Start a Plastic Footwear Making Plant

Start a Plastic Footwear Making Plant

The plant outlined in this proposal is just one of several dealing with the production of shoes. However, this plant is unique, in that many types of materials may be used to produce a wide variety of shoes including: PVC shoes, sandals, and slippers, genuine leather boots, high-heeled shoes for women, dress shoes for men, as well as a wide variety of casual shoes for men and women. The benefits of establishing a plant with the capability of producing such a wide variety of sizes and styles are obvious, particularly from a marketing point of view. An equally important benefit of operating such a plant is the fact that these shoes can be made from so many different types of material including leather, synthetic leather, canvas, and nylon, as well as PVC, PU, EVA, and rubber. The owner of such a plant can be sure he wills he able to keep up with the demand generated around the world for a wide variety of shoes. Of course the demand for shoes will never decline. Virtually, everyone in the world wears shoes everyday of the year and as the world’s population and its standard of living increase, the quantity of shoes sold in a given period of time will increase proportionately. All of this, in conjunction with the fact that shoes inevitably wears out means that the demand for shoes will continue to raise. This, of course, is no secret to the manufacturers of shoes in the Republic of China, which have, for more than twenty years, been involved in improving the methods and machinery used in producing shoes of all types. The endeavors of these companies have made the Republic of China the number one exporter of shoes in the world. It is, therefore, only logical that anyone wishing to make an investment in any country where the people desire to purchase comfortable, attractive, durable, and inexpensive shoes, would want to take advantage of the years of research done by the shoe makers in Taiwan and purchase the shoe making plant outlined in this proposal.
General Process Information
Process Description: Since a single plant can produce so many types of shoes, it is not possible to go into a full process description of every shoe. However, the process of making ladies shoes described below outlines the basic steps involved in fabricating most kinds of shoes.

• Material Preparation
• Upper
• Cutting

Sheets or strips of the materials used in making the upper of the shoe are cut into smaller segments by an automatic cutting machine as illustrated in figure number 1.
The cutting die being used determines the size and shape of each segment. If leather is being used, it is first split into the desired thickness.

• Folding and Binding -before being sewn together, the edges of each segment are automatically folded and bound.
• Stitching -The bound segments of material are then sewn together by a sewing machine to form the upper of shoe, as illustrated in figure number 2.
• Thermoplastic toe boxes, designed to provide support to the toe of the shoe, are made and inserted by a toe-puffing machine. At this point, the uppers are forwarded to the assembly line for further processing.
• Insole -The material used to make an insole is cut into the desired shape and size by the same machinery used in cutting the uppers.
• These segments of material are glued to the shank and shank-board. After gluing, the mid sole is molded to fit the sole of the shoe, as illustrated in figure 3.

• Sole and Heel -The soles and heels of shoes can be made from PVC or a wide variety of other materials including leather, rubber, cork, and synthetic leather. Heels and soles made from materials other than PVC are assembled from preformed materials as illustrated in figure 4. The process of making PVC soles and heels described below is also the process, in its entirety, of making the PVC sandals, slippers, and shoes mentioned in the introduction.
• The appropriate quantities of coloring and forming agents are added to PVC and mixed to a consistent texture. (It should be noted that premixed materials are readily available on the open market.)
• The PVC mixture is then fed into the holding tank of the direct injection-molding machine.
• The appropriate molds are attached to the machine.
• The machine then automatically heats, mixes, and injects the PVC mixture into the mold cavities.
• After solidification has taken place, the molds are opened and the shoes or soles are removed.
• Both the heel and outsole re purchased from the outside source. The heel is cemented, coated with heel lift, and then sealed with top lift, then sealed with top lift. Finally the heels are cemented with the outsole as in figure 5.

• The shoes are visually examined for flaws, packed, and then stored or shipped.
• The PVC soles are forwarded to the assembly area.
• Production Lines:
• Lasting: The insole in nailed to the last and the back part of the upper is molded into shape by machine designed for that purpose. The completed upper is put into the last and lasted by the lasting machine as in figure 6 and 7.
• Forming: The sole is cemented to the upper by using high strength glue and heat-set as in figure 8. The sole is pressed to ensure the seal with sole attaching machine.

