Detailed Project Report on production of parallel paper tubes

PRODUCTION OF PARALLEL PAPER TUBES
[CODE NO.3717]  


Paperboard tubes are ubiquitous and are found in every aspect of modern-day life. In the industry, the terms paperboard “tube” and paperboard “core” are used interchange-ably. They are produced for a myriad of industrial applications and consumer products and are sometimes considered to be commodity products, but most are actually highly engineered. On a global basis, the majority of paper tubes are used in industrial winding operations. In these applications, immediately after being manufactured, either paper, film, or textile yarn is wound directly onto paper tubes. The paper tube helps the wound material develop a stable roll structure and enables transportation of the manufactured material to a converting operation. These tubes range from small (10- to 25-mm diameter with 0.5- to 1.5-mm wall thickness) to wind paper, plastic, aluminum, cloth, and yarn consumer products, to large industrial cores (70- to 200-mm diameter having10- to 25-mm wall thickness) to wind rolls of printing paper, plastic film, textiles, and specialty metals. Such tubes are designed to be used in interior environments for winding, transportation, and finishing operations; not exterior environments where they are exposed to rain or high humidity. Most tubes for industrial markets are structurally optimized and engineered products. This is achieved by selecting proper paper-board strength and stiffness, tube thickness, ply positioning in the wall, and adhesive type in the design process. For example, certain paper mill cores are designed both for fatigue strength to support a heavy cyclic load from winding a large roll of paper and for sufficient axial modulus to prevent core vibrations when unwinding the paper roll on high-speed rotogravure presses. Such cores generally require thick walls (10e16 mm) and fabrication from high strength paperboards.

Paper tubes are defined as cylindrical containers made from cardboard that vary in thickness and size. These containers are used by a multitude of industries for countless applications because of their versatility and cost-effectiveness. For items that can either be rolled into a cylindrical shape or folded up to fit into a cylindrical container, paper tubes are useful containers for distributing, manufacturing, and shipping. Industries that use paper and cardboard for their applications include food, electronics, and automotive. They can be used in any department from distribution, insulation, parts protection, or storage.

 The paper tubes are broadly classified into a spiral type and a flatwise type. The spiral paper tube is formed by spirally winding a thin paper web around the outer circumference of a mandrel to a predetermined thickness. In contrast, the flatwise paper tube is formed by winding a paper web around the outer circumference of a mandrel in a direction perpendicular to the axis of the mandrel.

The flatwise paper tubes are further classified into a multi-layer type with a paper web wound in several layers to a predetermined thickness, and a single-layer type with a paper web wound in a single layer. The single-layer flatwise paper tube has a lapped portion where both side edges of the paper web are lapped and bonded with each other.

The spiral paper tube and the multi-layered flatwise paper tube have a rigidity which allows them to serve as the pipe member of the flavor inhaler. However, since such paper tubes are manufactured with an adhesive applied to the entire surface of the paper web, they contain a large amount of the adhesive which sorbs flavor components, and are therefore unsuitable as the pipe member of the flavor inhaler.

 On the other hand, the single-layered flatwise paper tube contains an adhesive only in the lapped portion, and is suitable as the pipe member of the flavor inhaler in terms of sorption of flavor components. However, due to its lower rigidity compared with that of the spiral paper tube or the multi-layered flatwise paper tube, the single-layered flatwise paper tube is not suitable as the pipe member of the flavor inhaler. In this regard, using a thick paper web to manufacture the single-layered flatwise paper tube is likely to increase the rigidity of the flatwise paper tube.


COST ESTIMATION

Plant Capacity                   7666.67 Nos/Day       
Land & Building (800 sq.mt.)      Rs. 1 Cr         
Plant & Machinery                      Rs. 42 Lac     
Working Capital for 2 Months     Rs. 72 Lac
Total Capital Investment              Rs. 2.28 Cr
Rate of Return            42%                   
Break Even Point             47%                



