LEATHER BOARD FROM LEATHER WASTE (CAPACITY- 2 TONS PER DAY)

LEATHER BOARD FROM LEATHER WASTE (CAPACITY- 2 TONS PER DAY)

 [EIRI/EDPR/4808] J.C.: 3029X(INR), 3030 (US$) XL

INTRODUCTION

Chrome tanned leather wastes are uniformly fibrised and made into a pulp like that of paperboards. The charges of the pulp may be modified suitably and then they are mixed with rubber latex solution and by changing the conditions the coagulated mass is pressed under a plate and dried. The leather board is used in footwear industry as insole. 

Generally leather board is made by extracting fibers from shavings and other solid waste using hammer mills, Hollander beaters, treating those fibers with chemicals and binders, Adding copious amounts of water to make a slurry, floating the in surrey on a wire gauze, allowing the water to drain off and then drying out the resulting sheet of matted fibers which is called leather board.

 Disadvantages in this utility 

1. Leather board are using as low value end products like mid sole, Insoles and reinforcement materials. 

2. Poor Physical and chemical properties. 

3. No pre treatment for leather waste. 

Preparation of parchment and leather like materials 

Preparation of parchment like materials and leather like materials to offer an alternative and better solution for the disposal of chrome shavings. Parchment membranes can be used in the preparation of lampshades, chandeliers, wall hangers, table tops etc. And leather like materials can be used in the preparation of chapel uppers, hand bags, purses etc, 

Disadvantages in this utility 

1. Restricted usage only. 

2. Low value end products 

Glue and gelatin from chrome shavings 

Chrome shavings are dechromed with 10% sodium glycolate at pH 8-9 and 40⃰ C for 24 hrs.The extraction is repeated with a fresh solution using the same condition. After dechroming shavings are washed thoroughly with water at room temperature and then they are pre treated with10% NaOH.After 8 hours treatment caustic liquor is drained out and the shavings are allowed to mature for a period of 40hours.The alkali conditioned materials is further treated with 5% hydrogen peroxide in5% sodium carbonate for 24 hours. After a through wash, the pH of the chrome waste is brought to 8.0-8.5 by HCL.Then the shavings are extracted for gelatin at different temperatures. 

Disadvantages in this utility 

1. Low value end product 

2. Limited usage only. 

3. Glue bonding strength is moderate only. 

Blended fabrics from chrome shavings 

Leather fibers were extracted from these solid wastes and they are mixed with various proportions of natural (cotton) and synthetic (polyester) fibers to prepare composites. These composites were further processed into leather blended yarns and leather blended fabrics. These fabrics have very good physicochemical and mechanical properties, which enable their use in leather and textile industry applications. This concept of fabric manufactures which is energy efficient, eco-friendly and cost effective. In this process 70% the leather shavings can be recycled for the fabrication of cotton blended fabrics. 

COST ESTIMATION

Plant Capacity                                    2 Ton/Day 

Land & Building (1000 sq.mt.)  Rs. 2.71 Cr    

Plant & Machinery                            Rs. 35.35 Lacs 

Working Capital for 2 Month            Rs. 1.17 Cr 

Total Capital Investment                  Rs. 4.42 Cr 

Rate of Return                                  36%

Break Even Point                              52%

CONTENTS

INTRODUCTION

COMPOSITE OF LEATHER WASTE

COMPOSITES

PINEAPPLE LEATHER VS ANIMAL LEATHER

ENVIRONMENTAL CLEARANCE PROCESS

USES AND APPLICATION

PLANT BASED LEATHER

TECHNOLOGY FOR LEATHER BOARD

MARKET OF LEATHER BOARD IN KENYA

LEATHER & RELATED PRODUCTS - KENYA

MARKET OVERVIEW OF LEATHER GOODS

KEY MARKET TRENDS & INSIGHTS

MARKET SIZE & FORECAST

TYPE INSIGHTS

REGIONAL INSIGHTS

KEY COMPANIES & MARKET SHARE INSIGHTS

OVERVIEW OF FOOTWEAR AND LEATHER

GARMENTS IN INDIA

FORMULATION OF LEATHER BOARD FROM LEATHER WASTE

MANUFACTURING PROCESS OF LEATHER BOARD 

FROM LEATHER SCRAP

PROCESS FLOW DIAGRAM

PROCESS IN DETAILS

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED

IN THE PROJECT REPORT

PROJECT IMPLEMENTATION SCHEDULES

ADDRESSES OF PLANT & MACHINE SUPPLIERS

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)