Detailed Project Report (DPR) on MANUFACTURING OF BIODEGRADABLE PLASTIC GRANULES/PELLETS FROM CORN STARCH (CAP: 30 TPD)

MANUFACTURING OF BIODEGRADABLE PLASTIC GRANULES/PELLETS FROM CORN STARCH (CAP: 30 TPD)

[EIRI/EDPR/4778] J.C. 2998BDT, 2998INR

Bioplastics are biodegradable materials that come from renewable sources and can be used to reduce the problem of plastic waste that is suffocating the planet and contaminating the environment. Does it make any sense to continue using packaging that can take centuries to disappear to pack products that only last days or months?

Plastic is the third most commonly used petroleum derivative in the world; each year 200 million tons of plastic are consumed on the planet. It comes from a non-renewable source (petroleum), it is contaminating and non-biodegradable (it can take more than 1000 years to decompose).

That is why countries such as Bangladesh have prohibited traditional plastic bags (they jam the sewage pipes and cause flooding), Africa has baptized them as a new 'national flower' because they are so visible all over the landscape and Europe has considered taxing them. In addition, this waste is the cause of the death of marine species and fowl that ingest them (whales, sea turtles, albatross, etc.) and pose a serious environmental problem, such as garbage patches (islands of garbage).

The term “Biodegradable” refers to anything or substances that can be degraded by the natural forces and micro-organisms and Bio-degradable plastics refer to those plastics that can be decomposed by the micro-organisms and also natural factors such as rain, sunlight, etc. and these plastics broaden the options for waste management treatment options over traditional plastics. The most favorable disposable options for these plastics are the municipal composting areas instead of the landfills. Hence, the biodegradable plastics can make significant contributions to material recovery options, reduction of landfill, and utilization of the natural resources.

COST ESTIMATION

Plant Capacity                                    30Ton/Day 

Land & Building (12000 sq.mt.)  Rs. 2.39 Cr    

Plant & Machinery                            Rs. 4.51 Cr 

Working Capital for 2 Month            Rs. 18.40 Cr 

Total Capital Investment              Rs. 25.83 Cr 

Rate of Return                                  38%

Break Even Point                              42%

CONTENTS

INTRODUCTION

FIG.: BIODEGRADABLE PLA PELLETS

MARKET POTENTIAL 

INDUSTRIAL SCENERIO

PRODUCT USES:

ADVANTAGES OF BIOPLASTICS:

USES OF BIOPLASTICS:

RAW MATERIAL REQUIREMENT

MANUFACTURING PROCESS

FIG.: SCHEMATIC DIAGRAM OF THE MANUFACTURING PROCESS 

INDUSTRY OVERVIEW

BIO PLASTICS MARKET DYNAMICS:

ADVANTAGES:

BIO PLASTICS MARKET BY PRODUCT:

BIODEGRADABLE BIOPLASTICS

NON-BIODEGRADABLE BIO-PLASTICS

BIO PLASTICS MARKET BY APPLICATION:

KEY PLAYERS ANALYSED IN INDIA BIO PLASTICS MARKET:

TRENDS INFLUENCING THE BIODEGRADABLE PLASTICS MARKET SIZE

DRIVERS FOR THE BIOPLASTICS MARKET 

GROWTH IN INDIA

CHALLENGES FOR BIOPLASTICS

GLOBAL PRODUCTION CAPACITIES OF BIOPLASTICS 2021-2026

COMPARATIVE ADVANTAGE OF BIOPLASTICS

POPULAR VARIANTS OF BIOPLASTICS

STARCH INDUSTRY

BYPRODUCTS FROM MAIZE

STARCHES

NATURAL STARCHES

CEREAL STARCHES 

BRIDGING THE GAP WITH STARCH COMPOSITE GRANULES

SUBSTITUTE FOR TRADITIONAL PLASTIC GRANULES

ENVIRONMENTAL BENEFITS AND REDUCED DEPENDENCY ON TRADITIONAL PLASTICS

APPLICATIONS OF STARCH PLASTIC COMPOSITE GRANULES

FUTURE PROSPECTS OF STARCH PLASTIC COMPOSITE GRANULES

TOP BRANDS LIST BIOPLASTIC COMPANIES IN INDIA

LEADING BIOPLASTIC COMPANIES IN INDIA

OVERVIEW OF MAIZE GLOBALLY 

MAIZE MARKET TRENRS (GLOBAL)