• Arrangement & Packing: The shoe is cooled and removed from the last as in figure 9. Then, the nails are imbedded in the heel with machine. Any thread or other waste material is removed by a hot air blower. Foot patch is inserted into the shoe. The metal detector is used to check for needles which protrude from the shoe during the manufacturing process. Finally the shoe is cleaned and visually inspected for flaws or defects and packed into boxes.
• Finishing, Inspection and Packing
• Any thread or other waste material is removed by a hot air blower. Shoelaces and insoles are inserted into the shoes. A metal detector is used to check for needles, which may have been imbedded in the shoe during the manufacturing process. Finally the shoe is cleaned and the shoe is cleaned and visually inspected for flaws or defects and packed in to boxes.

Plant Description
Production capacity: The production capacity of a plant will vary depending on the number of machines used, the allocation of manpower the overall production efficiency and the type of shoe being produced. For example, a plant equipped with the machinery and equipment described in section 3.4, utilizing the number of workers described in section 3.3, should be able to produce 2000 pairs of ladies shoes per eight hours. However, inefficient operation of the plant could drop that figure to as low as 1200 pairs for the same period of time.
Raw Materials: The materials needed to make ladies shoes are listed below. Few other materials, if any, would be needed to make other types of shoes.

• Box toe: Thermoplastic
• Upper: Wet PU sheet, Dry PU Sheet, Canvas, Leather, Nylon Cloth
• Lining: Dry PU Sheet, Split Leather, Foam, Tricot
• Foot Patch: Sponge, Foam
• Counter Pocket: Non-Woven Cloth, suede
• Heel: ABS, #475 ABS, Cork
• Heel Lift: Dry PU Sheet, Wet PU Sheet, Cork
• Top Lift: Injection-PU, Nylon, PVC, Cutting-PVC, Rubber
• Outsole: PVC, PU, EVA, Rubber
• Insole: Texon, Supertex
• Shank: Low Heel-Iron (1.2mm or 1.0mm)
• High Heel-Steel (1.2mm or 1.0mm)
• Shank board: Red, Blue or Black Hardboard (2mm or 1.5mm)
• Buckle
• Ornament
• Gore
• Latex
• Bond
• PE Bag

Machinery and Equipment

No.	Item	Set
	Machines for Insole Molding division:
1	Insole molding conveyor (18m long) (include 1-9.6KW heating case,	1
2	Shank board skiving machine,	1
3	Shank riveting machine	1
4	Mid sole molding machine, and	1
5	Insole shaving machine)	1
	Machines for sole injection molding division:
6	Chipping machine	1
7	Mixing & drying machine	1
8	Injection molding machine	2
	Machines for Cutting Division:
9	Hydraulic cutting machine	3
	Machines for Stitching Division:
10	Leather skiving machine	3
11	Edge folder for vamps & leathers	2
12	Edge binding machine	2
13	Flat bed single needle sewing machine	10
14	High post double needle sewing machine	10
15	High post single needle sewing machine	12
16	Trimming machine for inner lining & sole	2
17	Thermoplastic toe puff applying machine	1
	Machines for Production Line Division:
18	Lasting conveyor (18m long)
	(Including 19.6KW heating case and vulcanizing machine)
19	Forming conveyor 20m long	1
	Including 1-2.4KW, 1-6.8KW, 1-9.6KW heating case and rapid cold forming machine
20	Arrangement & packing conveyor (12m long)	1
21	Air nail tool	1
22	Back part molding machine	2
23	Front lasting machine	1
24	Rear rimming machine	1
25	Sole grinder machine	1
26	Sole attaching machine	1
27	Last slipping machine	1
28	Heal nailing machine	1
29	Packing machine	1
30	Air compressor	1

Miscellaneous Equipment

• Shoe Lasts -Approximately 1,200 pairs of aluminum or plastic lasts are needed for each production line.
• Tooling Equipment -Some hand tools will need to be purchased such as: tensile strength tester, hammers, pliers, are measuring needles, cutting dies, hold punches, and scissors.
• Spare Parts -Any spare parts needed during the first two years of operation will be supplied. This will account for approximately 10% of the total investment.

