Detailed Project Report on MANUFACTURING OF rPET CHIPS & SSP PLANT

PET-bottles more and more replace glass bottles in the beverage and food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages. On the one hand, the production of PET is less expensive and energy consuming than the production of glass. Secondly, the light weight of the PET-bottle makes it easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers more or less the same material properties as glass regarding hygiene, taste and gas impermeability. The consumption of bottled water has been increased very much in the past few years. Plastics are significant and make a positive contribution with regards to packaging in various ways. By sorting and processing plastic packaging that is found in predominantly homogeneous streams, the value and market availability is maximized for the collected plastic packaging industry.

1. www.eiribooksandprojectreports.com 1


ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



MANUFACTURING OF rPET
CHIPS & SSP PLANT
[EIRI/EDPR/4708] J.C.: 2928XL


PET-bottles more and more replace glass bottles in the beverage and food sector.
The success of PET in comparison to glass is based on several economic (and
environmental) advantages. On the one hand, the production of PET is less
expensive and energy consuming than the production of glass. Secondly, the light
weight of the PET-bottle makes it easier for merchants and consumers to handle
the bottles and crates. It saves energy during transport, particularly on long
distance haulage. Finally, PET offers more or less the same material properties as
glass regarding hygiene, taste and gas impermeability. The consumption of bottled
water has been increased very much in the past few years. Plastics are significant
and make a positive contribution with regards to packaging in various ways. By
sorting and processing plastic packaging that is found in predominantly
homogeneous streams, the value and market availability is maximized for the
collected plastic packaging industry. Plastic bottles, plastic tubs, and plastic bags
all have the potential to be recycled. One of the fastest growing types of collected
plastic materials for recycling is polyethylene terephthalate ("PET") from
postconsumer beverage and water bottles. For beverages and other juices, plastic
bottles are used more preferably. The growing utilization of plastics in industrial
and consumer applications, combined with increased consumer awareness
surrounding solid waste recycling, has led to an increased demand for recycled
plastic resins and products. One of the fastest growing types of collected plastic
materials for recycling is polyethylene terephthalate ("PET") from post-consumer
beverage and water bottles. Replay Plastics will capitalize on the opportunities in
the recycled resin.

2. www.eiribooksandprojectreports.com 2



Recycled Polyethylene Terephthalate (RPET) is simply a plastic made from
repurposed waste PET from businesses and consumers. It’s also the material used
most commonly by manufacturers to help meet their sustainability goals.

Because PET is so widely recyclable, bottles, food packages and other PET
containers are taken and repurposed to create RPET, PCR and other plastics that
can be used to make new products without damaging ecosystems and ending up
in landfill sites.

Every year, an estimated 7.7 billion plastic water bottles are used in the UK, and
38 billion bottles of water are thrown away annually across the United States –
not to mention the 4.9 billion tonnes of plastic waste produced globally already.

Unfortunately, most of these plastic bottles end up in landfill sites and oceans
across the globe. This increases the drive to use sustainable RPET materials when
manufacturing new products.

rPET has many benefits, including:

More environmentally friendly – than alternative plastics, because it’s made from
recycled plastic. rPET leaves a significantly reduced carbon footprint compared
with manufacturing new plastic and can be used again in other products. This
also helps to reduce the amount of plastic that populates landfill sites and oceans
worldwide.

Durability – rPET is highly resistant to chemicals and heat – making it an ideal
material to store food and for use in microwaves, fridges and freezers.

Hygienic and low-hassle – Because of its glossy surface, rPET repels water and dirt
– making it easy to clean.

Cost-effectiveness – rPET has low production costs. Developing recycled plastic
uses little water and energy. The end product is also lightweight, reducing
transportation costs and carbon emissions.

Encouraging use of recycled content

Establishing recycled content minimums for PET would send a signal to the
markets that demand for recycled material will be consistent, which would help to
stabilize its value. A number of markets have introduced directives setting targets
for including recycled content in PET bottles.

