Detailed Project Report (DPR) on pulp preparation plant from bagasse and other fibre

PULP PREPARATION PLANT FROM BAGASSE AND OTHER FIBRE

[CODE NO.4097] 

Bagasse is the by-product of the sugar industry and is also one kind of papermaking fiber material. As the foundation of paper and pulp industry, fiber materials include wood fiber and straw fiber. Except for the sugarcane bagasse, there are some other materials like wheat straw, reed, bamboo, and kenaf, etc. Among all kinds of fiber materials, bagasse is low-cost and inexhaustible to make paper pulp. The bleached bagasse pulp can be mixed to certain quantity of microfiber and used to manufacture various high-grade cultural paper and living paper, such as body stock paper, copy paper, two-side offset paper, sanitary tissue, napkin and etc. With the proper manufacturing process, the bagasse pulp also can be applied to make coated art base paper or newspaper.

Bagasse, also called megass, fibre remaining after the extraction of the sugar-bearing juice from sugarcane. The word bagasse, from the French bagage via the Spanish bagazo, originally meant “rubbish,” “refuse,” or “trash.” Applied first to the debris from the pressing of olives, palm nuts, and grapes, the word was subsequently used to mean residues from other processed plant materials such as sisal, sugarcane, and sugar beets. In modern use, the word is limited to the by-product of the sugarcane mill.

Bagasse - It’s Renewable & Compostable Bagasse is naturally grease and cut resistant, microwavable, freezer safe and can easily withstand temperatures of 200 degrees fahrenheit. Because it is a plant based product, it is easily compostable and welcomed in commercial composting facilities as a carbon introduction vehicle in the composting process. Most bagasse can be home composted, too - as long as the end user chops or shreds the product and uses proper composting measures. Bagasse is therefore well positioned as an excellent alternative to conventional paper, plastic and foam based products in a growing number of products including tissue, newsprint, tableware, writing paper and a number of other consumer products.

Sugarcane is the common name of a species of herb belonging to the grass family. The official classification of sugarcane is Saccharum officinarum, and it belongs to the family Gramineae. It is common in tropical and subtropical countries throughout the world. It can grow from eight to twenty feet tall, and is generally about 2 inches thick. Several different horticultural varieties are known, and they differ by their stem color and length. About 200 countries cultivate this crop and Brazil is the world’s largest sugar cane producer, responsible for around 25 percent of total world production, followed by India, Pakistan, China and Thailand. India is second largest producer of sugar in the world.

Sugarcane is annual rhizomatous plant, the average length of fiber is usually 1047-3.04mm. After squeezing, the length of bagasse fiber is similar to the hardwood fiber, is 1.0-2.34mm. Bagasse pith is a parenchyma cell, it reduces the opacity and strength of paper, and increase the chemicals consumption and difficulty of manufacture. So the depithing is important for bagasse pulping.

Sugarcane bagasse belongs to the straw fiber, is easy to cook or bleach and requires fewer chemicals consumption. Because silicon content of bagasse is lower than other straw fibers, which decide the bagasse pulp process or equipment is more mature and easier.

COST ESTIMATION

Plant Capacity                                    15 Ton/Day  

Land & Building (6000 sq.mt.)           Rs. 7.46 Cr    

Plant & Machinery                                Rs. 3.29 Cr 

Working Capital for 1 Month             Rs. 1.17 Cr 

Total Capital Investment                     Rs. 17.68 Cr 

Rate of Return                                       38%

Break Even Point                                   50%

• INTRODUCTION
  
• BAGASSE - IT’S RENEWABLE & COMPOSTABLE
• LOCATION-MIDDLE EAST (UAE)
• USES AND APPLICATIONS OF PULP
• BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,
• COMPOSITION OF BAGASSE
• THE TRUTH OF SUGARCANE BAGASSE
• RAW MATERIAL
• RICE STRAW: -
• MAIZE STRAW: -
• SUGARCANE BAGASSE
• TYPES OF BIODEGRADABLE TABLEWARE, CUTLERY
• SUGARCANE BAGASSE BOWLS
• ARECA LEAF TABLEWARE
• BIO-LUTIONS AGRO-WASTE FIBER TECHNOLOGY
• EDIBLE CUTLERY
• RICE HUSK TABLEWARE
• BAMBOO TABLEWARE
• COMPARISON TABLE FOR VARIOUS BIODEGRADABLE TABLEWARE & CUTLERY
• USAGE
• ADVANTAGE/BENEFITS
• BENEFITS OF USING BIODEGRADABLE PLATES ARE LISTED BELOW:
• 1) EASY COMPOSTING
• 2) SAFE TO USE WITH MICROWAVE
• 3) HIGHLY ENERGY EFFICIENT
• 4) NONTOXIC
• COMPARISON OF BAGASSE VS PAPER AND OTHER MATERIAL
• MARKET OVERVIEW OF DISPOSABLE CUTLERY
• INDUSTRY INSIGHTS
• U.S. BIODEGRADABLE CUTLERY MARKET
• RAW MATERIAL INSIGHTS
• REGIONAL INSIGHTS 
• OVERVIEW OF BIODEGRADABLE CUTLERY
• SUGARCANE BAGASSE PRODUCTS
• EDIBLE CUTLERY
• RICE HUSK TABLEWARE
• MARKET POSITION
• MAJOR MARKETS FOR ARECA LEAF PLATES
• LEAF PLATE TRADE IN INDIA
• DISPOSABLE CUTLERY MARKET ANALYSIS
• KEY PLAYERS 
• REGIONAL INSIGHTS
• BY THE PRODUCT TYPE, THE MARKET IS PRIMARILY SPLIT INTO
• MARKET ANALYSIS, POTENTIAL & GROWTH GLOBAL BIODEGRADABLE 
•     FOOD PACKAGING MARKET
• INDIAN FOOD PACKAGING MARKET
• MARKET SCENARIO 
• US DEMAND TO RISE 3.6% ANNUALLY
• PACKAGING PRODUCTS TO BE FASTEST GROWING TYPES
• SERVICE WARE TO BE SUPPORTED BY FAVORABLE MARKET TRENDS
• PRESENT MANUFACTURERS/SUPPLIERS
• PROPERTIES & CHARACTERISTICS
• BENEFITS OF THERMOFORMED FIBER
• RICE/MAIZE STRAW/BAGGASE PULP MAKING/PROCESS 
• PULPING PROCESS
• COMPONENTS OF RICE STRAW
• BAGASSE PULP PROCESSING
• MATERIAL PREPARATION
• BAGASSE PULP COOKING
• BAGASSE PULP WASHING
• BAGASSE PULP SCREENING
• BAGASSE PULP BLEACHING
• NOTES FOR STRAW PULP MAKING
• MANUFACTURING PROCESS OF PULP
• BAGASSE / RICE /WHEAT STRAWPULP PLATE MAKING MACHINE
• THERE ARE 5 MANUFACTURING STAGES:
• FLOW CHART OF BAGASSE TABLEWARE PRODUCTION LINE
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF RAW MATERIALS
• PULP & PAPER MILLS COMPANIES IN AUSTRALIA
• PRINCIPLES OF PLANT LAYOUT 
• 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:
• 8. TOTAL LOAD:
• 9.   LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING 
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• MACHINERY PHOTOGRAPHS STRAW/BAGASSE/WOOD/BAMBOO PULP
• RAW MATERIAL PHOTOGRAPHS
• PRODUCT PHOTOGRAPHS1

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)