Detailed Project Report (DPR) on Flexible and Rigid Plastic Recycling (100 MT/Day)

FLEXIBLE AND RIGID PLASTIC RECYCLING

[EIRI/EDPR/4589] J.C.: 2806XL

INTRODUCTION

Recycling flexible packaging is a relatively simple process but well worth the effort considering the alternative end result. The impact of preventing these materials from ending up in a landfill and prolonging their life cycle is substantial and helps contribute to reducing global waste. One caveat is that flexible packaging cannot be combined with other recyclables in a curbside bin used for other household papers and plastics. The current recycling program operating in the United States stipulates that these materials be dropped off at specific locations where they can be collected to then be reused.

Approximately 50% of flexible packaging in the U.S. is recyclable, so it is crucial to be able to differentiate between which items are and are not admissible for store drop-off. Flexible plastics made of polyethylene are recyclable, including grocery and produce bags, bread bags, and more. Some packaging that should not be included is biodegradable or compostable bags, pre-washed salad mix bags, and candy wrappers. 

The easiest way to tell if a product is eligible for recycling is by checking the label, which will be detailed further in step 2. Additionally, the infographic below provides some examples of common items that are included in the store drop-off program and which ones are not.

Once at your local grocery or retail store, you will see a specified disposal bin labeled for bags, films, and wraps. These recycling bins are typically located at the front of the store for your convenience. A handy trick is to have a reusable shopping tote at home to collect all of your flexible packaging materials, and then when you head to the store, simply grab the tote, deposit the flexible packaging, shop for your groceries, and then use the tote to bring your groceries home. This strategy ensures that all flexible packaging is collected in one place and prevents you from forgetting them at home. 

Plastic recycling is extremely important, both as a method to deal with our existing waste and as a component of both circular economy and zero-waste systems that aim to reduce waste generation and increase sustainability. There are social, environmental, and economic consequences surrounding our current waste generation and disposal habits, and whether that is the issue of micro plastics or an estimated $2.5 trillion in damage and lost resources to fisheries, aquaculture, recreational activities, and global wellbeing, the impact is no longer in doubt.

However, meeting the challenges posed by plastics is not simple, and there exists a lack of awareness surrounding the plastic waste problem. Despite the fact that potential issues were first flagged in the 1960s, historically, there has been a lot of pushback against implementing real change—mainly from the plastics industry itself. Recently, the tide seems to be turning on this issue as more people look for sustainable options and educate themselves about why plastic recycling is important.

Today, as both consumers and businesses look to recycle more materials, there is a lack of knowledge on how to do it effectively. This creates issues in the form of contamination, either by mixing non-recyclable plastics with recyclable plastics or trying to recycle plastics soiled by things like adhesives, chemicals, and food remnants that further impedes the recycling process. Both of these problems can lead to plastics being sent to the landfill rather than recycled.

Another complication is found within the products themselves. While some goods, like water bottles and other drink bottles, are frequently made from a single, common plastic (such as PETE) allowing them to be easily recycled, many others are designed to use a mix of plastics, which can cause serious issues in our current plastic recycling process. What’s more, many products are a mix of plastics and non-plastics such as wood or metal. Sadly, these products won’t even go near a recycling center.

COST ESTIMATION

Plant Capacity            100 MT/Day  

Land & Building (20,000 sq.mt.)    Rs. 6.83 Cr    

Plant & Machinery                    Rs. 5.36 Cr 

Working Capital for 1 Month    Rs. 7.82 Cr 

Total Capital Investment          Rs. 20.87 Cr 

Rate of Return                          49%

Break Even Point                      45%

CONTENTS

INTRODUCTION

PLASTIC CLASSIFICATION:

RESOURCES OF PLASTIC WASTE

PLASTIC RECYCLING AND ITS IMPORTANCE

APPLICATIONS FOR MECHANICALLY RECYCLED HOUSEHOLD PLASTICS

THE DIFFERENCE BETWEEN CHEMICAL AND MECHANICAL RECYCLING

MECHANICAL RECYCLING

ADVANCED RECYCLING

THE FOLLOWING ARE THE 6 COMMON TYPES OF PLASTICS

CHALLENGES FOR PLASTIC RECYCLING INDUSTRY

B.I.S. SPECIFICATION

TYPES OF RECYCLABLE PLASTICS

POLYSTYRENE

POLYPROPYLENE

LOW-DENSITY POLYETHYLENE

POLYVINYL CHLORIDE (PVC)

