Pp Disposable

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    25 PPDISPOSABLE

    PLASTIC

    CUPS/GLASSES

    cups arc

    now fast rcplacing

    conventional ups. ce-crcamand other dairy

    products

    arc

    packed

    n disposablc

    Besidcs cc-crcam ndustry hotels, restaurants, antecnsetc. have

    been ncreasingly

    using disposable

    cups as

    convc'ntional

    lass-warcs

    r ccramic cups. Disposable

    ups are mainly used or food items

    and are madc

    out of

    or

    polystlrcne

    sheets. he disposable ups arc

    gaining popularity

    due

    o

    attractivc ook,

    low weight for

    casc

    ol transportationand low impcrmeability.

    Organizations

    ike Railways,

    Airlincs are

    using disposable

    for scrving col-lce, ea etc. now-a-days.

    Potential

    ilbstylcs and attitudes, here has been an increasedmarket for the thermoformedproducts.The

    are

    hc

    major scctors

    n which these ind

    application.

    Food Industry

    hrdustry s onc

    ofthc lar5cstuscrsof Thermoformed

    ackaging.

    Their main application s for

    processed

    ood and

    scrving

    packaging.

    ndustry

    Ampoulcs, Diagnostic Kits etc., are

    packed

    n thermoformed

    packaging.

    Electronics ndustry

    components an be individually form packedand protcctedagainstdamagedue o handling.

    Industry

    arc many applications

    o

    pack

    fruits and

    vegetablesor

    bulk

    and consumcr

    pack.

    The thermoformed

    articlesare

    grcen

    house as secd

    rays

    and

    flower

    pots

    etc.

    Carc Products.& Cosmetics

    ndustry

    ogues mply shorter

    ife spanofproducts. Costly

    ooling s neededor inje'ctionmouldedcontainer/

    ackaging.

    packs

    are cheaper,

    astcr to make and

    the

    process

    has higher output rates making

    quick

    changes n

    economically

    'easible.

    ndustry

    and

    rolls of appropriate

    material can be formed and

    used as an excellent barrier against water seepage

    n

    etc. Many

    other

    products

    ike

    bathroom

    accessories,

    omes,

    panelling,

    ceiling etc can be made.

    Automobile

    ndustry

    sized hick

    wallcd thermoformed

    products

    like door liners, dash

    boards, frbnt

    grills

    are

    widely

    used n

    the

    automobile

    differs from injection

    molding, blow molding,

    rotational

    molding, and other forms ofprocessing

    plastics.

    hermoforming

    s

    primarily

    the

    manufactureofdisposable

    cups, containers,

    ids, trays, blisters, clamshells,

    * If you want to know more about detail project, contact WILLFORCE.

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    products

    for the food, medical, and

    general

    etail industries.Thick-gauge

    hermofbrming

    ncludcsparrs

    as

    as vehicledoor and

    dash

    panels,

    efrigerator

    iners, utility vehicle

    beds,and

    plastic

    pallets.

    are the advantages f thermoformed

    products

    n

    packing

    rotection o the product packed.

    and convenient

    placement

    of the

    product

    due to

    contoured orming.

    ost of

    packing.

    packing.

    visual inspectionwithout

    opening he whole

    package.

    proof packaging.

    moisture Resistantpackaging.

    nert to many chemicals.

    formed

    as transparent,Printed,

    Opaque etc.

    ostsare comparatively ower

    and high volumes

    can

    be

    produced

    within

    a very

    shorr time.

    of the reasons or thermoformed

    PP

    packaging's

    mmense

    popularity

    are

    asily ecyclability.

    of Rigidity

    /

    flexibility

    in

    packing.

    at

    sub-zero

    cmperatures.

    moisture

    barrier

    properties.

    suitable for micro-wave

    ovcns.

    contact clarity

    (Clarified

    PP).

    Capacity

    proposed

    production

    s estimated

    o be

    of

    two

    t1pes, ea/coffee

    ups of 65

    -80

    ml and

    water/juice

    glasses

    of I lio

    . The ollowing

    table details

    he

    production

    plan.

    Particulars

    Per

    Hour

    Production

    Estimated

    Daysof

    Prodn

    Working

    hours I day

    Total

    Annual

    Production

    65-80

    ml

    of tea

    / coffee

    cups

    84000000

    8 hours

    84000000

    180

    ml

    of

    water

    /

    juice

    glasses

    Total

    168,000,000

    unit

    has

    been

    assumed

    o

    operate

    at

    80oA,90o/o

    nd

    onwards

    of

    its

    operation

    with

    8 workinq

    hours/dav

    100%

    of

    its

    nstalled

    apacity

    n

    rh e

    i.e.1

    hif tand

    300

    workins

    davs n

    first,

    second

    nd

    hird

    year

    a

    year.