Manpower Required:

Job Classification	Person
Staff	30
Operator	120
Total	150

Utilities: Electricity 150KW
Plant Site Planning: A shoe making plant located in any region where adequate supplies of the raw materials needed are easily accessible, should have no problem making money, providing the area in question is developed enough to provide electrical power, adequate ways and means of transportation, and a capable work force.


List of Suppliers:
King Steel Machinery Co., Ltd.
No. 22.7th Rd., Industrial Park. Taichung, Taiwan.
Tel: 886-4-23503999
Fax: 886-4-23503998
E-mail: webmaster@kingsteel.com
URL: http://www.kingsteel.com

Start a PP Woven Sack Making Plant

Start a PP Woven Sack Making Plant

Onion bags are widely used in Agricultural products packing purposes, such as onion, potato, garlic, ginger, green piper, paprika, orange…. etc. Further more, in addition to agricultural products the seafood is also available such as mussel, crab, oyster…etc.
Onion bags are mainly used for packing purpose, it were made by double needle bed Raschel knitting machine. Through the special function of knitting machine, each of the mesh loop all stitch together making the bags stronger then any other type of mesh bags. It can make full piece of bags, including the threading of the bags mouth, the size of the bags can be flexible adjusted in the machine. When equipped with our new improving yarn feeding systems (Slitting & Extension machine), the bags will be lighter with the same strength, increasing the competition in the world market with the material cost down.
Beside the bags making function, the line also can made the light duty extra wide nets, for shading and safety purpose, if not using the bags making function, it can using the side stitch function to made nets, from it’s one side stitch maximum can made up to 10 M width nets, it was a special function for the double needle bed Raschel knitting, it give the customer more choice.
Raschel knitting onion bags making plant, its working process is very simply, the whole turnkey project only need three process including the final packing,
Compare to the circular loom, weaving machine the Raschel knitting bags making plant are more efficiency and competitively, it save the man power, electric consumption, raw material, plant occupy, one times investment bring you whole profit.

General Processing Information:

• Mixing machine: Different color of bags is for different kind of agriculture products & fruits packing, so high density polyethylene (HDPE) should mix with color pigment to stir even and then send to blown film machine.
• Inflation machine: PE materials sent to heated cylinder to stir fully and paste form, then strongly extruding 0.05mm – 0.12mm thickness, 900 mm – 1200mm wide of tubular films, two layers of films separate automatically and wind into two rolls of PE films back to back. The diameter of each roll of film is about 750mm – 1,000mmØ, the weight is about 500kg – 750kg.
• Double Raschel knitting machine: 1 set of double Raschel knitting machine attached 4 sets of Slitting and Extension machine, per set of slitting unit mounted two rolls of film, the total weight of eight rolls of film are about 4,000kg – 6,000kg. Through slitting and extension machine it was like a automatic yarn feeding systems, 500 denier tape yarns will be finished and directly sent to the knitting machine’s main stitching elements to knit the designed bags, the finished bags can be (A) direct cutting by the on-line auto cutting device or (B) rolled up by automatic winder. The tie-string is also auto-inserted for the bags opening mouth.
• Cutting equipment: Working on line with the knitting machine, on the machine the design bags is connected to each other, between two bags have a cutting line mark, after heat cut to the cutting mark the bags will be speared and sent to the platform, in the platform it can setting the bags numbers, when it up to our setting number then will pull out, for example: we setting the bags number is 50 pieces, each 50 pieces will pull out by the platform then sent to the pressing for packed.
• Heat cutting machine: by manual -Sent a roll of connected bags to the cutting machine, which is operated with human labor and cut the connected bags into one piece of bag with heater, after measuring the bags numbers then sent to the pressing machine for packed.
• Hydraulic baling presses: Separate different sizes of bags and measuring a number of bundles, then put into hydraulic baling presses to press smaller volume packages for covenant transpiration.

Products Description:

• Name: Onion Bags, 16,000,000 pieces of 50cm x 80cm onion bags, for 300 working days, per days for 3 working shift.