3. www.eiribooksandprojectreports.com 3




In the European Union, the Single-Use Plastics Directive incorporates recycled
content mandates for plastic beverage containers, setting a 25% target for recycled
content in PET bottles by 2025 and 30% for all plastic bottles by 2030.

4. www.eiribooksandprojectreports.com 4


CONTENTS


INTRODUCTION
RPET HAS MANY BENEFI TS, INCLUDING:
ENCOURAGING USE OF RECYCLED CONTENT
A GROWING APPETITE FOR RPET PLASTIC
PRODUCTS AND ITS APP LICATION
A PILE OF USED PET BOTTLES AT A WASTE TR ADER
FIBER MADE FROM RECY CLED PET BOTTLES; INDIAN CRICKET TEAM T -SHIRTS
MADE FROM RECYCLED P ET BOTTLES
MARKET INSIGHTS
MAJOR COMPANIES GLOB ALLY
MAJOR RAW MATERIAL S
WHY RECYCLE
RECYCLING TIPS
PET SAFETY FACTS
APPLICATIONS
RPET FLAKES APPLICATIONS
RPET SSP GRANULES
B.I.S. SPECIFICATION
PROMOTION
INDIAN ASSOCIATIONS
MANUFACTURING PROCES S
PET FLAKES
HARMONIZED SYSTEM (H S) FOR PET FLAKES:-
USES OF PET FLAKES
PET FLAKES GRADES
SOME GRADES ARE:
TYPES OF PET FLAKES
RECYCLING PROCESS OF PET FLAKES
THE RECYCLING PROCES S TAKES PLACE IN FOLLOWING STEPS: -
1. MANUAL SORTING:
2. SHREDDING :
3. BELT CONVEYOR:
4. WASHING TANK:

5. www.eiribooksandprojectreports.com 5


RECYCLING PROCESS OF PET FLAKES
DIFFERENCE BETWEEN P ET FLAKES AND PET CHIPS
MARKET IN INDIA
SCOPE IN INDIA
ADVANTAGES
THEY HELP CONSERVE R AW MATERIALS IN MANY DIFFERENT INDUSTRIES
DISADVANTAGES
PET BOTTLE TO BOTTLE RECYCLING PROCESS
WASHING LINE
PELLETIZING PROCESS
CONTINUOUS SSP PROCE SS
DETAILED VALUE CHAIN OF PET
TRENDS IN USAGE OF RECYCLED PET RESIN IN INDIA
RAW MATERIALS USED
GENERATION OF PLASTIC WASTE
YEAR WISE DATA FOR PLASTIC WASTE GENERATION AS PER CPCB ANNUAL
REPORTS
INDUSTRYOVERVIEW
1. GLOBALPLASTICMARK ET-MARKETPERFORMANCE
1.1. MARKET BREAKUP BY MATERIAL TYPE - VALUE TRENDS
TRENDS IN ASIA PACIFIC:
GLOBAL PET MARKET - MARKET PERFORMANCE
GLOBAL PLASTIC WASTE MARKET - MARKET PERFORMANCE
TRENDSINASIAPACIFIC:
1.1. MARKET BREAKUP BY MATERIAL TYPE
PET WASTE HIGHLIGHTS :
1.1. MARKETBREAKUPBY USEOFPLASTICWASTE
MISMANAGEDWASTE:
INCINERATION:
RECYCLING:
PETWASTEMARKETBREAKU PBYUSE
COUNTRY WISE COMPARI SON OF RECYCLING RAT E BY MATERIAL TYPE
1.1. TRENDS ON INCREASING PENETRATION OF RECYCLED MATERIAL US ED FOR
PET APPLICATIONS
GLOBALREGULATIONS:WA STECOLLECTION
INDIAPLASTICCONSUMPT ION–MARKETPERFORMANCE
VOLUMETRENDS