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    i )

    Process,

    Plant& Machinery

    Deta i ls

    L is t o f

    Machinery

    uppl iers)

    Manufactur ing

    rocess

    thc urcst conrrnon

    rsthod ot high-volume,

    contilluous hemrolbrming of thin-gauge

    products, plastic

    sheet s li'd

    roll or l iorrr rr cxtrudcr

    nto a sct of indexing llains

    hat ncorporate

    ins,

    or

    spikes,

    hat

    picrce

    he sheet

    nd

    thioLr .irrrrovcn l irr

    hcating o fbrming cmpcraturc.

    fhe

    hcated heet hen

    ndexes nto

    a ftrrm statit,n

    nrttingnrtrld nd

    prcssLrre-bor

    loscon

    thc

    sheet,

    ith vacu[m thenapplicd o remove rapped ir and o

    pull

    nto or orrto hemoldaiong

    with

    prcssurizcd

    ir to fbrm

    hc

    plastic

    o the

    detailed hapc

    fthc mold.

    Pluil-

    typicallyused

    n atlditiur o vacuum

    n thc

    casc

    of tallcr,dceper-drawbnned

    parts

    n ordcr o

    provide l lc

    listribrrtion

    nd hicknessesn

    the inished arts.)

    a short

    irrnr cyclc.

    a burst of revcrscair

    prcssurc

    s actuatcd rom thc racuum sideof

    the

    mold as

    thc lbrrn

    opcns, orlnronly

    cl 'crrcd

    o

    as air-cjcct,

    o brcak hc vacuunlandassisl

    tle bnned

    parts

    off of, or out oi, tl,c

    platc rrxy alsobc uti l izcdon

    thc molclas it opcnS br tjection of more detailed

    arts

    or thoscwilh

    rn(icrcul rcas.

    Thc shcctcontainilg

    hc lbrmctl

    parts

    hen ndcxes nto a trirn stationon

    thc sar'lre

    hcrc a dic

    ctrts hc

    parts

    rom

    the remaining hcetweb, or

    indcxcs nto a se paraterim

    press

    u,here lre

    trts are rirnllrcd.

    lrcshcetweb remaining

    lier the brmedpartsare rimmed s typicallywoundontoa takJ-

    p

    rcelor t'ecl

    nto an nline

    granulatorbr recycling.

    hcnnolorrning

    onrpaniesecyclc

    heirscrapand

    waste

    plastic,

    eitherby cor:rpressing

    n a balingmachinc r l.y

    ntoa

    glanulator

    grindcr)

    nrl

    producing

    round

    lakc, br salc

    o reproccssingompaniesr

    re-usen thcir oun

    irequentiy,

    scrap

    and wastc

    f,lastic

    iorn

    the thermotbrming

    process

    s convertedback into

    extrudedsheet irr

    gain.

    Plantand

    Machinery

    hc mqr)r

    cqllipl-Itcnt

    cclui l 'ecl

    v

    thc unit

    fbr

    rnanufactr"rriug

    lastic

    disposablc

    cups

    are as fbllows:

    Autolnlltic

    thennofbnning

    machlne

    Dic

    Punch

    ibr

    clrps

    Othcr

    acccssor ics

    Air

    colnpressor)

    Shcet

    cxtrudcr

    and scrap

    grinder

    T'estiug

    quiplncnt

    ) Plant

    and

    Machinery

    upPl iers

    arc

    he

    plant andmachinery

    lrppliers

    or

    the

    projt:ct.

    I

    S t x o

    Name

    M/s

    Klockner

    Windsor

    ndia

    Ltd.

    Mis

    Wonderpack

    ndustries

    .Ltd.

    72,lst

    floor,

    Shivalaya

    ansion,

    Hamington

    Road,

    Mumbai-

    400 008

    Mi s

    Isimat

    India Scrcen

    Machinery

    Pvt. Ltd.

    Printing

    Cl , /510,

    GIDC,

    Gundlav,

    __l :stt.

    Valsad,Gujarat-396

    35

    29,

    Apurva

    ndustrial

    Estate,

    Makvana

    Road,

    Andheri

    Kurla

    Road,

    Andheri

    East),Mumbai

    400 059

    Communication

    Address

    E-6

    -

    UZ

    Road,Thane

    ndustrial

    Estate,

    Thane

    400

    604

    i M/s Solex

    Machincs

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    Material

    & Util ities

    Requirement

    raw rnatcrial

    required for the

    project

    would be

    polypropylerre

    which is as follorvs.

