FILE: ISIC 3 How To Start Manufacturing Industries Porcelain Insulator Making Plant ‘There is a wide variety of electric porcelain insulators which are used for supplying electricity, and the quality and shape differ depending on the use. ‘There are the super high-tension and high-tension insulators used for trans. mitting electricity along a transmission Tine from the power station to the substation, There are the high, middle, and low-tension insulators used for transmitting electricity from a sub: station to the consumer through an electric power company. And there ate other types of insulators which go with the transmitting and supplying systems The demand of electric insulator is constantly increasing with regional development, rise in cultural and living standards of a nation, and the improve: ment in conditions of electric supply. The teend in various countries is toward domestic production, depending on internal conditions. Depending on the variety and use, however, the method of manufacturing requires high skill, technology, and knowledge. ‘The manufacture of super high-tension glass insulator, especially, requires high manufacturing technology In planning to establish an insulator plant, it would be advisable to begin manufacturing low-tension and hi tension insulators which are easy to manufacture, or something similar with a simple shape; then, by gradually acquiring the manufacturing technology, manufacturing should shift toward more complicated shape or high-tension insu. lators. This is the quickest way to suc- ceed in the project. A plant which is capable of producing 800 tons per year of four items (nine types) of insulators which are relatively easy to manufacture and which have a huge demand has been given here as a model. The production items are shown in Table-1 As a characteristic of ceramic indust- ry, research of raw materials and body requires a considerably long time. Accordingly, in taking up this plan in the actual plant, sufficient research of raw materials available in respective countries should be effected before setting up the plant. This plan on the supposition that the problem of raw materials has been solved in one laid out Table 1: Production Scheme Production quanti Item ——— palyeny Gomlyear “Pin type insulator Large 300,000 5 510 ‘Small 230,000 ......... 161 Strain insulator Large ......+ 30,000 36 ‘Small. 30,000 21 Spool insulator Large 100,000 50 Small 100,000 2.10 Wire holder Large 20,000 . . 10 Middle... 30,000 . 9 Small 20,000 3 Total 860,000 pes./year 810 tons/year Table 2: Operation Condition 1) Firing unit 3 shifts per day, 8 hours per shift 350 days/year 2) Other celevant unit: 1 shift perday, 8 hours per shift 300 days/yearway or another. Ceramic industry also requires con- siderable time in the aquisition of production technics and the training of skilled workers. For this reason, in setting up the porcelain insulator plant, the manufacturing should be started from comparatively simple types and extended gradually to more com- plicated ones. Producing insulators up to standard quality requires materials of high quality, and it will be desirable co acquire these materials in respective countries. But if self-support is not possible, it will be necessary to import them. Any obstruction in the way of the import will cause an immediate impediment to the production. ies of considerable scale will be required for the study of raw materials and green body, and the test of pro: duets, but in, view of the scale of the plant proposed in this plan, it will not be possible to install in the plant such scale of laboratory and testing equip- ment. Therefore, maximum assistance should be obtained from ceramic laboratory, electric testing institute and others situated in respective countries. Also, as for maintaining and repair- ing machinery and equipment, co- operations with maintenance workshop would be necessary. But the minimum facilities required to manufacture machine tools used in the plant must be prepared. Table 3: Required Raw Materials Main raw materials and subsidiary materials are quartz, feldspar, kaolin, ball clay or plastic clay, limestone, gypsum plaster, alumina, ete. The consumption will be about 1,300 tons/ year. Yearly required quantity is shown below. Yearly required om _quantity (tons) Feldspar 240 Kaolin : 200 Silien 2021) 420 Ball clay (plastic clay) 340 Limestone or Dolomite 20 Gypsum plaster... . 40 Alumina... 02 Tap bolt a 40 5 1,300.7 Tora Fig. 1: Process Flow Sheet for Porcelain Insulator Making Plant Glaze materials Gay materia] [Sony mater] [Gypoum plas] Weighing. \ Grinding Screening (& Magnetic separation Storage —— & Magnetic separation Glazed Weighing, | Mixing [Gypsum mould Casting slip Casting | Inspection Ly Fitting Inspection PRODUCTSFILE: L ‘Table 4: Required Machinery and Equipment Kem Quantity 5) Gypsum mould making section Item ‘Quantity Plaster mixer... + wees se Lset Finishing jigger machine 1 set ishing hand jigger .- cece hl Beet Jaw crusher... 1 set Fhe ee se Rotating screen set a ee aaa ' Roll crusher set 6) Fittings setting section Ball mill (4,000 kg) « + 2sets Mixers... 1 set Ball mill ( "400 ke) - vies Resets Setting tools. lot Filter press : Laet 7) Laboratory equipment Diaphragm pump . 1 sat Pot mill with driving unit . . 2 set Magnetic separator . . 2 sets Mortar with pestle. . 2set Vibrating screen . 2 sets Standard screen . «+ Lot Agitator . A sets Electric test kiln... fe : 1 set De-airing auger machine Lact Testing tools sss. 1 lot Care aoe 20 sets Extruding machine we 1 set Weighing balance ; 2 sets Refractoriness testing apparatus pees Bele conveyor 2 sets t convey 8) Workshop 2) Moulding section Bench dell BosbEseneeeoReee Fs Semi-automatic moulding press sets Grinder ‘A set ‘Semi-automatic finishing machine . +S sets rake set Casting apparatus Lset ~ Continuous dryer 4 sets 9) Others Hot aie geneettor » set Water supply facilites 1 oni Ce 35 sets elcrerhead tank water pump, pipe and fittings, sets) say sect letrie supply facilities... . wi a eae a oa 1 (receiving facilities for primary input, transformer, amber dryer set distributions panel, lighting equipment, wiring Glazing conveyor and accessories . set materials and fittings ete) 4) Firing section Fuel oil supply facilities . 1 oni Endless type tunnel kiln. set (main oil tank, ol service tank, eae ° ‘ho sets strainer, pipe and fittings, ete.) ‘Transportation equipment 1 set FOB price of machinery and equi (shovel loader, forklift teuck) ment (approx.) SUS 1,233,001 Table 5: Required Us 1) Fuel oil (Light diesel oil) 2) Blectric power ..... 550,000 kWh 3) Industeial water... .. . 6,000 m? 4) Machine oil. « 2ke 5) Grease see ce eee e eens ORR Table 6: Required Manpower Item No. 7 manager Tose Engineer... 4... aeeeeas| Clerical worker +3 Foreman . . eeeeereeess| Skilled worker . 25 Unskilled worker - Total Locational Condition ‘The main factors of selecting the location for porcelain insulator manufac. turing plant are as follows: (1) Raw materials easly available (2) Easy-torget utilities (clean water, electricity and fuel oil) (3) Free from iron contamination (4) Near the atea of consumption (5) Machine works for maintenance ble (6) Good workers available Table 7: Required Area for Plant Si oes Tome oma 000. 2) Badge: Otel ndiabortor: * 1oma tome 200 Sundown me am £105 informacion as been pepued by. the Japan Consulting Institute Gedy and’ reproduced by UNIDO With special permission from JCI Further reproduction of this docu- 3 ovene ithour permission of Jct is § probivies Any inguiry about the information Fans eat eet Blorcoor, egisry “ile “No. 1D) 562/12, UNIDO, P.O. 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