6. www.eiribooksandprojectreports.com 6
PLASTICCONSUMPTIONBY TYPE
VALUE TRENDS
PET:
INDIANPETMARKET
VOLUMETRENDS:
1.1.1. VALUETRENDS
VOLUMETRENDS
VALUETRENDS
INDIANPETPACKAGINGMA RKET
VALUETRENDS
INDIAPLASTICWASTEGEN ERATION
VOLUMETRENDS
PLASTIC WASTE GENERA TION BY STATES
INDIANREGULATIONSSUP PORTINGPLASTICWASTEC OLLECTION&RECYCLING
PLASTICWASTEMANAGEMENTRULES:
TIMELINEOFPLASTICWASTEMAN AGEMENTRULESININDIA
CATEGORIES,TARGETS,ANDTIMELINES
ASPERPLASTICWASTEMAN AGEMENT(AMENDMENT)RU LES,2022,THECLASSIFICATI
ONOFPLASTICSISDEFINE DBELOW:
GUIDELINESONEXTENDEDPRODUCERRESPONSIBILI TY(EPR)FORPLASTICPAC KAGI
NG
INDIAWASTEPLASTICRECYCLIN GMARKET
MARKETOVERVIEW
VOLUMETRENDS
RECYCLINGPLASTIC:BRE AKUPBYSTATES
INDIAPETWASTEMANAGEM ENT(VOLUMETRENDS)
GLOBAL RPET MARKET
MARKETOVERVIEW
TRENDSFORINCREASINGUSEOFRPET
LARGECORPORATIONSHAV INGSUSTAINABILITYMAN DATES
NUMBEROFBOTTLESCONSUMEDININDIA(VOLUMETRE NDS)
INDIA RPET MARKET
MARKET OVERVIEW
VOLUME TRENDS
VALUETRENDS
MARKETBREAKUPBYAPPLI CATION
VOLUMETRENDS
VALUE TRENDS
BENEFITSOFUSINGRECYC LEDMATERIALSOVERVIRG INPLASTIC

7. www.eiribooksandprojectreports.com 7
LISTOFINDIANKEYPLAYE RS
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
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 FACTOR S:
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:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:

8. www.eiribooksandprojectreports.com 8
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND P AYROLL
UTILITIES
INDIAN MANUFACTURING INDUSTRY
INTRODUCTION
MARKET SIZE
INVESTMENT
SOME OF THE MAJOR INVESTMENTS AND DEVELO PMENTS IN THIS SECTOR IN
THE RECENT PAST ARE:
GOVERNMENT INITIATIVES
ROAD AHEAD
PLANT AND MACHINERY M ANUFACTURERS
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
RPET PROCESSOR/MANUF ACTURERS IN INDIA
WEIGHING BREIDGE MANUFACTURER
WEIGHING MACHINES
PACKAGING MACHINE
LABORATORTY EQUIPMEN TS MANUFACTURERS
D.G. SET MANUFACTURE RS & SUPPLIERS
ELECRICAL GOOD & SWITCH MANUFACTURE
EXTRUDER MACHINE MANUFACTURERS (GLOBALLY )
SS PIPE & TUBE MANUFACTURER
DOCUMENTS REQUIRED F OR LICENSES
LIST OF DOCUMENTS:
LICENCE OF PLASTIC WASTE IMPORT
DOCUMENTS REQUIRED A RE:-
ADDRESSES OF RELEVAN T GOVERNMENT OFFICES
ADDRESSES OF FINAN CIAL INSTITUTIONS
SWOT ANALYSIS
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
ORGANIZATION CHART
PLANT LATOUT
IMPLEMENTATION SCHED ULE

9. www.eiribooksandprojectreports.com 9



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)

10. www.eiribooksandprojectreports.com 10

COST ESTIMATION

Plant Capacity 24 MT/Day

Land & Building (2 Acres) Rs. 12.01 Cr

Plant & Machinery Rs. 115.10 Cr

Working Capital for 1 Month Rs. 2.56 Cr

Total Capital Investment Rs. 130.18 Cr

Rate of Return 2%

Break Even Point 94%