Detailed Project Report (DPR) on Manufacturing of rPET Chips & SSP Plant (24 MT/Day)

MANUFACTURING OF rPET CHIPS & SSP PLANT

[EIRI/EDPR/4708] J.C.: 2928XL

INTRODUCTION

PET-bottles more and more replace glass bottles in the beverage and food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages. On the one hand, the production of PET is less expensive and energy consuming than the production of glass. Secondly, the light weight of the PET-bottle makes it easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers more or less the same material properties as glass regarding hygiene, taste and gas impermeability. The consumption of bottled water has been increased very much in the past few years. Plastics are significant and make a positive contribution with regards to packaging in various ways. By sorting and processing plastic packaging that is found in predominantly homogeneous streams, the value and market availability is maximized for the collected plastic packaging industry. Plastic bottles, plastic tubs, and plastic bags all have the potential to be recycled. One of the fastest growing types of collected plastic materials for recycling is polyethylene terephthalate ("PET") from postconsumer beverage and water bottles. For beverages and other juices, plastic bottles are used more preferably. The growing utilization of plastics in industrial and consumer applications, combined with increased consumer awareness surrounding solid waste recycling, has led to an increased demand for recycled plastic resins and products. One of the fastest growing types of collected plastic materials for recycling is polyethylene terephthalate ("PET") from post-consumer beverage and water bottles. Replay Plastics will capitalize on the opportunities in the recycled resin.

Recycled Polyethylene Terephthalate (RPET) is simply a plastic made from repurposed waste PET from businesses and consumers. It’s also the material used most commonly by manufacturers to help meet their sustainability goals.

Because PET is so widely recyclable, bottles, food packages and other PET containers are taken and repurposed to create RPET, PCR and other plastics that can be used to make new products without damaging ecosystems and ending up in landfill sites.

Every year, an estimated 7.7 billion plastic water bottles are used in the UK, and 38 billion bottles of water are thrown away annually across the United States – not to mention the 4.9 billion tonnes of plastic waste produced globally already.

Unfortunately, most of these plastic bottles end up in landfill sites and oceans across the globe. This increases the drive to use sustainable RPET materials when manufacturing new products.

rPET has many benefits, including:

More environmentally friendly – than alternative plastics, because it’s made from recycled plastic. rPET leaves a significantly reduced carbon footprint compared with manufacturing new plastic and can be used again in other products. This also helps to reduce the amount of plastic that populates landfill sites and oceans worldwide.

Durability – rPET is highly resistant to chemicals and heat – making it an ideal material to store food and for use in microwaves, fridges and freezers.

Hygienic and low-hassle – Because of its glossy surface, rPET repels water and dirt – making it easy to clean.

Cost-effectiveness – rPET has low production costs. Developing recycled plastic uses little water and energy. The end product is also lightweight, reducing transportation costs and carbon emissions.

Encouraging use of recycled content

Establishing recycled content minimums for PET would send a signal to the markets that demand for recycled material will be consistent, which would help to stabilize its value. A number of markets have introduced directives setting targets for including recycled content in PET bottles.

In the European Union, the Single-Use Plastics Directive incorporates recycled content mandates for plastic beverage containers, setting a 25% target for recycled content in PET bottles by 2025 and 30% for all plastic bottles by 2030.

COST ESTIMATION

Plant Capacity            24 MT/Day

Land & Building (2 Acres)    Rs. 12.01 Cr

Plant & Machinery                    Rs. 115.10 Cr

Working Capital for 1 Month    Rs. 2.56 Cr

Total Capital Investment          Rs. 130.18 Cr

Rate of Return                          2%

Break Even Point                      94%

CONTENTS

INTRODUCTION

RPET HAS MANY BENEFITS, INCLUDING:

ENCOURAGING USE OF RECYCLED CONTENT

A GROWING APPETITE FOR RPET PLASTIC

PRODUCTS AND ITS APPLICATION

A PILE OF USED PET BOTTLES AT A WASTE TRADER

FIBER MADE FROM RECYCLED PET BOTTLES; INDIAN CRICKET TEAM T-SHIRTS MADE FROM RECYCLED PET BOTTLES

MARKET INSIGHTS

MAJOR COMPANIES GLOBALLY

MAJOR RAW MATERIAL S

WHY RECYCLE

RECYCLING TIPS

PET SAFETY FACTS

APPLICATIONS

RPET FLAKES APPLICATIONS

RPET SSP GRANULES

B.I.S. SPECIFICATION

PROMOTION

INDIAN ASSOCIATIONS

MANUFACTURING PROCESS

PET FLAKES

HARMONIZED SYSTEM (HS) FOR PET FLAKES:-

USES OF PET FLAKES 

PET FLAKES GRADES

SOME GRADES ARE: 

