Detailed Project Report (DPR) on Plastic Moulded Chairs (PP)

PLASTIC MOULDED CHAIRS (PP)

[EIRI/EDPR/4360] J.C.: 2546XL

INTRODUCTION

The hunt for lightweight and affordable materials in the furniture industry is giving rise to the adoption of plastics in lieu of heavy-weight metals in modern furniture designs. Owing to the high-performance material properties of plastic, the demand for plastic furniture is likely to surge rapidly in the upcoming years. 

The business of Molded Furniture has marked its place in the country through growth during the last ten years. This growth has opened up new opportunities. The prime reason for this is awareness about the product. Along with that, companies are offering conditional warranty of plastic chairs minimizing risk of customer. Molded Furniture is basically produces in developed countries to be used as Lawn Furniture and outdoor restaurants. 

One of the most important plastics processing operations, in terms of variety of products made and amount of material handled, is injection molding. This production method now is being used to manufacture items from practically every known plastic.

Manufacturers in the plastic furniture market are modifying their business strategies to capitalize on the growth of the e-commerce industry as a potential distribution channel, as millennial consumers are highly inclined towards purchasing furniture online.

With the growing awareness about the negative impacts of plastic pollution on the environment, the adoption of recycled plastic materials is expected to increase in the plastic furniture market.

Injection molding is somewhat unusual among production methods in that essentially the entire process in carried out on the injection molding machines were similar in general design to metal die casting machines, but the processing characteristics of plastic have led to change in design & evolution that are still going on. The product injection molded plastic furniture are the products produced by these injection molding machines with varied shape & size along with different colour & shades according to the choice of customers & even according to the pattern as per the modern society such as office culture, drawing rooms of houses, which give style & liking of consumers.

At present, these injection molded plastic furniture frequently used at every mode of the social occasions & places.

The global market for plastic furniture has been witnessing healthy growth with commercial sector accounting for more than one-third share of the market revenues. However, with the increasing growth of the construction industry worldwide, especially in developing countries, the demand for plastic furniture is expected to surge significantly in the residential sector.

Leading manufacturers in the plastic furniture market account for over 45% revenue share of the market. Market leaders are predominantly focusing on expanding distributors’ network and strengthening their geographical foothold in the market.

New entrants and start-ups in the plastic furniture market are concentrating on launching innovative designs and cheaper alternatives to plastic furniture to gain recognition and create brand identity in the market.

A mounting number of small businesses are entering the plastic furniture market with an environmental conscience by launching new designs of plastic furniture made of recycled plastic, in order to capitalize on the growing consumer demand for eco-friendly products.

This type of chair is injection moulded. This manufacturing process is most cost effective for batch produced pieces of furniture. The initial sets up costs are high as expensive equipment is needed. The development and skillful manufacture of a dye (former) is an expensive task. However, if thousands of these type of chair are to be manufactured each chair is relatively cheap. Each chair should be of the same high quality. The modern contemporary materials suit a modern style and environment.

It is intended to prepare a Feasibility Report to install 120000 Nos/Year Plastic Moulded Chairs production facilities as a Green Field Project. 

COST ESTIMATION

Plant Capacity                              400 Nos./Day

Land & Building (14,160 sq.mt.) Rs. 1.72 Cr

Plant & Machinery                         Rs. 2.32 Cr

Working Capital for 2 Months     Rs. 46.80  Lac

Total Capital Investment              Rs. 4.64 Cr

Rate of Return                               16%

Break Even Point                           69%

CONTENTS

INTRODUCTION

PROPERTIES

PHYSICAL PROPERTIES:

MECHANICAL PROPERTIES:

THERMAL PROPERTIES:

PHYSICAL-CHEMICAL PROPERTIES:

USES & APPLICATIONS

MARKET OVERVIEW

BENEFITS OF SWITCHING TO PLASTIC

LOW MAINTENANCE

DURABLE

PORTABLE

ECONOMICAL

INNOVATIVE DESIGNS

MODERN FINISH

CHANGING CONSUMER DEMOGRAPHICS

THE BOOM IN REAL ESTATE AND HOUSING INDUSTRY

TOURISM AND HOSPITALITY GROWTH

THE PLASTIC FURNITURE INDUSTRY

EMERGING TRENDS IN THE PLASTIC FURNITURE INDUSTRY

FOREST-FRIENDLY

RECYCLED PLASTIC

ECOMMERCE 

INNOVATIVE PLASTIC DESIGNS

PLASTIC-STEEL COMBINATION FURNITURE 

GLOBAL PLASTIC INDUSTRY VS. INDIAN PLASTIC INDUSTRY

FUTURE SCOPE

PRESENT MANUFACTURERS/EXPORTERS 

BIS. SPECIFICATION

PRODUCTION LINE

PLASTIC CHAIR PRODUCTION LINE INCLUDE BELOW UNIT:

INJECTION MOLDING MACHINE

INJECTION MOLDING

INJECTION MOULDING PROCESS

LINE DIAGRAM OF MOULD

INJECTION MOULDING CYCLE TIME

PRESSURE CHANGE IN MOULDING CYCLE

PLASTIC CHAIR MOULD

PLASTIC CHAIR MOULD INCLUDING BELOW SEVERAL TYPES:

AUXILIARY MACHINERIES

MICROBUBBLES

MANUFACTURING PROCESS

THERE ARE THREE SUCCESSIVE MAIN STAGES, WHICH ARE GIVEN HERE

PREPARATION

INJECTION POSITION

INJECTION MOULD - CLOSED & PRESSED AGAINST NOZZLE.

WORKING POSITION

INJECTION MOULDED IS STILL PRESSED AGAINST NOZZLE.

CURING TIME

INJECTION POSITION REMAINS PRESSED AGAINST NOZZLE.

EJECTION POSITION

INJECTION MOULDING DATA

FINISHING

PROCESS STEPS

RAW MATERIAL FEEDING 

HEATING

COOLING

PROCESS FLOW 

HEAT TREATED PLASTIC CAN BE USED TO FORM A CURVE.

MOLDED PLASTIC CHAIR, WITH MOLDED PLASTIC ANY DESIRED FORM CAN BE OBTAINED.

PROCESS VARIABLES 

SPEED RELATED PROCESS VARIABLES 

PRESSURE RELATED PROCESS VARIABLES 

TIME RELATED PROCESS VARIABLES 

TEMPERATURE RELATED PROCESS VARIABLES 

PRELIMINARY LAYOUT

SUPPLIERS OF RAW MATERIALS

POLYPROPYLENE GRANULES

COLOUR MASTERBATCHES

TURNKEY PLANT SUPPLIERS 

SUPPLIERS OF PLANT & MACHINERY

INJECTION MOULDING MACHINE

MOULDS

SCRAP GRINDER

PLATFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

COOLING TOWER

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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)