INCREASE IN DEMAND FOR ANIMAL-BASED PROTEIN SOURCES

DEMAND- WORLD WIDE

CORN SCENARIO IN BANGLAGESH

BANGLADESH’S PRODUCTION, SUPPLY, AND DISTRIBUTION OF CORN

PRODUCTION

PRICES

CORN PRICE RISES

TRADE

CORN IMPORTS DECLINE

INDIA IS THE PREFERRED EXPORTER

CONSUMPTION

FEED AND RESIDUAL USE

FEED DEMAND SHRINKS DUE TO HIGH PRICES

FSI CONSUMPTION

STOCKS

CONSTITUENTS AND VARIETY OF MAIZE

SPECIFICATION OF CORN STARCH

CORN STARCH SPECIFICATION

USES OF STARCH:

STARCH HAS MANY INDUSTRIAL APPLICATIONS. THESE INCLUDE:

A) TEXTILE INDUSTRY:

B) FOOD INDUSTRY:

C) PAPER INDUSTRY:

D) PHARMACEUTICAL INDUSTRY:

E) MANUFACTURE OF GLUCOSE AND DEXTROSE BY HYDROLYSIS:

F) MANUFACTURE OF MODIFIED STARCHES, SUCH AS:

G) MISCELLANEOUS OTHER USES:

IN ADDITION TO THESE USES, BY PRODUCTS OF STARCH ARE ALSO OBTAINED DURING THE WET MILLING OF MAIZE.

A) CONCENTRATED STEEP LIQUOR:

B) GERM OIL AND GERM AND CAKE:

C) GLUTEN:

PHYSICAL AND CHEMICAL MODIFICATION OF STARCH

COMPONENTS OF YELLOW DENT CORN

QUALITY CONTROL 

FINAL PRODUCTS PHOTOGRAPHS

LIST OF LAB TESTING EQUIPMENTS

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:

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

UTILITIES

UTILITIES

STEAM

POWER

WORKING 

TOTAL MANPOWER AND PAYROLL 

MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY

SUPPLIERS OF LAB TESTING EQUIPMENT

MANUFACTURERS AND SUPPLIERS

STARCH

OTHER RAW MATERIALS SUPPLIERS

LIST OF SOME STARCH PROCESSING INDUSTRIES

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR PROCESSING MACHINE

IMPORTED COMPLETE PLANT & MACHINERY SUPPLIERS

FOREIGN COLLABORATORS

SUPPLIERS OF PLANT & MACHINERY

STARCH MAKING PLANT AND EQUIPMENTS

TANKS

TRAY DRIER

DISINTEGRATORS

PULVERISER/GRINDER

INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

TURNKEY CONSULTANT FOR SETTINGUP MAIZE PROCESSING PLANT

OTHER MANUFACTURER OF BIODEGRADABLE PLASTIC RAW MATERIALS

RAW MATERIAL SUPPLIERS

GRANULATORS

MIXER

OXO BIODEGRADABLECARRY BAGS MANUFACTURE IN INDIA

TESTING FACILITIES/CERTIFICATIONS

PACKAGING MACHINE

EXTRUDER MACHINE MANUFACTURERS (GLOBALLY)

WEIGHING BREIDGE MANUFACTURER

PLANT LOCATION COUNTRY BANGLADESH

ORGANIZATION STRUCTURE

IMPLEMENTATION SCHEDULE

PLANT LAYOUT

SWOT ANALYSIS

PLANT & MACHINERY

FIG.: HAMMER MILL

FIG.: PULPING MACHINE

FIG.: MIXING TANKS

FIG.: INDUSTRIAL FERMENTATION SYSTEM

FIG.: JACKETED REACTION VESSEL

VACUUM CRYSTALLIZER:

FIG.: VACUUM CRYSTALLIZER

FIG.: POLYMERIZATION REACTOR

SMR (STATIC MIXER REACTOR) OR THE PLUG FLOW REACTOR:

FIG.: PLUG FLOW REACTOR

VACUUM DEGASSER:

FIG.: VACUUM DEGASSING SYSTEM

PELLETIZER MACHINE:

FIG.: UNDERWATER PELLETIZER

PLASTIC PELLETS PACKAGING MACHINE. 

FIG.: PELLET PACKING MACHINE

FIG.: HEAT EXCHANGER

FIG.: CENTRIFUGAL PUMPS

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)