HIGH-DENSITY POLYETHYLENE (HDPE)

POLYETHYLENE TEREPHTHALATE (PET)

NUMBER 1: PETE (OR PET) – POLYETHYLENE TEREPHTHALATE

NUMBER 2: HDPE – HIGH-DENSITY POLYETHYLENE

NUMBER 3: PVC – POLYVINYL CHLORIDE

NUMBER 4: LDPE – LOW-DENSITY POLYETHYLENE

NUMBER 5: PP – POLYPROPYLENE

NUMBER 6: PS – POLYSTYRENE

PLASTIC RECYCLING TARGETS

STAGES IN PLASTIC RECYCLING PROCESS

1. COLLECTION

2. SORTING

3. WASHING

4. SHREDDING OR RESIZING

5. IDENTIFICATION AND CLASSIFICATION OF PLASTIC

6. COMPOUNDING OR EXTRUDING

PROCESS OF PLASTIC RECYCING

STEP BY STEP DETAIL

COLLECTION

SORTING

MANUAL PICKING

TROMMELS

OCC SCREENING

BALLISTIC SEPARATOR

MAGNET SEPARATOR

EDDY CURRENTS – FOR NON-FERROUS METALS

OPTIC SORTING MACHINE

SINK-FLOAT SEPARATOR

REPROCESSING

FURTHER SORTING FOR QUALITY CONTROL

WASHING – CONTAMINANTS ARE CLEANED OFF THE PLASTIC RECYCLING

SHREDDING/GRINDING – PLASTIC PRODUCTS ARE GROUND INTO SMALLER PIECES

SEQUENCES ON PLASTIC RECYCLING

1. COLLECTION + DISTRIBUTION

2. SORTING + CATEGORIZING

3. WASHING

4. SHREDDING

5. IDENTIFICATION AND SEPARATION OF PLASTICS

6. EXTRUDING + COMPOUNDING

THE DIFFERENT TYPES OF PLASTIC

NUMBER 1: PETE (OR PET) – POLYETHYLENE TEREPHTHALATE

NUMBER 2: HDPE – HIGH-DENSITY POLYETHYLENE

NUMBER 3: PVC – POLYVINYL CHLORIDE

NUMBER 4: LDPE – LOW-DENSITY POLYETHYLENE

NUMBER 5: PP – POLYPROPYLENE

NUMBER 6: PS – POLYSTYRENE

NUMBER 7: OTHER

MARKET OVERVIEW OF PLASTIC RECYCLING

PROCESS OF MANUFACTURE TO PRODUCE COLORLESS TRANSPARENT PLASTIC GRANULES FROM WASTE

SORTING

SMASHING

WASHING

CONCENTRATION OF BLENDING

SOLVENT ADDITION

REMOVAL OF COLOUR TO OBTAIN TRANSPARENT GRANULES BY ACTIVATED CARBON TREATMENT

FILTERATION

DISTILLATION

COOLING AND DEHUMIDIFYING

GRANULATION

WEIGHING, FILLING AND PACKING

MANUFACTURING PROCESS FLOW CHART

RECYCLING POLYETHYLENE TEREPHTHALATE (PET)

RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:

PET COLLECTION AND SORTING

PROCESS OF PET RECYCLING UNIT

SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT

PROCESS FLOW DIAGRAM OF PET RECYLING

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

IMPLEMENTATION SCHEDULE

EFFLUENT TREATMENT AND DISPOSAL

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

MANPOWER

GENERAL

BASIS OF ESTIMATION

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF PLASTIC RECYCLING PLANT

COMPLETE PLANT SUPPLIERS FOR PLASTIC GRANULES FROM WASTE

SUPPLERS OF PLANT & MACHINERY

SUPPLERS OF REACTION VESSEL

SUPPLERS OF GRANULATORS

SUPPLERS OF MIXER

WASTE RAW MATERIAL SUPPLIERS ADDRESSES

PLASTIC PROCESSING MACHINERY SUPPLIER IN INDIA

MACHINERY AND PROCESS KNOW HOW

PLASTIC TESTING LABS IN INDIA

ADDRESSES OF RAW MATERIALS 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)