Detailed Project Report (DPR) on bagasse tableware [plates, glass, bowl, food container etc.]

BAGASSE TABLEWARE 

[PLATES, GLASS, BOWL, FOOD CONTAINER ETC.]

[CODE NO.4438]  

Biodegradable disposable tableware and utensils manufactured from wood-based or plant-based raw materials, including materials that may be traditionally discarded such as sawdust, plant stalks, seed or grain hulls or the like. 

The process includes the use of a resin made from the discarded materials to form disposable utensils and flatware.

Today consumption of Disposable products is breaking records. Disposable products are easy to handle, economical and can be disposed easily. With the changing lifestyle of Mankind, the use of disposable products is raising 

like anything. Plastic Disposable products are very popular because it can be carried easily and very low in prices too.

The products include food containers and tableware – like plates, bowls, 

meal trays and cups – which decompose within 30-60 days after being discarded. The company sources processed bagasse from other organizations. 

This material is then moulded, dried, heated, and given other final touches. 

Heat-induced pressing during the manufacturing process gives structural strength to the cutlery. Additionally, the inter-fibre bonding makes the products water and oil resistant. It is a completely natural process and 

involves no binders, additives, coatings or chemical residues, resulting in a nontoxic, harmless and healthy alternative to plastic. The cutlery also does not impart colour, odour or taste to food. The products are microwave-

safe and have an estimated shelf life of two years. Users cannot wash the tableware or containers after use; they have to be discarded.

This is 100% biodegradable & compostable tableware, which is widely used in various functions ,restaurants , festivals as ECO FRIENDLY single time (Use & throw) crockery , it’s produce by Plant extract or residue like Sugarcane Bagasse (SCB) etc., which is Proven Environment friendly 100% Biodegradable and Compostable and not harmful for food, human , soil and Nature. This is becoming more popular due to environment awareness, climate change & NGT/State govt. bans on recyclable plastics. This can be use in microwave and refrigerator also.

10 inch Bagasse Round Regular Plate

Disposable products are made of various materials such as dry leaves, pulp, papers and plastic etc.

Thermoformed fiber is a material made by forming paper fibers or other natural fiber in a mold. The end product can be made into almost any shape for any type of solution. In the process of making thermoformed fiber, the 

product begins with a process similar to transfer molding. During the process of thermoforming fiber, the product is transferred to a set of heated metal molds that dry the fiber under intense pressure and heat, making an extra drying process unnecessary. The process of thermoforming the pulped fiber delivers parts that have a smooth finish on both sides of the thin and dense walls of the product. There are many advantages to having a thermoformed fiber product with smooth walls. They include: reduced freight and storage costs and the ability to use mechanical denesting. The use of thermoformed fiber is very desirable when visual appearance is preferred.

140ml Bagasse Cup

The process of pulp thermoforming is employed to develop sturdy and smooth packaging. This type of packaging can be used in various industrial and commercial uses. Thermoformed pulp is a desirable alternative to petroleum-based products. American Fiber Packaging has invested in the latest equipment technology and has developed a process to manufacture high-quality thermoformed fiber solutions. Through this process we are able to deliver environmentally responsible products to our customers.

Thermoformed molded fiber products can be customized to specifications and can include clamshells, trays, inserts, and many other types of packaging. 

Thermoformed pulp is a great alternative to petroleum-based foam products like expanded polystyrene (EPS) for protecting and positioning products inside packaging.

Range & Variety

The present project report is fully based on biodegradable cups and plates from Sugarcane bagasse, wood pulp. These products have got good demand in throughout the country. The project many be setup in small scale sector. All the required plant & equipments and Raw materials are easily available in India.

The plastic industry in India plays a very important and key role in Industrialization. Wide spectrums of plastics and articles manufactured by the industry have touched the life of every Indian in many ways through consumer plastics. Now we have entered into another era of plastic consumer goods continuously replacing the traditional items. The items cover from furniture to medical sciences from lutchen equipment to daily use articles.

Biodegradable cups and plates from Sugarcane bagasse, wood pulp or bamboo pulp are used in daily life now a day. In addition to be used at home these are largely used during at hournies, parties and other functions.

The use of disposable items is increasing day by day because of better hygienic conditions, low cost, easy usability and impressive appearance.

