are always exposed to risks, that is the
reason why you must make it a point of duty to enforce best practices when it comes to safety
measures. It is fact that if the necessary safety measures are not put in place, your factory may
stand the chance of being shut down by local authorities.

Another important factor that is sure to guarantee your PVC pipes manufacturing company to
become relevant is when you are committed to producing only high quality PVC pipes. If the
PVC pipes you manufacture are known to get damaged easily under little pressure, people may
likely not patronize you. High quality PVC pipes are known to withstand pressure caused by
earth tremors and even earthquakes.

7. Advertise and Market Your PVC pipes

If you are confident about the quality of PVC pipes your factory churns out, then you would be
bold and confident in the market place. The market for the PVC pipes is massive and the profit
you stand to make is huge as well. Your target market should be those that are involved in all
form of construction and plumbing jobs, and those who are into laying underground wires and
cables. So endeavor to go to their offices, sites or any place where you can meet them so that you
can market your products to them.

In marketing your PVC pipes, you might even enter a deal where you would have to design and
produce PVC pipes based on your clients’ specification. Another factor that will give you edge in
the market place is when you choose to deliver the purchased PVC pipes free of charge to your
client rather than allowing them to transport it on their own.

There you have it; 7 solid tips that can help you build your own PVC pipe manufacturing
company from the very scratch to great success.

BANKER

ORIENTAL BANK OF COMMERCE

COMPANY OFFERS WIDE RANGE PRODUCTS WITH BRAND NAME NIGS

 Water supply pipe & fittings

 CPVC pipes & fittings

 UPVC pipes & fittings

 PRP-C pipes & fittings

 HDPE submersible coil

 Bath accessories

 PTMT taps

 PTMT taps

 PP based economic taps

 Unbreakable bath accessories

RAW MATERIALS

 PVC GRAINS- A synthetic thermoplastic material made by polymerizing chloride. The

 UPVC - It is a form of plastic and stands for unplasticised polyvinyl chloride. It is also
known as rigid PVC due to the fact that it is hard and not flexible. It is a resistant form of PVC
that is often used for pipework
SUPPLIER

HDPE from IOCL, Panipat, Haryana.

BALA JI ENTERPRISES REPOL POLY PROPLYENE (from RELIANCE

PETROCHEMICAL INDUSTRY LTD.) VADODARA GUJARAT

MACHINES THAT WILL BE USED

1. INJECTION MOULDING MACHINES (6)

2. IMM1 VISHKARMA
 3. IMM2 NIGARIBUSHI (JAPAN)

4. IMM3 FAIRMATIC

5. IMM4 NISAI (JAPAN)

6. IMM5 JSW

7. IMM6 MIRCHIBUSHI

MANPOWER PLANNING

 Manpower Planning involves two stages planning of manpower requirements

,planning of manpower supplies and determining the number and types of
employees to be recruited or phased out of the organisation. It involve the
forecasting for the future and finding out how many employees will be needed in
the future by the business and what types of skills should they possess.

 The manpower planning of Jb industries provides they use the optimum amount
of manpower to complete the order of the customer in time .they avoide facing the
dilemma about the over or less manpower resources.

 Daytime 45

 Night 25
  Skilled 05

 Electricity bill-1.8 lacs to 2.0 lacs per month

FACILITY LOCATION

 CHEAP LABOUR

 LOW RATES FOR ELECTRICITY Rs. 6/UNIT & 24 HRS.VAILABILTY

 AVAILABILITY OF WATER

 CHEAP LAND

 SAFETY

 INFRASTRUCTURE

 FAVOURABLE ENVIRONMENT

MARKET

 DELHI

 UTTAR PRADESH
 BIHAR

 HIMACHAL

 ASSAM

 MADHYA PRADESH

 RAJASTHAN

SELLING PRICE:

49% OF THE MRP

COST PRICE:38% OF THE MRP PROFIT :11% OF THE MRP

BATCH PRODUCTION

Different types of products require different moulds, raw material, temperature range, etc. When
the order is received from headquarter we start the production according to the demand.

In the production of pipe Fittings , thousands of fittings are processed as a batch. The tiny
Fittings, are then separated and individually assembled with other fittings elements on a
continuous line to produce the final product.
DIFFERENT MOULDS FOR DIFFERENT PRODUCTS

RAW MATERIAL It depends on the type of location of the suppliers as different suppliers are at
different location. Reliance petrochemical industries ltd. Order is received after 5 days of
placing the order. IOCL Order is received on the 3rd day of the commencement of the order.

PLASTIC GRAINS WITH DYE TO HAVE DIFFERENT COLOURED PRODUCTS.

PVC Pipe Manufacturing Process Flow Chart

In the manufacturing process, various steps are taken as follows:

#1. Extrusion

PVC uncompounded resin, unlike some other thermoplastics, is not suitable for direct
processing. To confer the required processing and end instability, it is necessary to mix additives
with the PVC resin. Following are some of the additives which are generally used for the
manufacture of rigid PVC pipes. Plasticizers:
#2. Sizing

The pipes coming out from the extruder is cooled in the sizing operation. There are basically two
types of sizing used for manufacturing of pipes. They are (i) Pressure sizing & (ii) Vacuum
sizing.

#3. Traction

The next operation needed after sizing is traction. The tube traction unit is required for
continuous haulage of the pipes being extruded by the extruder. Cutting: The last operation
needed is cutting. There are basically two cutting techniques for rigid PVC pipes viz. manual and
automatic. The pipes are then tested for ISI marks and are ready for dispatch.

