Full PVC Footwear

Home » Technology » Project Profiles » Leather » Full PVC Footwear
Product Code 301201005
Quality and Standards (1) PVC Sandals IS 2167:1972
(2) PVC Industrial Boots IS 12254:1993
Production Capacity Quantity: Pairs 1,50,000
Value: RS. 41,25,000
Uploaded on March 2007


Full PVC Footwear such as Chappal, Sandals and Shoes are popular in Indian Market due to their cheap prices, durability and easy maintenance and affordability by a common man. Used PVC footwear containing basic rawmaterial i.e. PVC can again be used for making cheaper types of footwear. The plant and machinery and raw materials are available indigenously. The PVC Footwears are generally light weight and very comfortable to wear in rainy seasons.

Market Potential

PVC Footwears were introduced in 1964 and it gained momentum in 1967. Initially, plants and moulds were being imported generally of multisation type. Although the capacity creation was restricted due to shortage of rawmaterial, additional capacity continued to be created with indigenously available two-station machinery and moulds. The capacity at present is estimated 300 million pair per annum. There is scope for setting up these units in rural and backward areas using PVC granules in combination units PVC Scrap materials.

Basis and Presumptions

  • It is proposed to manufacture 500 pairs per day on double shift(each shift=8hr) basis of 16 hours duration and 25 working days in a month.
  • The project may take 3 year to achieve full capacity utilisation depending on various factors.
  • Labour charges has been given on per month basis including 15% of perquisites for 25 working days.
  • The rate of interest for both fixed and working capital is assumed at 12% per year.
  • The entrepreneur is expected to raise 20 to 25% of the capital as margin money.
  • The operative period of the project may be given 10 to 15 years considering obsolescence of technology. The loan may be paid back within 10 years. The unit is proposed to function in own building.
  • Cost of machinery and equipment has been taken as per the rates quoted by machinery manufacturers/suppliers.

Implementation Schedule


Duration (in Week)

Arrangement of Finance 1st to 8 th
Arrangement of Electric Supply 8th to 30 th
Procurement of Machinery 15th to 30th
Selection of personnel 20th to 30th
Installation of Machinery 30th to 38th
Trial Production 39th to 40th
Commencement of Commercial Production 40th

The unit is expected to start commercial production from 40th week onwards.

Technical Aspects

Process of Manufacture

As per the design of the sample, PVC Footwear to be manufactured, the moulds are obtained and fitted in the machine. Then the PVC compound is fed according to requirement into a heated cylinder from sopper either in strip, granular or powder form. Ceramular form is more common. The Injection Cycle starts with closing and locking of the moulds under pressure either applied by hand or mechanical levers or automatically by hydraulic or pneumatic power. When PVC in the cylinder is sufficiently softened by heat, the same is forced forward by ram or screw action through an intermediate channel known as 'SPRUE' into the mould until it has cooled down to a state of sufficient rigidity and the pressure in the mould relaxed. The time cycle, therefore, can be adjusted into several stages, namely, mould filling time, dwell time under pressure, cooling time and mould opening time. The cooling time usually is the longest of all and has to be cut especially in small machine and the same has been recommended in the project.

PVC compounds are available as natural/transparent granules. Prior to use, colour concentrate granules known as master batches are mixed with the natural PVC Compound in the required proportion to give the desired colour. Initial mixing can be done in any convenient container units, a scoop or small showel. The final mixing is automatically achieved in the cylinder of the moulding machine.

The PVC compound, suitably mixed with the master batch is fed into the sopper of the machine. Normally 10 to 12 kg. PVC compound are fed at a time. Shore hardness of 70 to 78 for PVC granules temperature of 160oC and pressure of 80 lbs/square inch gives satisfactory results.

The main operations are

  • Feeding of PVC granules into the sopper
  • Trimming of surplus materials
  • Cleaning and spraying (if required)
  • Fixing of fittings
  • Checking and Packing.

Quality Control and Standards

Following specifications are followed to customer's requirements

  • PVC Sandals IS 2167:1972
  • Polyvinyl Chloride Resins Method of text IS 4669:1968.

Production Capacity

Quantity 1,50,000 pair
Value Rs. 41,25,000
Motive Power 2 KW.

Pollution Control

There is no pollution in the manufacturing of PVC Footwear.

Financial Aspects

Fixed Capital

Land and Building
Land 500 sq. mtr. @ Rs. 3500 per sq. mtr including registration 700000
Cost of land development, fencing, approach road, inside roads, land scaping, drainage etc. @ Rs. 1000 per sq. mtr. 500000
Total built-up area 425 sq. mtrs. as follows  
Administrative building 75 sq. mtrs. construction cost @ Rs. 7,500 per sq. m 562500
Factory shed 300 sq. mtrs. construction cost @ Rs.5000 per sq. mtr. 1500000
Stores, staff canteen etc. 50 sq. mtrs. @ Rs. 6,000 per sq. mtr. 300000
Water System (including Bore Well + over head tank etc) 500000
Total civil cost= cost of land + building = 17,50,000+3362500 5112500

Machinery and Equipments


Imp./ Ind.