COST ESTIMATION

Plant Capacity                            2 Ton./Day  

Land & Building (2000 sq.mt.)    Rs. 3.14  Cr    

Plant & Machinery                            Rs. 8.50  Cr 

Working Capital for 1 Month    Rs. 70.31 Lac 

Total Capital Investment                  Rs. 12.63 Cr 

Rate of Return                                 29%

Break Even Point                             59%

• INTRODUCTION
• 10 INCH BAGASSE ROUND REGULAR PLATE
• 140ML BAGASSE CUP
• RANGE & VARIETY
• COMPARISON OF BAGASSE VS PAPER AND OTHER MATERIAL
• WHAT IS BAGASSE
• BACKGROUND ON BAGASSE:
• HOW BAGASSE IS PRODUCED:
• HOW WELL DO BAGASSE PRODUCTS HANDLE HEAT?
• OVERVIEW OF GLOBAL BIODEGRADABLE CUTLERY AND TABLEWARE MARKET
• US DOMINATE THE DISPOSABLE TABLEWARE AND CUTLERY MARKET
• GLOBAL GROWTH AND PROSPECTIVE OF BIODEGRABLE DISPOSABLE TABLEWARE
• “ECO-FRIENDLY PACKAGING SOLUTIONS GAIN MOMENTUM”
• COVID-19 IMPACT
• COMPOSTABLE TABLEWARE MARKET POSITION
• COMPOSTABLE TABLEWARE MARKET
• CLASSIFICATION OF GLOBAL FOOD PACKAGING
• INDIAN MARKET SCENARIO OF BIODEGRADABLE CUTLERY & TABLEWARE
• SUGARCANE BAGASSE PRODUCTS
• ARECA LEAF CUTLERY
• EDIBLE CUTLERY
• RICE HUSK TABLEWARE
• BAMBOO TABLEWARE
• MARKET POSITION OF BIODEGRADABLE CUTLERY & TABLEWARE
• PRESENT MANUFACTURERS/SUPPLIERS OF BIODEGRADABLE DISPOSABLE CUTLERY
• KEY BIODEGRADABLE PACKAGING PLAYER IN INDIA
• PROPERTIES & CHARACTERISTICS
• RAW MATERIALS
• PROS
• CONS
• BENEFITS OF THERMOFORMED FIBER
• PULP THERMOFORMING AND MOLDED FIBER PACKAGING
• DETAILS OF MOULDED PULP
• ABOUT MOLDED PULP
• FIGURE ONE: CUSHION CURVES
• FIGURE TWO: DROP TEST
• CONVERTING BAGASSEINTO PLATES AND BOWLS
• BAGASSE PRODUCTION FLOW CHART
• MANUFACTURING PROCESS OF BIODEGRADABLE CUPS AND PLATES PLANT
• PROCESS FLOW DIAGRAM
• PROCESS OF MOLDED PULP
• SUSTAINABILITY OF MOLDED PULP
• BAGASSE PULP PLATE MAKING MACHINE
• THERE ARE 5 MANUFACTURING STAGES:
• FLOW CHART OF BAGASSE TABLEWARE PRODUCTION LINE
• PULP FIBRE TABLEWARE PRODUCTION PROCESS
• PULP TABLEWARE PRODUCTION LINE
• TESTING METHOD OF BIODEGRADABLE MATERIAL
• APPARATUS:-
• ANALYTICAL EQUIPMENTS:
• REAGENTS AND MATERIALS:-
• COMPOST INOCULUM:
• TEST SPECIMEN:
• PROCEDURE:
• CARBON DIOXIDE ANALYSIS:
• CALCULATION:
• COMPLETE BIODEGRADATION (USING ASTM D5338 TEST METHOD):
• DISINTEGRATION:
• SAFETY
• TEST METHOD TO MEASURE THE RATE AND EXTENT OF MICROBIAL UTILIZATION 
• (BIODEGRADATION) OF BIODEGRADABLE PLASTICS
• SUGARCANE BAGASSE PULP MOLDED TABLEWARE PRODUCTION 
• LINE (SEMI-AUTO ELECTRIC HEATED) CAP: 1 TPD
• SUGARCANE BAGASSE PULP MOLDED TABLEWARE PRODUCTION 
• LINE (SEMI-AUTO ELECTRIC HEATED) 3 TPD
• TECHNICAL SPECIFICATION OF PULP PROVIDING SYSTEM FOR 1 TPD 
• (150-180 KG/HR.)
• TECHNICAL SPECIFICATIONS OF PULP PROVIDING SYSTEM FOR 3 TPD 
• (150-180 KGS/HR.)
• SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
• SUPPLIERS OF PLANT AND MACHINERY (INDIAN)
• VENDORS ADDRESSES OF BIODEGRADABLE CUPS & PLATES
• ADDRESSES OF TURNKEY SUPPLIERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)