Detailed Project Report (DPR) on tableware and food containers from rice straw

TABLEWARE AND FOOD CONTAINERS 

FROM RICE STRAW

 [CODE NO.4169] 

Biodegradable disposable flatware and utensils manufactured from wood-based or plant-based raw materials, including materials that may be traditionally discarded such as sawdust, plant stalks, seed or grain hulls or the like. The process includes the use of a resin made from the discarded materials to form disposable utensils and flatware.

Today consumption of Disposable products is breaking records. Disposable products are easy to handle, economical and can be disposed easily. With the changing lifestyle of Mankind, the use of disposable products is raising like anything. Plastic Disposable products are very popular because it can be carried easily and very low in prices too.

The products include food containers and tableware – like plates, bowls, meal trays and cups – which decompose within 30-60 days after being discarded. The company sources processed bagasse from other organizations. This material is then moulded, dried, heated, and given other final touches. Heat-induced pressing during the manufacturing process gives structural strength to the cutlery. Additionally, the inter-fibre bonding makes the products water and oil resistant. It is a completely natural process and involves no binders, additives, coatings or chemical residues, resulting in a nontoxic, harmless and healthy alternative to plastic. The cutlery also does not impart colour, odour or taste to food. The products are microwave-safe and have an estimated shelf life of two years. Users cannot wash the tableware or containers after use; they have to be discarded.

This is 100% biodegradable & compostable tableware, which is widely used in various functions, restaurants, festivals as ECO FRIENDLY single time (Use & throw) crockery, it’s produce by Plant extract or residue like Sugarcane Bagasse (SCB) etc., which is Proven Environment friendly 100% Biodegradable and Compostable and not harmful for food, human, soil and Nature. This is becoming more popular due to environment awareness, climate change & NGT/State govt. bans on recyclable plastics. This can be use in microwave and refrigerator also.

10 inch Bagasse Round Regular Plate

Disposable products are made of various materials such as dry leaves, pulp, papers and plastic etc.

Thermoformed fiber is a material made by forming paper fibers or other natural fiber in a mold. The end product can be made into almost any shape for any type of solution. In the process of making thermoformed fiber, the product begins with a process similar to transfer molding. During the process of thermoforming fiber, the product is transferred to a set of heated metal molds that dry the fiber under intense pressure and heat, making an extra drying process unnecessary. The process of thermoforming the pulped fiber delivers parts that have a smooth finish on both sides of the thin and dense walls of the product. There are many advantages to having a thermoformed fiber product with smooth walls. They include: reduced freight and storage costs and the ability to use mechanical denesting. The use of thermoformed fiber is very desirable when visual appearance is preferred.

140ml Bagasse Cup

The process of pulp thermoforming is employed to develop sturdy and smooth packaging. This type of packaging can be used in various industrial and commercial uses. Thermoformed pulp is a desirable alternative to petroleum-based products. American Fiber Packaging has invested in the latest equipment technology and has developed a process to manufacture high-quality thermoformed fiber solutions. Through this process we are able to deliver environmentally responsible products to our customers.

Thermoformed molded fiber products can be customized to specifications and can include clamshells, trays, inserts, and many other types of packaging. Thermoformed pulp is a great alternative to petroleum-based foam products like expanded polystyrene (EPS) for protecting and positioning products inside packaging.

COST ESTIMATION

Plant Capacity                               1000 Kg./Day

Land & Building (2000 sq.mt.)     Rs. 2.49 Cr

Plant & Machinery                          Rs. 2.71 Cr

Working Capital for 2 Months      Rs. 99.91 Lac

Total Capital Investment               Rs. 6.38 Cr

Rate of Return                                27%

Break Even Point                           62%

• INTRODUCTION
• 10 INCH BAGASSE ROUND REGULAR PLATE
• 140ML BAGASSE CUP
• USE OF RICE STRAW FOR PACKAGING MATERIALS
• FORKS, PLATES, TRAYS, CONTAINER FROM PADDY STRAW
• COMPARISON OF BAGASSE VS PAPER AND OTHER MATERIAL
• OVERVIEW OF BIODEGRADABLE CUTLERY
• SUGARCANE BAGASSE PRODUCTS
• ARECA LEAF CUTLERY
• EDIBLE CUTLERY
• RICE HUSK TABLEWARE
• BAMBOO TABLEWARE
• MARKET ANALYSIS, POTENTIAL & GROWTH GLOBAL 
• BIODEGRADABLE FOOD PACKAGING MARKET
• INDIAN FOOD PACKAGING MARKET
• CLASSIFICATION OF GLOBAL FOOD PACKAGING
• MARKET SCENARIO OF DISPOSABLE CUTLERY
• GLOBAL MARKET OF BIODEGRABLE CUTLERY
• 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 OF 
• BIODEGRADABLE DISPOSABLE CUTLERY
• KEY BIODEGRADABLE PACKAGING PLAYER IN INDIA
• PROPERTIES & CHARACTERISTICS
• RAW MATERIALS
• PROS
• CONS
• BENEFITS OF THERMOFORMED FIBER
• MANUFACTURING PROCESS OF RICE STRAW PULP
• PULP THERMOFORMING AND MOLDED FIBER PACKAGING
• DETAILS OF MOULDED PULP
• ABOUT MOLDED PULP
• FIGURE ONE: CUSHION CURVES
• FIGURE TWO: DROP TEST
• MANUFACTURING PROCESS OF BIODEGRADABLE CUPS & PLATES PLANT
• PROCESS FLOW DIAGRAM
• SEQUENCES IN PULPING RICE STRAW
• RICE STRAW PULPING PROCESS
• COMPONENTS OF RICE STRAW
• NOTES FOR RICE STRAW PULP MAKING
• PROCESS OF MOLDED PULP
• SUSTAINABILITY OF MOLDED PULP
• RICE STRAW/BAGASSE PULP PLATE MAKING MACHINE
• THERE ARE 5 MANUFACTURING STAGES:
• FLOW CHART OF BAGASSE TABLEWARE PRODUCTION LINE
• PULP FIBRE TABLEWARE PRODUCTION PROCESS
• PULP TABLEWARE PRODUCTION LINE
• TECHNICAL SPECIFICATION OF PULP PROVIDING 
• SYSTEM FOR 1 TPD (150-180 KG/HR.)
• TECHNICAL SPECIFICATIONS OF PULP PROVIDING 
• SYSTEM FOR 3 TPD (150-180 KGS/HR.)
• OTHER BAGASSE/WOOD/BAMBOO PULP PRODUCTS
• PLANT LAYOUT
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS ADDRESSES OF PULP BOARD

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)