• Raw Material: High density Polyethylene (HDPE).
• Specification: 500 denier flat yarn, 2 gauge/1”, 6course/1”, the bags size can be adjusted according to the customer’s require. The bags size if small then the output will increase.
• Net weight: 50 cm x 80 cm 30 gm, per piece
• Packing capacity: 50cm x 80 cm (50 lb. onion or potatoes).

Plant Description
Equipment Requirement:
1. Inflation machine: TGI-85, one set
Screw: 85 mm Ø, L/D: 30: 1
Power Consumption: 118 kW
Film thickness: 0.05mm – 0.13mm
Capacity: 65 kg – 90 kg / per hour
Occupy place: 11 M (L) x 4.5 M (W) x 5.5M (H)
Operator: 1 person
2.Double Rascel Knitting machine: DR-2-F-170, 4 sets.
Working width: 170”
Gauge of needle bed: 6 gauge / per inch
Gauge of needle: 2 gauge / per inch
Knitting element: 2 compound needle bars, 4 ground bars and 5 functional bars.
Yarn let-off systems: By Slitting & Extension unit.
Auto-stop device: Drop-wire stops motion in each yarn, controlled by electrical contact
Power consumption: 9 kw.
Capacity: Max r.p.m. 700 course, Normal working r.p.m. 640 course, for 50cm x 80cm, warp yarn: 2 gauge / per inch, weft yarn: 6 stitches / per inch, per hour about 590 pieces for one machine.
Occupy place: 6.5 M x 12 M (including Slitting & Extension machine).
Operator: 1 person.
3. Slitting & Extension machine: SE-130-N, 16 set (one set of knitting need 4 sets of S&E machine)
Working width: 120 cm.
Power consumption: 6.2kw.
Capacity: It can offer the flat yarn from 200 – 1000 denier; the speed was going with the knitting m/c.
Occupy place: 1.5 M x 1.46 M x 2.4 M.
Operator: operated by the same operator of knitting machine.
4. Cutting device: In this device we have two optional choice, (A) On-line auto cutting. (B) Manual.
On-line auto cutting. Auto cutting device: it was on-line with the knitting machine, total need 4 sets.
PLC control:
Power consumption: 3.75 kW
Capacity: the same as the knitting machine.
Occupy place: 1.5 M x 5.2 M
Operator: Operated by the same operator of Raschel knitting machine.
Heat cutting machine: by manual, total need 6 sets.
Pneumatic control:
Smoke extractor: 1/4 HP
Heater: 2 kW
Capacity: 500 pcs / hour. (depend on the operator skill, will be more or less)
Occupy: 1.5 M x 2 M.
Operator: 1 person.
5. Hydraulic baling presses: HP-60T, 1 set.
Capacity: 60 Tons.
Electric Power: 20 HP.
Table size: 120cm x 80cm.
Occupy place: 2 M x 2.5M.
Operator: 2 persons.
Manpower Requirement Man power: working for 3 shifts, per shift for 8 hours.
With on-line auto cutting device: 24 persons (it was actual working for the production line not including the office staff).
With manual cutting: 42 person
Raw Material: Raw material preparation: it suppose the production is 50 cm x 80 cm bags, weight is 30gm for per one piece, for 1 month it require at least 50 tons of HDPE, for each different country’s marketing we strong recommend to prepare at lease 3 months storage.
Power Consumption Total electric power: 290 kw for on-line auto cutting device, 300 kw for manual cutting.
Technique Guide, Training & Technology Transfer:

• The seller is responsible for dispatching technician to buyer’s plant to install the machinery, till the sample to be made and installation is complied. The to and fro plane ticket and accommodation of the technician are supported by the buyer, the buyer will pay technician guide salary, one person is USD 180- per day.
• For the Training & Technology Transfer issues, we have a full set of project program for the customer, mainly it was design according to customer situation and require, before we offer them the program will fully discussed with customer.

Suppliers Information: FUNG CHANG INDUSTRIAL CO., LTD.
9, Shih Chi Tau, Kaoping Village Lungtan Hsian,
Taoyuan Hsien, Taiwan
Tel: 886-3-4717824, 4717825, 4717453
Fax: 886-3-4717702, 4580170,
E-mail: fungchan@ms3.hinet.net
Web Site: http://www.fungchang.com