Ethylene-Vinyl Alcohol (EVOH) Manufacturing Plant Project Report 2024

The report is the result of extensive primary and secondary research, offering a detailed analysis of current market trends. It profiles key industry players, giving insights into their market strategies, production capacities, and financial performance, which are crucial for benchmarking and competitive analysis.

It delves into historical, current, and forecasted price trends, helping stakeholders understand market dynamics and price volatility. The report provides a thorough analysis of the mass balance and raw materials requirements, ensuring a clear understanding of the input-output ratios essential for efficient production. Detailed examinations of the various unit operations integral to the ethylene-vinyl alcohol (EVOH) manufacturing process are included, highlighting process optimisation techniques and technological advancements.

The report presents a comprehensive capital cost analysis, detailing the financial investment required for setting up a ethylene-vinyl alcohol (EVOH) plant. This includes an exhaustive breakdown of costs associated with raw materials, catchem, utilities, labour, packaging, transportation, land acquisition, construction, and machinery. Additionally, it offers an in-depth look at the operating costs, providing clarity on the recurring expenses involved in running the plant.

Projected profit margins and optimal product pricing strategies are outlined, offering guidance on maximising profitability. The report also addresses regulatory frameworks, environmental impacts, and sustainability measures pertinent to the ethylene-vinyl alcohol (EVOH) industry.

About Ethylene-Vinyl Alcohol (EVOH)

Ethylene-vinyl alcohol (EVOH) is a copolymer made from ethylene and vinyl alcohol. It is renowned for its exceptional barrier properties against gases, making it ideal for food packaging. It is flexible, mouldable, and recyclable, but its production is complex and costly. EVOH is often used in thin layers within multi-material packaging to enhance shelf life and protect food flavours. EVOH was developed by Kuraray in the late 1950s to meet the growing demand for effective food packaging. The first commercial product, named EVAL, was launched in 1972 after extensive research and development. Furthermore, its unique properties were discovered through copolymerisation, which improved gas barrier performance under varying humidity.

Properties of Ethylene-Vinyl Alcohol (EVOH)

Ethylene-vinyl alcohol (EVOH) is a copolymer known for its excellent barrier properties, particularly against gases like oxygen and carbon dioxide. It exhibits high transparency, flexibility, and resistance to oils and solvents, making it suitable for food packaging. Other major properties include a density of 1.14 to 1.20 g/cm cube, a melting temperature (Tm) ranging from 165°C to 190°C, and a glass transition temperature (Tg) between 55°C and 65°C. EVOH is also recyclable, although its production is complex and costly, limiting its widespread use.

Manufacturing Process of Ethylene-Vinyl Alcohol (EVOH)

The production process of ethylene-vinyl alcohol (EVOH) begins with the preparation of raw materials, including ethylene, vinyl acetate, and a catalyst. The first major step involves the polymerisation of ethylene and vinyl acetate (EVA) using various methods such as solution, suspension, bulk, or emulsion polymerisation, resulting in the formation of the EVA copolymer.

Next, the EVA copolymer is dissolved in a lower straight-chain fatty alcohol, commonly methanol, to prepare it for the saponification process. An alcoholic solution of alkali is then added as a catalyst, and the mixture is maintained at a specific temperature to facilitate the saponification reaction. After saponification, the EVOH resin undergoes a series of washing and purification steps to remove any by-products and unreacted materials. The purified resin is then dried and pelletised, ready for extrusion, blow moulding, or vacuum moulding.

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Synthesis of Ethylene-Vinyl Alcohol (EVOH)

Below are the detailed steps involved in the production of EVOH.

Raw Materials

• Ethylene (C2H4)

• Vinyl acetate (CH3COOCH=CH2)

• Catalyst (e.g., organic peroxide)

• Hydrochloric acid (HCl) or sodium hydroxide (NaOH) for hydrolysis

• Water (H2O)

Process Description

Step 1: Co-polymerisation

Ethylene and vinyl acetate are co-polymerised in the presence of a catalyst to form ethylene-vinyl acetate (EVA) copolymer. This reaction typically occurs under high pressure and temperature.

nC2H4 + mCH3COOCH=CH2 → (C2H4)n-(CH3COOCH=CH2)m

Ethylene + Vinyl acetate → Ethylene-vinyl acetate copolymer (EVA)

Step 2: Hydrolysis

The EVA copolymer is then subjected to hydrolysis, where the vinyl acetate units are converted to vinyl alcohol units. This can be achieved using an acid or base catalyst such as hydrochloric acid (HCl) or sodium hydroxide (NaOH).

(C2H4)n-(CH3COOCH=CH2)m + H2O → (C2H4)n-(CH2CHOH)m + CH3COOH

EVA + Water → Ethylene-vinyl alcohol (EVOH) + Acetic acid

Step 3: Removal of By-products

After hydrolysis, the mixture contains EVOH and acetic acid, along with any unreacted monomers. The acetic acid and other by-products are removed through washing and drying processes.