    Raw Material Requirement

    Mil l i l i tre

    Wt

    in

    gms Total in I \ IT

    65-80

    ml tcalcoffee ups

    80

    1 032

    7

    4 .30

    180

    200

    ml

    watcr

    uice

    cups

    200 2 .s8

    1 0 8 . 3 6

    Total Raw Material

    Reqd

    including3'h wastage

    r8 8 . 1

    has beenassumed o operate

    at

    807o

    and 90% of its installedcapacity n the first and

    second

    ear andat I

    009'o

    rom third

    year

    and onwardsof

    its

    operation.

    utilities required are

    power

    and water Around 220 KW of Power and 450 KLPA of water a-^

    --^"i--'r

    Land

    &

    Built-up Area Requirement

    land area s 500 sq metresand the built up area

    s

    300 sq mt.

    ManpowerRequirement

    manpower equiredwould be

    l3 Nos

    of which

    administrative s 4

    and lactory staff is 9.

    Personnel

    Nos

    Works Manager

    1

    I

    Accountant-cum-Store

    Keeper

    I

    Admini

    trativc

    ssistant

    Cl"tk

    Ski l l .d

    / , . , tk .^

    S"- i St

    l lc . lW"rk.^

    P."t/ Vrrcl'rr.r',rn

    I

    I

    I

    5 - -

    t--

    Total

    l 3

    Project

    CosU

    Fixed

    CapitalRequirement Meansof Finance

    been consideredas a

    part

    of the

    project

    cost

    because

    t has been considcrcd o

    bc taken on lease

    as

    Charges

    have

    been aken as

    part

    of

    tlrc Project

    Cost.

    Also,

    Special

    Chargesand an Annual

    ServiceCharge

    have

    been considered s

    part

    of operatingcost.

    fhe

    project

    cost

    199.87 akhs s as ollows.

    Sl

    No

    Particulars

    Rs

    n l ,akhs

    Site

    Devclopn-rent

    os t

    r . 0 0

    Building

    Plant

    andMachinery

    Miscellaneous

    ixed

    Assets

    Preliminary

    nd Pre-Operativc

    .xpcnses

    Margin

    Money

    on Working iapital

    Contingencics

    24.00

    i :s i

    9. 1_s

    2 .0 0

    iq

    oo

    Total

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    5/7

    Means of

    Finance

    Rs n

    lakhs

    Equity

    49.97

    Dcbt

    r49.90

    Total

    199.87

    prolect

    cost

    may

    be

    financed at a debt

    equityratio

    of 3:1

    as

    follows.

    WorkingCapitalRequirement

    working

    apital

    equirement

    s

    given

    elow:

    Sl

    No

    Particulars

    Years of Operation

    I

    2

    3

    4

    5

    I

    Net Working

    Capital

    76.00

    85.50

    95.00

    95.00

    9s.00

    2

    Available

    Bank

    Finance

    57.00

    64. r2 71 25

    71 .25

    7

    .25

    .\

    J

    Margin

    Money

    19.00

    2 t . 3 7

    23.7

    23.7

    23.1

    Operating

    Expenses

    annual

    perating

    xpenses

    stimated

    t

    Rs 177.02

    akhs

    80%

    apacity

    tilization)

    s

    given

    elow:

    Sl

    No

    Particulars

    Rs

    in Lakhs

    I

    Annual

    Land Charges

    0 . 1 2

    2

    Raw

    materials

    101

    73

    1

    -)

    Uti l i t ies

    1

    . 1 3

    4

    Wagcs&

    Salanes

    9.00

    5

    Overheads

    3.53

    6

    Sell ing

    expenses

    0.67

    7

    Packing

    expenses

    8.06

    B

    lntcrest

    on

    temt

    loan

    22.49

    9

    Interest n

    llank

    Financc

    or Working

    Capital

    8 .5 5

    l 0

    Depreciation

    5 .74

    Total

    r77.02

    Profitability

    Estimates

    SI

    No

    Particulars

    Year

    Y r

    - l

    Yr-2

    Yr

    -3

    Yr

    -4

    Yr-5

    Production/Sales

    InstalledCapacity(inakh

    nos)

    I 680 I 680 l 680 1680 I 1680

    Capacity

    Utilization

    80%

    90%

    l00Yo

    r00%

    r00%

    E,stimated

    roduction

    in

    lakh

    nos)

    t344

    I512

    1680

    1

    680

    1680

    I

    Gross

    Sales

    Revenue

    4 0 3

    |

    4 0 3 _ l

    4 0 3

    1 3 5

    1 3 5

    1 3 5

    Expense

    108

    I2 l

    aw

    Material

    ConsumPtion

    utilities

    1 1

    1 1

    1 l

    u

    1 1

    Administrative

    Overheads

    4

    4

    4

    4

    4

  • 8/17/2019 Pp Disposable

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    -

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    l

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    rr": 0. r

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    ----r i

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    T'otal

    'i

    146

    i

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    qq

    I

    Ztl

    t,

    214

    ,

    214

    i

    '

    Gros1

    j

    Financia l xpenses

    .

