nonwoven bags project report dubai

7/22/2019 Nonwoven Bags Project Report Dubai

http://slidepdf.com/reader/full/nonwoven-bags-project-report-dubai 1/54



C A U T I O N

This project report has been prepared on the basis of information available with M/S. ENGINEERS INDIA RESEARCH INSTITUTE. The intention here is to provide preliminary information to the prospective entrepreneur. Prior to making a firm decision for investment in the project the entrepreneur must verify the

various feasibility aspects together along with the addresses for the procurement of plant & machinery and raw materials independently. The informations supplied in this report is obtained from the reliable sources but it is not guaranteed and the money once paid will not be refunded back in any case. Claims for incomprehensiveness of the project report will not be entertained and no legal action in this regard would be entertained in any case (Subject to Rajkot Jurisdiction only). Any matter relating to our standard points covered in the report may be modified with in 5 days time only from the date of purchase.

Indian Project Research Institute



NON-WOVEN CARRY/SHOPPING BAGS

[IPRI/BAGS/44A6] T.154

CONTENT PAGE NO

01. INTRODUCTION 4 02. USES AND APPLICATIONS 9 03. NONWOVEN FABRIC- RAW MATERIAL 10 04. MARKET SURVEY 15 05. NON WOVEN POLYPROPYLENE 16 06. DEMAND SUPPLY GAP 17 07. PRESENT MANUFACTURERS 18 08. MANUFACTURING PROCESS 20 09. PRINCIPLES OF PLANT LAYOUT 23 10. PLANT LOCATION FACTORS 29 11. EXPLANATION OF TERMS USED IN THE PROJECT REPORT 33 12. SUPPLIERS OF RAW MATERIAL (INDIAN) 36 13. SUPPLIERS OF PLANT & MACHINERY (INDIAN) 38

14. SUPPLIERS OF PLANT & MACHINERY (FOREIGN) 39

APPENDIX - A

1. COST OF PLANT ECONOMICS A 1 2. LAND & BUILDING A 2 3. PLANT AND MACHINERY A 3 4. FIXED CAPITAL INVESTMENT A 5

5. RAW MATERIAL A 6 6. SALARY AND WAGES A 7 7. UTILITIES AND OVERHEADS A 8 8. TOTAL WORKING CAPITAL A 9 9. COST OF PRODUCTION A11 10. PROFITABILITY ANALYSIS A12 11. BREAK EVEN POINT A13 12. RESOURCES OF FINANCE A14

3




[IPRI/BAGS/44A6] T.154

INTRODUCTION

Non woven poly bags are liquid resistant and offered in

variety of patteAED These can be used for regular purpose and

manufactured to meet the requirements of the clients. They are

designed in variegated patterns and following the latent trends to

satisfy the end user and available in reasonable prices.

Printed Nonwoven Punch Bag

This puch bag is made from nonwoven fabric instead of plastic. It has the same style as the plastic punch bag. But it's environment friendly and can be reusable. It's printed on 2 Sides, logo can also be printed. The 2 bag edges are heat cut and sealed, no stitching. We can offer various colors of such bag, and can produce any size. It's very great for shopping, gifts, makeups, favors, parties, jewellery, and much more.

Name: Printed Nonwoven Punch Bag

Size: 30 * 40 cm

Pack: 10 pcs per pack, 100 pcs per box

Fabric: Nonwoven fabric, edge heat cut & sealed, no stitching

4



Nonwoven Tote Bag W/Zipper

This nonwoven tote bag has a zipper on top to open and a small pocket inside. It gets a customized logo on both sides. Logo can also be printed on it. Sizes and colors can all be customized. its widely used for shopping, fashion,

gifts, and more.

Name: Nonwoven Tote Bag W/Zipper

Size: 38 * 40 * 12 cm

Thickness: 80 GSM

Pack: 100 pcs per box

Material: Non-woven fabric

Foldable Nonwoven Tote Bag

This nonwoven tote bag can be folded into a purse so you can save your space and take it very conveniently. It gets a snap at front to close when you fold it into a purse. Your logo can be printed on it. Sizes and colors can all be customized.

It's

widely used for shopping, fashion, gifts, and

more.

5



SPECIFICATIONS

Nonwoven Shopping Bag

This bag is made form polypropylene fiber, and is 100%

degradable.

Fashion design, good quality

Non woven shopping bag, non woven bag:

Non woven grocery bags:

Stock up on reusable grocery type non-woven bags:

All colors can supply.

No printing

Size: 36*46cm

Non-woven bags made out of material made from fibers that are bonded together by a process other than weaving (such as chemically, with heat,etc.). These bags are made

from polypropylene fiber, and are 100% degradable.