#4. Cutting

The last operation needed is cutting. There are basically two cutting techniques for rigid PVC
pipes viz. manual and automatic. The pipes are then tested for ISI marks.
FLOW CHART
 Market Potential

The Indian PVC pipes market is growing at a healthy rate due to tremendous government
spending on infrastructure. The construction sector and the agricultural sector are expected to
boost demand for PVC pipes in the future. PVC pipes are used for a variety of purposes e.g.
water supply schemes, spray irrigation, deep tube well schemes and land drainage schemes.

PVC slotted and corrugated pipes are ideal systems for drainages of water from the land where
water logging is inevitable. In view of the priorities to rural water suppliers, irrigation facilities
in the national planning, immense growth in the construction industry and rapid rural
electrification, the demand for rigid PVC pipe is growing regularly. The 60% of the total demand
of PVC pipe exist today is up to 110 mm outer diameter.

The Chief Advantage of PVC are:

1. Resistance to corrosion

2. Light weight

3. Toughness

4. Rigidity

5. Economical in laying

BUSINESS PROCESS WITH RESPECT TO THE PRODUCT

CUSTOMER OREDER

ORDER RECORDING DELIVERY INVOICE PAYMENT

PRODUCTION SHIPPING

Production Planning

Production Planning is the future of production .it can help in efficient manufacturing or setting
up of a production sites by facilitating required needs . Production planning also said to be a
techinque of forecasting , every step in the long process of production , taking them at right time
and trying to complete operation at maximumefficiency . it can comprise the following
activities :

 Determination sequence of operation for continuous Production

 Planning plant capacity for future production programmes

 Matching the required level of production to the existing resources

 Setting up and delivering production orders to production facilities .

In the plant of industries

In order to developed production plan ,the production planner or production planning

department needs to work closely together with the marketing department and sales department .
They can provides sales forecasts , or a listing of customer orders. As per the listing of customer
orders production Planning are made and worked upon.
Raw material Planning

Material planning is a Production planning , scheduling and Inventory control System used to
manage Manufacturing processes . it provide the right part at the right time to meet the schedules
for completed products. It also balance the demand for materials wityh the supply of materials so
that an appropriate quantity of materials is available when they are needed.

 The raw material planning of JB Industries provides the pull system , order is received
after 5 days of placing the order wherein the customer first places an order and
accordingly the company forecast the amount and types of raw material they will
purchase.
  PVC grain

 UPVC

Operational Planning

Organisation of an overall manufacturing system to produce a product to provide a physical

system together with a set of operating guidelines for efficient conversion of raw material
,human skills and other inputs into finished products. Operational plan does present highly
detailed information specifically to direct people to perform the day to day tasks required in the
running the organisation .

 The operational plan of JB industries provides the what ,who ,when and how
much :-

 What – the stragies and task must be undertaken

 Who- the person who have responsibility of each of the tasks

 When-the timelines in which task must be completed

  How much –the amount of financial resources provided to complete each task

WASTAGE

The total waste produced is 5% of the total production. Which is later on send for recycling
process.
Warehousing Planning

Need for storage arise both for raw material as well as finished products . it involves proper
management for preserving goods from the time of their production or purchase till actual
use.this storage is done on a large scale in a specified manner .it create time utility by bridging
the time gap between production and consumption of goods .

 The warehousing plan of jb industries shows that they have prioper space
for the raw material and the inventory .there is uninterrupted movement of
materials ,people and traffic within its building .
MAINTENANCE

There are two ways to do the maintenance of extrusion machine, which are

1-daily maintenance

2-periodic maintenance

 Daily maintenance

Daily maintenance is routine work, and doesn’t occupy the operational working hour. usually it
can be finished when the machine starts. The key is to clean the opponents and lubricants every
piece inside, fasten threaded fitting, check and adjust the electrometer, control the meter and so
on.

 Periodic maintenance

Periodic maintenance is done timely, it usually begins with the extrusion machine continuously
work for 2500 to 5000 hours. Machine needs to be separated into piece for the checking,
measurement and examination of the opponents condition. Then the ruined opponents can be
changed and broken ones can be fixed.

PLANT LAYOUT

Plant layout is the most effective physical arrangement, either existing or in plans of industrial
facilities i.e arrangement of machines, processing equipment and service departments to achieve
greatest co-ordination and efficiency of 4M’s (Men, Materials, Machines and Methods) in a
plant.

Layout problems are fundamental to every type of organization/enterprise and are experienced in
all kinds of concerns/undertakings.

1. Product or Line Layout:

The raw material is supplied at one end of the line and goes from one operation to the next quite
rapidly with a minimum work in process, storage and material handling. Fig. 3.3 shows product
layout for two types of products A and B.
2. Process or Functional Layout:

This layout is commonly suitable for non-repetitive jobs. Same type of operation facilities are
grouped together such as lathes will be placed at one place all the drill machines are at another
place and so on. See Fig. 3.4 for process layout. Therefore, the process carried out in any area is
according to the machine available in that area.

3. Fixed Position Layout:

In this type of layout the major component remain in a fixed location, other materials, parts,
tools, machinery, manpower and other supporting equipment are brought to this location.

4. Combination Type of Layout:

This type of layout is the combination of the process and product layout.

The Plant Layout of KSM Industries shows that, they have Product or Line Layout as all
the processing equipment and machines are arranged according to the sequence of
operations of a product. In this type of layout, only one product or one type of products is
produced in an operating area. This product are standardized and produced in large
quantities in order to justify the product layout. The raw material is supplied at one end of
the line and goes from one operation to the next quite rapidly with a minimum work in
process, storage and material handling .