    -

    . - ; - -

    i

    lnler(st

    On

    T't'rn

    Loutr

    ??

    |

    '"')

    t

    l ' l

    I

    l t

    ;

    ;:

     

    i

    Interest

    Un I crnt Loun

    22

    - I

    t,

    Irtttrest

    On Working

    Cutrtitul i

    q

    : 2

    |

    n

    r f l

    i -

    l ,

    l ( ) ; l l l l

    SubTor r l

    i

    3 l

    i

    . r t

    I

    :S

    I

    l t

    l ( r

    l _

    . .

    I

    i

    i

    _ _

    . .

    , f ) r ' ^ . o , - i , r t i ^ n

    i

    - - - i . - | - n |

    - -

    | - -

    l ) cp rec ia t ion

    . i 7

    i

    - i , 7

    I

    _ tZ

    |

    _ ; .2

    |

    S ;

    i l ) r o f l t B e f b r c J ' a x

    I t r t t

    I

    t l a i t < K I r A r r A -

    ndicators

    Ilrcak Irvcn

    Point

    for

    thc projcct

    is

    36(%.

    I

    Sales

    Real isat ion

    |. __

    I

    l.'ixed

    Costs

    i Salarrcs

    L_____

    F -

    ;d

    S

    'il | ng

    L.

    Ler,",*;

    j

    Depreciat ion SLM)

    I

    lrrr l )rsurau()n

    )Llvr)

    -

    i

    Rcpai rs

    & Maintcnancc

    Yr-2

    Yr

    -3

    403

    Yr

    -rl

    - - - - -

    -l

    i

    Yr-5

    ,

    I

    I

    l

    --1-

    - - - r

    1_

    t i l i t i cs

    l ' ixed)

    Admin.

    Overheads

    ncl

    I"rcr..tffi

    '-

    Loan

    l(cpayment

    Total

    Fixed

    Costs

    V*i"bt.

    C"rt

    i l l l l l

    I -

    - -

    - -

    l 4 i 1

    |

    - -

    - l - - _

    1 1 -

    |

    - -

    |

    - -

    [-

    --

    -i--

    r r

    i

    -

    |

    - ) t

    l 6 0 l e e

    L -

    u

    - I -

    l _ _ 1

    __

    l + l + l +

    i--i7-1--

    rr--l--e--

    i-ltl--.t

    t-;--

    I*--I- 2--[qt_-

    I-- it-T-]:s T r35

    awMaterials

    r08 [lr r

    Packing

    8

    9

    l 0

    l 0

    t 0

    Interest

    On

    Working

    Capital

    Loans

    9

    1 0

    l t

    11

    l l

    Total

    Variable

    Costs

    124

    t40

    r55

    155

    155

    Contribution

    198

    223

    248

    248

    248

    Breakeven

    n

    7o

    300h

    440h

    380

    360

    340h

    Average

    Breakeven

    In

    7o

    36"h

  • 8/17/2019 Pp Disposable

    7/7

    thc

    pro. icct

    s27.4nh,

    Average

    OI is

    86'% and average

    SCR

    s

    3.0I.

    Part iculars

    Year

    of

    Operation

    I

    2

    3

    4

    5

    Revcnuc

    323

    363

    403

    403

    403

    Profit []cfbrc

    Tax

    1 3 9 .9 5

    126.24

    155.64

    161.26

    r66 .88

    ProfitAftcr Tax 93.77 84.58 104.28 108.04 I 11 . 8 1

    LT

    Intcrcst

    22.49

    22.49

    16 .86

    Lt .24

    5.62

    Depreciation

    5.74

    5.74

    5.74

    s.74

    5.74

    LT Loan

    Repayment

    0.00

    37

    48

    37.48

    37.48

    37

    48

    Return

    n

    Investment

    %)

    84(J 770h

    890/.,

    890h

    89V"

    AverageROI

    86'Yo

    Debt-Service

    CoverageRatio

    -

    Debt

    Service

    22.49

    59.96

    54.34

    48.72

    4 3 . 1

    -

    Coverage

    t 2 t . 9 9

    r 1 2 .8 1

    t26.8rl

    t25.03

    r 2 3 . r 7

    DSCR

    5.43 1.88 2.33

    2.57

    2.86

    AverageDSCR

    3.0