Value (Rs.)

Six Station PVC Injection Moulding Machine fully automatic Rotary Type Ind. 1 1000000
Cost of Moulds 4 Sets each consists of four sizes sandal and shoes   1 200000
Tools and Equipments/ Jigs and Fixtures     50000
Cost of Office Equipments, Working Table, Racks, Trollies, Stools etc.     250000
Excise, sales tax & erection and installation charges 40% of total of 1 to 4     600000
Total     2100000
Pre-operative Expenses 100000
Total 7312500

B. Working Capital (per month)

(i) Personnel (per month)



Rate (Rs.)

Total (Rs.)

Manager 1 15,000 15000
Engineer Mechanical/Electrical 1 10,000 10000
Designer 2 7,000 14000
Supervisor 2 7,000 14000
Accountant/Cashier 1 6000 6000
Clerk-cum-typist 1 5,000 5000
Chowkidar 1 3000 3000
Skilled Workers 6 6,000 36000
Un-skilled Workers 12 4000 48000
Total     151000
22% Perquisites on Total Salary 33220
Total 184220
Say 184220

(ii) Raw Material (per month)




Rate @/unit (Rs.)

Value (Rs.)

PVC Granules 5600 Kg 70 392000
Master Batch (Colour) 110. Kg 130 14300
Fittings, Buckles, Button and Lacer etc. 12500 Pairs 5 62500
Packing Material 12500 Pairs 4 50000
Total 518800

(iii) Utilities (per month)


Amount (Rs.)

Power 5,000 kWH 25000
Total 25000

(iv) Other Contingent Expenses (per month)


Amount (Rs.)

Repair and Maintenance 10000
Postage and Stationery 15000
Travelling Expenses 15000
Telephone/internet etc 10000
Consumable Stores 20000
Advertisement and Publicity 100000
Insurance 7000
Sales Expenses 40000
Misc. Expenses 20000
Total 237000

(v) Total Working Capital (per month)


Amount (Rs.)

Personnel 184220
Raw Material 518800
Utilities 25000
Other Contingent Expenses 237000
Total 965020

vi) Working capital is considered for an average working Capital cycle of 1½ months

Hence, Working Capital (965020 * 1.5) 1447530

C. Total Capital Investment

Fixed Capital 7312500
Working Capital 1447530
Total 8760030
Machinery Utilisation 70% - 80%

Financial Analysis

Cost of Production (per annum)

Amount (Rs.)

Total Recurring Expenditure 11580240
Depreciation on Machinery @ 10% 120000
Depreciation on Building @ 5% 255625
Depreciation on Tools-dies @ 25% 12500
Depreciation on Furniture @20% 50000
Interest on Total Investment @ 12% 1051204
Total 13069569

Turnover (per annum)



Rate (Rs.)

Value (Rs.)

PVC Shoes and Sandals pairs 1500000 100 150000000

Net Profit (before taxation) (per year)



  Total Turnover – Cost of Production
  1,50,00,000- 13069569

Net Profit Ratio


Net profit x 100

Turnover per annum

  1930431 x100

Rate of Return on Total Investment


Net Profit x 100

Total Capital Investment

  1930431 x100

Break-even Point

Fixed Cost (per annum)


Amount (Rs.)

Depreciation on Machinery @ 10% 120000
Depreciation on building @ 5% 255625
Depreciation on Tools-dies @ 25% 12500
Depreciation on Furniture @20% 50000
Interest on Total Investment @ 12% 1051204
40% of Salary Wages 884256
40% of other Contingent expenses 1137600
Total 3511185
B.E.P Fixed Cost x 100
Fixed Cost +Profit
  3511185 x 100
  3511185 + 1930431
  3255560 x100

Addresses of Machinery and Equipment Suppliers

  • M/s. Indian Hydraulic Industries,
    70, Najafgarh Road,
    New Delhi –15
  • M/s. J.K Traders & Engineering,
    Industrial Area, Kirti Nagar,
    New Delhi – 15
  • M/s. Ambika Dies and Moulds
    B-217, Naraina Industrial Area,
    Phase-1, New Delhi –28
  • M/s. National Engineering Works
    New Nagapada Road,
  • M/s. R.H. Windser India Ltd.,
    E-7, U. Road,
    Thana Indl. Estate,

  • Raw Material Suppliers

  • M/s. Pioneer Plastic Industries,
    Industrial Estate, Okhla,
    New Delhi – 20
  • M/s. National Organic Chemical Industries Ltd.
    Worli, Mumbai – 18
  • M/s. Calico Plastic and Chemicals
    Anik Chamber,
    Mumbai – 400 074
  • M/s. Chemicals and Plastic,
    Mettur, Tamil Nadu
  • M/s. Kundatia Industries,
    No. 69, Najafgarh Road,
    New Delhi.
  • M/s. Omega Polymicrons Pvt. Ltd.
    Meerut Road,
    Mawana- 250401
    Meerut (U.P.)

For further information please contact

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com