EVOH + CH3COOH (impurities) → EVOH (pure)

Step 4: Pelletising

The purified EVOH is then extruded and pelletised for ease of handling and further processing.

EVOH (pure) → EVOH pellets

Applications and Drivers of Ethylene-Vinyl Alcohol (EVOH)

The ethylene-vinyl alcohol (EVOH) market is experiencing significant growth driven by its diverse applications in packaging, automotive, and pharmaceutical sectors. In packaging, EVOH is valued for its excellent oxygen barrier properties, making it ideal for preserving the freshness of perishable foods and enhancing the shelf life of products like pre-cooked meals and snacks. For instance, retortable plastic containers made from EVOH are increasingly used in the food industry due to their ability to maintain sensory and nutritional quality without heat treatment. Additionally, the automotive industry uses EVOH in fuel systems and components for its durability and resistance to environmental factors. The pharmaceutical sector also benefits from EVOH's barrier properties and uses it in the packaging of medications and clinical applications such as ampoules and parenteral nutritional bags. The rising demand for sustainable and efficient packaging solutions, alongside the growth of the processed food industry, further propels the EVOH market growth.

Key Features of the Ethylene-Vinyl Alcohol (EVOH) Production Cost Report:

This production cost analysis report by Expert Market Research scrutinises the ethylene-vinyl alcohol (EVOH) manufacturing process, offering a comprehensive overview necessary for stakeholders considering venturing into this sector. Based on the latest economic data, the report encompasses detailed insights into the primary process flow, raw material requirements, reactions involved, utility costs, operating costs, capital investments, pricing strategies, and profit margins. This report is an indispensable resource for entrepreneurs, investors, researchers, consultants, business strategists, and all those who have any kind of stake in the ethylene-vinyl alcohol (EVOH) industry. It equips them with essential information and strategic insights to effectively navigate the complexities of the market.

The following sections detail the comprehensive scope of the prefeasibility report for an ethylene-vinyl alcohol (EVOH) production plant:

• Market Dynamics and Trends: This section analyses the prevailing market conditions, growth drivers, and trends impacting the ethylene-vinyl alcohol (EVOH) industry. It offers a thorough examination of demand fluctuations and projections.

• Geographic Analysis: Detailed insights into the major regions active in ethylene-vinyl alcohol (EVOH) production and consumption, highlighting regional market specifics and growth potential.

• Key Industry Players: Profiles of leading manufacturers in the ethylene-vinyl alcohol (EVOH) sector, outlining their market share, strategic positions, and operational strengths.

• Price Fluctuations: Analysis of historical, current, and projected price trends, providing stakeholders with essential pricing intelligence.

• Technical Specifications and Process Description: A detailed overview of the ethylene-vinyl alcohol (EVOH) production process including the technology used and innovations within the industry.

• Raw Material Requirements and Sourcing: Evaluation of necessary raw materials, their sourcing strategies, and cost implications.

• Utility Requirements and Costs: Detailed analysis of utilities needed to produce ethylene-vinyl alcohol (EVOH), such as electricity, steam, and process water along with their cost assessments. 

• Labour Force Dynamics: Insights into manpower requirements, including skill specifications and labour cost projections.

• Packaging Needs: Overview of packaging requirements for ethylene-vinyl alcohol (EVOH) to ensure product integrity and cost efficiency.

• Logistics and Transportation: Examination of transportation needs and logistics planning for distribution and supply chain efficiency.

• Capital and Operating Costs: An in-depth look at investment requirements, including land acquisition and its development cost, civil work costs, construction, machinery procurement, and ongoing operational expenses, such as salaries and wages, plant overheads, tax and insurance as well as packaging, transportation, and administration costs.

• Financial Performance and Profitability Analysis: Projected profit margins and return on investment based on current market and operational parameters.

• Product Pricing Strategy: Recommendations on pricing mechanisms based on industry benchmarks and production costs.

• Environmental Impact and Regulatory Compliance: Analysis of environmental considerations and compliance with local and international regulations.

• Risk Assessment and Mitigation Strategies: Identification of potential risks associated with ethylene-vinyl alcohol (EVOH) production and strategies to mitigate them.

Key Questions Addressed:

• What are the detailed unit operations for ethylene-vinyl alcohol (EVOH) production?

• Who are major technology licensors with their process evaluation?

• How are raw materials or catchem procured and what are their cost implications?

• What utilities are essential for production and what will they cost?

• What are the labour requirements and how does this affect operational costs?

• What packaging solutions are optimal for cost and efficiency?

• What logistical arrangements are necessary for efficient product distribution?

• What are the estimated land and construction costs for a new ethylene-vinyl alcohol (EVOH) plant?

• How can profitability be maximised in the ethylene-vinyl alcohol (EVOH) market?

• What pricing strategy should be adopted for ethylene-vinyl alcohol (EVOH) to remain competitive?

This prefeasibility report aims to equip potential investors and existing manufacturers with crucial insights to make informed decisions in the ethylene-vinyl alcohol (EVOH) industry.