INTRODUCTION    
TYPES OF PAPER TUBES    
THE TYPES OF PAPER TUBES ARE:    
ADVANTAGE AND CARE OF PAPER TUBES    
ACCESSORIES    
PROPER CARE FOR PAPER TUBES    
STANDARDS    
USES AND APPLICATIONS    
B.I.S. SPECIFICATION    
PROCEDURE FOR PAPER TUBE MAKING    
PROCEDURE FOR SEAMLESS PAPER TUBES    
SEQUENCES FOR MAKING PAPER TUBES    
STEP 1: ROLLS OF PAPER    
STEP 2: GLUE THE PAPER    
STEP 3: WIND THE PLIES    
STEP 4: CUT THE PAPER TUBE    
PAPER TUBE MANUFACTURING    
(A) COLUMN FORMS AND (B) VOIDED SLAB TUBES. PHOTOGRAPHS WITH
ERMISSION FROM SONOCO PRODUCTS COMPANY.    
(A) A 160-CM-DIAMETER TUBE, (B) TUBE SEGMENTS (FOR 610-MM SPAN), AND (C) CONCRETE CAST ON TUBE SEGMENT.    
PAPER TUBE MANUFACTURING OPERATION. WITH PERMISSION FROM PAKEA.    
FIGURE UNWIND STANDS.    
FIGURE PLY POSITIONING AND ADHESIVE APPLICATION. WITH PERMISSION FROM PAKEA.    
(A) TUBE CUTTER (WITH PERMISSION FROM PAKEA.) AND (B) PALLETIZED TUBES    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
MATERIALS    
ADHESIVES FOR PAPER TUBE    
MAIN STEPS    
MAKING PROCEDURES FOR SEAMLESS TOP GRADE PAPER TUBE:    
STEP 1    
STEP 2    
STEP 3    
STEP 4    
STEP 5    
MANUFACTURING TECHNOLOGY    
1. PUNCHING DEVICE:-    
2. BEVELLING DEVICE:-    
3. EMBOSSING DEVICE:-    
4. GLUING DEVICE:-    
5. WINDING DEVICE:-    
6. TOP CURLING DEVICE:-    
7. NOTCHING DEVICE:-    
8. PRINTING DEVICE:-    
9. TOP COLOUR PAINTING DEVICE:-    
10. VELVETTING DEVICES    
11. BRUSHING DEVICE:-    
MARKET POSITION    
THE PAPER TUBE AND PAPER CORES INDUSTRY    
FEW INDIAN MAJOR PLAYERS ARE AS UNDER    
PRODUCT SPECIFICATION PAPER CORE TUBE    
THERE ARE 4 TYPES OF PAPER CORES SUCH AS:    
1. PAPER CORE STD CORE    
2. PAPER CORE CORE WG    
3. PAPER CORE CORE SPC    
4. PAPER CORE PRIME CORE    
PAPER TUBE    
1. FDY PAPER TUBE    
2. PAPER TUBE POY    
3. PAPER TUBE DTY (DRAWN YARN TEXTURE)    
EXPORT DATA OF PAPER TUBE    
IMPORT DATA OF PAPER TUBE    
GLOBAL MARKET POSITION OF PAPER TUBES    
THE GLOBAL PAPERBOARD TUBES PACKAGING MARKET HAS BEEN SEGMENTED
AS FOLLOWS –    
ON THE BASIS OF RAW MATERIAL, THE GLOBAL PAPERBOARD TUBES
PACKAGING MARKET HAS BEEN SEGMENTED AS:    
ON THE BASIS OF THICKNESS, THE GLOBAL PAPERBOARD TUBES PACKAGING ARKET HAS BEEN SEGMENTED AS:    
ON THE BASIS OF END-USE INDUSTRY, THE GLOBAL PAPERBOARD TUBES PACKAGING MARKET HAS BEEN SEGMENTED AS:    
GLOBAL PAPERBOARD TUBE PACKAGING MARKET: GEOGRAPHICAL OUTLOOK    
THE GLOBAL PAPERBOARD TUBES PACKAGING MARKET HAS BEEN DIVIDED
INTO SEVEN REGIONS AS FOLLOWS -    
DEMAND FOR COMPOSITE CARDBOARD TUBES MARKET IS EXPECTED
TO RISE AT A VALUE CAGR OF 5.7% THROUGHOUT THE FORECAST, 2017-2026    
COSMETICS AND PERSONAL CARE END USE INDUSTRY TO OFFER POTENTIAL OPPORTUNITIES FOR COMPOSITE CARDBOARD TUBE MANUFACTURERS    
APEJ TO GRAB A MAJOR SHARE IN THE GLOBAL COMPOSITE CARDBOARD
TUBES MARKET    
RING LID FOIL ASSEMBLY TO BE LARGELY USED FOR PACKAGING PURPOSES    
GLOBAL MANUFACTURERS OF PAPER TUBES    
ACE PAPER TUBE CORPORATION    
VALK INDUSTRIES, INC.    
MARSHALL PAPER TUBE COMPANY, INC.    
WESTERN CONTAINER CORP.    
CHICAGO MAILING TUBE CO.    
PAPER TUBES & SALES    
HEARTLAND PRODUCTS GROUP LLC    
PLANT LAYOUT    
PRESENT MANUFACTURERS OF PAPER TUBES    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PAPER ADHESIVE GLUE    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF PAPER TUBE TESTING EQUIPMENTS    
SUPPLIERS OF POWER TRANSFORMER    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFLUENT TREATMENT PLANT    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF JIGS AND FIXTURE    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    


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)