Detailed Project Report (DPR) on pp bags (1000 kg.)

PP BAGS (1000 KG.)

[CODE NO.4290] 

Packaging is both a symbol of society's consumption habits and reflection of its progress. The user expects it to have better strength, easier handling, to be lighter, more aesthetic, safer from a hygiene point of view, etc. The manufacturer undertakes research and development to meet these demands and to offer a high quality product. In addition to its standard attributes, today's packaging just also contributes to protecting the environment, and certainly must not damage it besides being friendly to human health. 

PP oriented strips are becoming increasingly popular in India & have caught the eye of many end users for their requirement of packing materials. They have become popular on account of their inertness towards chemical, moisture & excellent resistance towards rotting & fungus attack. They are non toxic. Lighter in weight & have more advantages than conventional bags.

PP woven sacks laminated with PP liner have wider applications. PP woven sacks are much stronger & can withstand much higher impact loads because of PP strips elongation at break is about 15-25% as compared to 30% of Jute. These sacks are much cleaner & resist fungal attack. Jute prices are very unstable in the market since Jute is an agriculture product. These sacks have many advantages over other conventional sacks materials & are quite competitive in price. PP Woven Sacks can be non-laminated, Laminated and along with PE liners. The size range for bags made from tubular fabric is from minimum 24 inches (60 cm.) upto 61 inches (155 cm).

Woven Sacks are the best and the most cost effective packaging solution for Industries like Cement, fertilizer, sugar, chemicals, food grains etc. off late Woven fabric, which is the first stage of Woven sacks, is a preferred medium for bale wrapping and rain protection in the form of Tarpaulin.

 Polypropylene Bags 

Polypropylene is a form of plastic. It’s available in a wide variety of forms but is essentially a flexible resin polymer. While the formal chemical name for the material is polypropylene, the generic layman’s term is “non-woven” simply because it’s really a large sheet of plastic and not a woven fabric. The material has been debossed to give it the appearance of woven cloth, yet it is really a non-woven material.

Polypropylene bags are made from virgin polypropylene plastic. Polypropylene bags are versatile, attractive bags most commonly used for packaging small items such as beads. These bags can be sealed with a heat sealer like many other plastic bags. While polypropylene is similar to cello, polypropylene bags are much clearer with neater seals, and have the advantage of being less expensive than cello bags.

Polypropylene poly bags have been the choice for product presentation and preserving freshness. Polypropylene poly bags are a high clarity crystal clear bag, which enhances the product's image. They provide a highly protective barrier against moisture, dirt and vapors and meet FDA and EFSA specifications for food content. Polypropylene bags also referred as 'Polyprop bags' or 'PP bags'. 

Material Grades of Polypropylene

Three types of Poly-Propylene are currently available. Each suits particular specifications and costing (although there is often some overlap). 

Homopolymers - A General Purpose Grade that can be used in a variety of different applications. 

Block copolymers - incorporating 5-15% ethylene, have much improved impact resistance extending to temperatures below –200C. Their toughness can be further enhanced by the addition of impact modifiers, traditionally elastomers in a blending process. 

Random copolymers - incorporate co-monomer units arranged randomly (as distinct from discrete blocks) along the polypropylene long chain molecule. Such polymers typically containing 1-7% ethylene are selected where a lower melting point, more flexibility and enhanced clarity are advantageous. 

Different PP grades are available dependent on the application and chosen processing method.

Polypropylene Properties

It is semi-rigid, translucent, good chemical resistance, tough, good fatigue resistance, integral hinge property, good heat resistance. 

Production of polypropylene takes place by slurry, solution or gas phase process, in which the propylene monomer is subjected to heat and pressure in the presence of a catalyst system. Polymerization is achieved at relatively low temperature and pressure and the product yielded is translucent, but readily coloured. Differences in catalyst and production conditions can be used to alter the properties of the plastic.

PP does not present stress-cracking problems and offers excellent electrical and chemical resistance at higher temperatures. While the properties of PP are similar to those of Polyethylene, there are specific differences. These include a lower density, higher softening point (PP doesn't melt below 160ºC, Polyethylene, a more common plastic, will anneal at around 100ºC) and higher rigidity and hardness. 

Additives are applied to all commercially produce polypropylene resins to protect the polymer during processing and to enhance end-use performance.

COST ESTIMATION

Plant Capacity                                   2000 Pieces/Day

Land & Building (4020 sq.mt.)  Rs. 5.62 Cr

Plant & Machinery                              Rs. 3.48 Cr

Working Capital for 2 Months    Rs. 3.12 Cr

Total Capital Investment                  Rs. 12.39 Cr

Rate of Return                                    13%

Break Even Point                               84%

• • INTRODUCTION
  
• • USES/APPLICATION/ADVANTAGES
• • BIS SPECIFICATIONS
• • MARKET OVERVIEW
• • RAW MATERIAL
• • MANUFACTURING PROCESS/PROCESS FLOW
• • SUPPLIERS OF RAW MATERIAL
• • SUPPLIERS OF PLANT AND MACHINERY
• • PRODUCT & MACHINERY 
• • PRINCIPLES OF PLANT LAYOUT
• • PLANT LOCATION FACTORS
• • GENERATION AND MANAGEMENT OF WASTES
• • ANTICIPATED ENVIRONMENTAL IMPACTS 
• • MITIGATION MEASURES (PROPOSED)
• • HEALTH SAFETY & ENVIRONMENT
• • PROPOSED IMPLEMENTATION SCHEDULE
• • PROJECT FINANCIALS

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)