TEXTURISED YARN FROM WASTE PET BOTTLES
[EIRI/EDPR/4327] J.C.: 2510XL
INTRODUCTION
Poly-Ethylene Terephthalate (PET) is one of the most widely used plastics today. PET bottles are ubiquitous in our day-to-day lives–one has to just look around to spot a PET bottle containing mineral water or soft drink or used for other applications. PET bottles, post use, still carry a lot of value, and recycled PET (r-PET) can be used in a wide variety of applications. This makes post-consumer PET bottles a very sought after item by waste collectors. Discarded PET bottles fetch waste collectors Rs. 20-25/kg. These bottles are bought by kabadiwallahs or waste traders, who employ people to segregate, sort and further sell it to large vendors or recyclers. The caps, neck rings, labels (non-PET components) are removed, and the bottles are shredded, washed, and sold as what is called ‘washed flakes’. These washed flakes are then used to make (predominantly) polyester fiber, which is used as filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. These end products sell at anywhere between Rs. 50-60/kg; the market for r-PET products is quite large. There are 40+ large manufacturers across India who uses r-PET as raw material. The PET recycling business can be estimated (roughly) to be around Rs. 5,000- 10,000 crore in a given year in India.
PET Recycling
Discarded PET bottles are collected, sorted, cleaned, shredded, and made into ‘washed flakes,’ which are then used to produce a variety of products, starting from polyester fiber, which is used for a variety of applications like filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. Recycled PET (a small percentage) is also used for the manufacture of PET straps, monoYarn, sheets etc.
Value Chain of PET Recycling
There are a large number of people involved in the PET recycling business, starting from the waste collectors and kabadiwallahs to the small and medium traders, recyclers, and manufacturers who use recycled PET for various products. The chart above provides a simplistic illustration of the participants in the PET recycling business in India.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (4935 sq.mt.) Rs. 5.70 Cr
Plant & Machinery Rs. 9.80 Cr
Working Capital for 1 Month Rs. 3.70 Cr
Total Capital Investment Rs. 20.09 Cr
Rate of Return 27%
Break Even Point 66%
CONTENTS
INTRODUCTION
PET RECYCLING
VALUE CHAIN OF PET RECYCLING
CHARACTERISTICS/APPLICATIONS
THE MAJOR CHARACTERISTICS OF POLYESTER YARNS INCLUDE
SPECIFICATIONS OF PRODUCTS
MARKET OVERVIEW
REGIONAL SEGMENTATION ANALYSIS:
SALIENT TRENDS OF THE POLYESTER YARN MARKET
KEY PLAYERS IN THE POLYESTER YARN MARKET ARE
MARKET-O-NOMICS
FORMULATION
THE POLYESTER TEXTURIZED YARN IS MANUFACTURED WITH THE FOLLOWING COMPOSITION
PRODUCT YIELD IS AS FOLLOWS:
RAW MATERIALS DETAILS
POST-CONSUMER PET BOTTLES
CLEANING AGENT
FINISH OIL
ANTISTATIC OIL
CHEMICAL USED FOR PURIFICATION
MANUFACTURING PROCESS STEPS/PROCESS FLOW
STEP - A
PRODUCT: PET GRADUALS
STEP - B
PRODUCT: POLYESTER YARN (PY)
EFFLUENT TREATMENT FACILITY
UTILITIES REQUIREMENT (ESTIMATED - MONTH)
WASTE EFFLUENT/FLUE GAS EMISSION (ESTIMATED)
GREEN BELT
WATER
EMISSION
WASTE MANAGEMENT (ESTIMATED)
BIS SPECIFICATION
POTENTIAL TURNKEY PLANT/EQUIPMENT SUPPLIERS/CONSULTANT
BOILERS
SUPPLIERS OF EFFLUENT TREATMENT PLANT
D.G. SETS
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
LABORATORY TESTING EQUIPMENT
ENGINEERING CONSULTANTS/CONTRACTOR
STORAGE TANKS
LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT
GOVT. LICENSE DETAILS
PLANT & MACHINERY (MAJOR)
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:
PROJECT MANAGEMENT
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
POTENTIAL RISKS
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING)
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
SAFETY DATA SHEETS
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)
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