Detailed Project Report (DPR) on kraft paper from waste paper (20 tpd)

KRAFT PAPER FROM WASTE PAPER (20 TPD) [CODE NO.3688]

Paper form a commodity of prime importance to day from the parts of view of mass communication, education, and industrial and economic growth. The art of paper making was first discovered in China in and around 2nd century. B.C. pan where it travelled slowly west ward and reached the prantiens of Europe. By the end of 14th century, a member of paper mill existed in Europe, particularly in Spain, Italy, France and Germany. the invention of printing in 1956 brought a vastly in creased demand for paper, and paper-manufacturing was introduced to  England. America followed in 1690.

Agricultural residues, such as bagasse, rice husk, wheat husk jute sticks, grasses, etc are fast becoming  popular  materials for  paper making. considerable attention is being given to the utilization of  various agricultural by products  for  preparing pulp for paper manufacture landable efforts are being make in this direction.

Paper production requires a disintegration of the bulky fibrous material to individual or small agglomerate fibres.

This is called pulping. The ideal fibre for high grade paper should be long, high in cellulose content and low in ligrin content. Most ideal raw material for paper products is bamboo. Other sources are bagasse and hardwoods like jute stick must be developed and good quality paper pulp make by blending with bamboo fibre.

Over recent years, the emergencies of mini paper plants on a reality seems to hold the promise of adding new horizons to the development and growth of Indian paper industry. In may be  noted with  concern that the large sector of this industry  for  quite sometime,  has  failed to sustain any appreciable  growth  due  to various factors  eg. The plant being highly capital intensive low rats  of  return  and the raw material bottlenecks etc. mini paper plants are viewed as an effective remedy to the current  ailments of  the paper industry  as they involve much less  capital cost and are proved to be technically feasible and economically viable these  plants can be erected on the basis of fully indigenous expertise, know how and  machinery. Moreover, they after an effective means of lasing considerably the burden an conventional raw materials.

COST ESTIMATION

Plant Capacity            20 MT/Day       
Land & Building (3 Acres)      Rs. 6.80 Cr         
Plant & Machinery                      Rs. 8.05 Cr     
Working Capital for 2 Months     Rs. 3.38 Cr
Total Capital Investment              Rs. 18.73 Cr
Rate of Return            26%                   
Break Even Point             56%                