TYPES OF PET FLAKES

RECYCLING PROCESS OF PET FLAKES

THE RECYCLING PROCESS TAKES PLACE IN FOLLOWING STEPS: -

1. MANUAL SORTING: 

2. SHREDDING : 

3. BELT CONVEYOR:

4. WASHING TANK: 

RECYCLING PROCESS OF PET FLAKES

DIFFERENCE BETWEEN PET FLAKES AND PET CHIPS

MARKET IN INDIA 

SCOPE IN INDIA

ADVANTAGES

THEY HELP CONSERVE RAW MATERIALS IN MANY DIFFERENT INDUSTRIES

DISADVANTAGES

PET BOTTLE TO BOTTLE RECYCLING PROCESS

WASHING LINE

PELLETIZING PROCESS

CONTINUOUS SSP PROCESS

DETAILED VALUE CHAIN OF PET

TRENDS IN USAGE OF RECYCLED PET RESIN IN INDIA

RAW MATERIALS USED

GENERATION OF PLASTIC WASTE

YEAR WISE DATA FOR PLASTIC WASTE GENERATION AS PER CPCB ANNUAL REPORTS

INDUSTRYOVERVIEW

1. GLOBALPLASTICMARKET-MARKETPERFORMANCE

1.1. MARKET BREAKUP BY MATERIAL TYPE - VALUE TRENDS

TRENDS IN ASIA PACIFIC: 

GLOBAL PET MARKET - MARKET PERFORMANCE

GLOBAL PLASTIC WASTE MARKET - MARKET PERFORMANCE

TRENDSINASIAPACIFIC:

1.1. MARKET BREAKUP BY MATERIAL TYPE

PET WASTE HIGHLIGHTS: 

1.1. MARKETBREAKUPBYUSEOFPLASTICWASTE

MISMANAGEDWASTE:

INCINERATION:

RECYCLING: 

PETWASTEMARKETBREAKUPBYUSE

COUNTRY WISE COMPARISON OF RECYCLING RATE BY MATERIAL TYPE

1.1. TRENDS ON INCREASING PENETRATION OF RECYCLED MATERIAL USED FOR PET APPLICATIONS

GLOBALREGULATIONS:WASTECOLLECTION

INDIAPLASTICCONSUMPTION–MARKETPERFORMANCE

VOLUMETRENDS

PLASTICCONSUMPTIONBYTYPE

VALUE TRENDS

PET: 

INDIANPETMARKET

VOLUMETRENDS:

1.1.1. VALUETRENDS

VOLUMETRENDS

VALUETRENDS

INDIANPETPACKAGINGMARKET

VALUETRENDS

INDIAPLASTICWASTEGENERATION

VOLUMETRENDS

PLASTIC WASTE GENERATION BY STATES

INDIANREGULATIONSSUPPORTINGPLASTICWASTECOLLECTION&RECYCLING

PLASTICWASTEMANAGEMENTRULES:

TIMELINEOFPLASTICWASTEMANAGEMENTRULESININDIA

CATEGORIES,TARGETS,ANDTIMELINES

ASPERPLASTICWASTEMANAGEMENT(AMENDMENT)RULES,2022,THECLASSIFICATIONOFPLASTICSISDEFINEDBELOW:

GUIDELINESONEXTENDEDPRODUCERRESPONSIBILITY(EPR)FORPLASTICPACKAGING

INDIAWASTEPLASTICRECYCLINGMARKET

MARKETOVERVIEW

VOLUMETRENDS

RECYCLINGPLASTIC:BREAKUPBYSTATES

INDIAPETWASTEMANAGEMENT(VOLUMETRENDS)

GLOBAL RPET MARKET

MARKETOVERVIEW

TRENDSFORINCREASINGUSEOFRPET

LARGECORPORATIONSHAVINGSUSTAINABILITYMANDATES

NUMBEROFBOTTLESCONSUMEDININDIA(VOLUMETRENDS)

INDIA RPET MARKET

MARKET OVERVIEW

VOLUME TRENDS

VALUETRENDS

MARKETBREAKUPBYAPPLICATION

VOLUMETRENDS

VALUE TRENDS

BENEFITSOFUSINGRECYCLEDMATERIALSOVERVIRGINPLASTIC

LISTOFINDIANKEYPLAYERS

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:

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. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

UTILITIES 

POWER

WORKING 

TOTAL MANPOWER AND PAYROLL 

UTILITIES

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

SOME OF THE MAJOR INVESTMENTS AND DEVELOPMENTS IN THIS SECTOR IN THE RECENT PAST ARE:

GOVERNMENT INITIATIVES

ROAD AHEAD

PLANT AND MACHINERY MANUFACTURERS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

RPET PROCESSOR/MANUFACTURERS IN INDIA

WEIGHING BREIDGE MANUFACTURER

WEIGHING MACHINES

PACKAGING MACHINE

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

EXTRUDER MACHINE MANUFACTURERS (GLOBALLY)

SS PIPE & TUBE MANUFACTURER

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

LICENCE OF PLASTIC WASTE IMPORT

DOCUMENTS REQUIRED ARE:-

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

ORGANIZATION CHART

PLANT LATOUT

IMPLEMENTATION SCHEDULE

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)