 
INTRODUCTION    
1. SHORTAGE OF FIBROUS RAW MATERIAL    
2. HIGH PROCESS AND SHORTAGE OF CHEMICALS    
USES AND APPLICATION    
BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,    
B. I. S. SPECIFICATION    
B.I.S. SPECIFICATION FOR KRAFT PAPER    
SCOPE    
GRADES    
REQUIREMENTS    
MATERIAL    
FINISH    
SIZE AND TOLERANCE ON SIZE    
PHYSICAL REQUIREMENTS:-    
PACKING AND MARKING    
PACKAGE    
ROLL    
MARKET POSITION OF KRAFT PAPER    
GLOBAL KRAFT PAPERS MARKET CLASSIFIED ON THE BASIS
    OF REGION AS FOLLOWS:    
OVERVIEW OF INDIAN PAPER INDUSTRY    
CHART 1: INDIA'S SHARE OF THE GLOBAL MARKET    
CHART 2: PER CAPITA CONSUMPTION OF PAPER (KG)    
CHART 3: DOMESTIC PAPER DEMAND (IN MN TONNES)    
THE BROAD CHARACTERISTICS OF THE INDUSTRY ARE:    
CHART 4: INDIA VS. WORLD - SEGMENT WISE CONSUMPTION    
DOMESTIC DEMAND FOR PAPER IS EXPECTED TO CONTINUE GROWING
   AT A ROBUST PACE WITH PACKAGING PAPER & BOARD AND SPECIALTY
   SEGMENTS REGISTERING THE FASTEST GROWTH RATES    
DEMAND DRIVERS    
RISING INCOME LEVELS & GROWING PER CAPITA EXPENDITURE    
CHART 5: PER CAPITA INDICATORS (RS '000 AT CURRENT PRICES)    
A LARGER PROPORTION OF EARNING POPULATION TO DRIVE CONSUMPTION    
CHART 6: AGE DISTRIBUTION OF INDIAN POPULATION    
INCREASING URBANIZATION    
CHART 7: DISTRIBUTION OF INDIAN POPULATION (%)    
WIDENING SPREAD OF EDUCATION AND INCREASE IN LITERACY RATE    
CHART 8: LITERACY RATE (%)    
CHART 9: NO. OF COLLEGES    
CHART 10: ENROLMENT IN HIGHER EDUCATION (IN MN)    
RISING CIRCULATION AND NUMBER OF NEWSPAPERS AND MAGAZINES    
P&W SEGMENT TO WITNESS SLOWER CAPACITY ADDITION, WHILE
ACKAGING PAPER & BOARD SEGMENT TO WITNESS RAMP UP    
CHART 11: PLANNED CAPACITY (IN MILLION TONNES)    
CHALLENGES    
ACCESS TO QUALITY AND COST COMPETITIVE RAW MATERIAL    
COMPETITION FROM IMPORTS    
TECHNOLOGY    
RAPIDLY INCREASING IMPORTS ALONG WITH STEADY EXPORTS AND
   DOMESTIC PRODUCTION INDICATES INCREMENTAL DOMESTIC
   DEMAND IS BEING MET THROUGH IMPORTS    
CHART 12: IMPORTS - PAPER (EXCL. NEWSPRINT)    
CHART 13: EXPORTS - PAPER (EXCL. NEWSPRINT)    
CHART 14: IMPORTS - NEWSPRINT    
CHART 15: EXPORTS - NEWSPRINT    
PAPER AND PAPER PRODUCTS PRICE MOVEMENT    
RAW MATERIAL SCENARIO    
CHART 16: SWEDISH PULPWOOD PRICES    
FINANCIAL ANALYSIS    
CHART 18: REVENUE GROWTH    
CHART 19: MARGINS    
CHART 20: DEBT LEVEL    
CONCLUDING REMARKS    
PRESENT MANUFACTURERS/SUPPLIERS    
REFINING    
PAPER MAKING AND FINISHING:-    
FORMING OF WET WEB:-    
PRESSING THE WET SHEET    
DRYING THE SHEET:    
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF KRAFT PAPER
   FROM WASTE PAPER    
FLOW SHEET OF MANUFACTURE OF PAPER    
FORMING OF WET WEB, PRESSING THE WET SHEET & DRYING THE SHEET    
METHOD OF PREPARATION OF DIFFERENT    
TYPES OF PULPS    
(I) PROPOSED SYSTEM FOR PRODUCING UN-BLEACHED PULP
    FROM WET STRENGTH PAPER.    
PLANT LAYOUT    
POLLUTION CONTROL IN PULP AND PAPER INDUSTRIES    
(IN DETAIL)    
PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS:-    
COMMON PULPING PROCESSES    
CHEMICAL CHARACTERISTIC OF EFFLUENT FROM    
A LARGE SULPHATE (KRAFT) PULP AND PAPER MILL USING CHEMICAL
    RECOVERY    
POLLUTION CONTROL FOR LIQUID EFFLUENTS    
INPLANT MEASURES    
PROCESS CHANGES:-    
COMPLETE MACHINERY MANUFACTURERS/SUPPLIERS FOR PAPER PLANT    
SUPPLIERS OF RAW MATERIALS    
WASTE PAPER    
CAUSTIC SODA    
ALUM    
ROSIN    
LIME POWDER    
PLANT AND MACHINERY SPECIFICATIONS    
FOR KRAFT PAPER FROM WASTE PAPER    
LIST OF PLANT & MACHINERY WITH COST    
WASTE TREAD STREET    
LIQUOR AND CHEMICAL PREPARATION SECTION    
STOCK PREPARATION AND APPROACH FLOW SYSTEM    
MACHINE SECTION:-    


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)