6



Features of the Non Woven Shopping Bag:

1. Eco-friendly

2. Suitable for advertisements

3. Shpping, packing, promotion

4. Anti-pull, anti-tear, strong, extensible and hig in the

intensity of machanics

5. Acid-resistant, alkali-resistant, non-poisonous and no harm

to human body

6. Good in ventilation

7. Recycle, environmentally friendly material

8. Water resistant and mosture proof

9. Durable and tear resistant

10. Available in a wide variety of styles

11. Various shapes, sizes and disigns acceptable

12. Buyer logos and designs acceptable

13. Materials: non woven fabric, any thickness

14. Printing: Solid colorfull colors printing

15. Surface decorative finishing: Gloss/matte lamination,

glitter, embossing, creasing, foil stamping, die cutting,

oil printing, screen printing;

16. Usually used for gift/clothes packaging and craftwork;

17. Carry handle; non woven, polyester

7



Specifications:

1. Weight range: 10-150gsm

2. Maximum width: 2.4m (subject to customer's desire)

3. Colors: many colors are available

4. Widely used such as promotional, shopping, packing,

supermarket packing and anywhere like

5. Printing: silk screen printing, intagilo printing, heat

trasfer printing

6. Speciality: good appearance beautiful and graceful,

incredibly strong, no-toxin and irrtation

7. We can offer you high quality and excellent service and

competitive price, we welcome to inquiry

Products Applications:

1. Nonwoven shopping bag

2. Gift bag

3. Dustproof cover

4. Storage Application

5. Bedding

Package: 100pcs/ctn or as customer requirement

8



USES AND APPLICATIONS

Non Woven Bags that are used shopping & promotional purposes bag, as a grocery bag, tote bag, gift bag and in trade shows as give aways. These eco firendly bags can be reused as these are made from non woven fabric and hence are eco friendly bags can be reusedas these are made from non woven fabric and hence are eco fiendly. Customization in terms of thickness of the bag, sizes and shapes can be altered as per client's requirment. These bags are also provied with modifiable side gusset and are available with standard carry handles or over the soulder

handles for the easy carrying.

Range of packaging products also include a wide variety of

nonwoven bags which are manufactured by using good quality eco- friendly materials like propylene. These bags are used for serving in various purposes. Non woven bags are 100% recyclable as these are manufactured with a durable, liquid

resisting and dehumidifying fabric which can be recycled.

Designing of Non Woven Bags and woven interlining fabric products. Special care is taken in getting these bags made from finest quality basic material. Besides the fact that these bags come in myriad shapes, sizes and volumes, these can be availed at market leading prices. Furthermore, Non woven

bags have made foray into a number of different applications.

Coated and uncoated non-woven polypropylene sacks/bags in number of sizes in addition to strength, ability, standard and superior at cost effective prices, offer non-woven fabric form 50 GSM to 200 GSM to 200 GSM in different colors and shapes. These bags can be used for promotion, shopping and packing of a range of consumer material up to packing of 25 kg. These are

available in desired color, shape and sizes.

9



NONWOVEN FABRIC- RAW MATERIAL

Nonwoven Fabric is a fabric-like materail from long fibers, bonded together by chemical, mechanical, heat or solvent treatment. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. Nonwoven materials typically lack strength unless densified or reinforced by a backing. In recent years, nonwovens have become an alternative to polyurethane

foam.

Nonwoven fabrics are broadly defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally or

chemically. They are flat, porous sheets that are made directly from separate fibers or from molten plastic or plastic film. They are not made by weaving or knitting and do not require converting the fibers to yarn. Typically, a certaing percentage of recycled fabrics and oil-based materials are used in nonwoven fabrics. The percentage of recycled fabrics vary based upon in nonwoven fabrics. The percentage of recycled fabrics vary based upon the strength of material

needed for the specific use.

Nonwoven fabrics are engineered fabrics that may be a limited life, single-use fabric or a very durable fabric.

Nonwoven fabrics provide specific functions such as absorbency, liquid repellency, resilience, stretch, softness, strength, flame retardancy, washability, cushioning, filtering, bacterial barrier and sterility. These properties are often combined to create fabrics suited for a specific jobs, while achieving a good balance between product use- life and cost. They can mimic the appearance, texture and strength of a woven fabric and can be as bulky as the thickest paddings. In combination with other materials they provide a spectrum of products with diverse properties, and are used alone or as components of apparel, home funishings,

health care, engineering, industiral and consumer goods.

10



Non-Woven Materials are Used in Numerous Applications,

Including

* Baby diapers

* Feminine hygiene

* Adult incontinence products

* Wet wipes

* Bandages and wound dressings

* Isolation gowns

* Surgical gowns

* Surgical drapes and covers

* Sugical scrub suits

* Caps

* Gasoline, oil and air - including HEPA filtration* Water, coffee, tea bags

* Pharmceutical industry

* Mineral processing]

* Liquid cartrige and bag filters

* Vacuum bags

* Allergen membranes or laminates with non woven layers

* Soil stabilizers and roadway underlayment

* Foundation stabilizers

* Erosion control

* Canals construction

* Drainage systems

*

Geomeambranes protection* Frost protection

* Agriculture mulch

* Pond and canal water barriers

* Sand infiltration barrier for drainage tile

* Carpet backing, primary and secondary

* Composites:

* Marine saillaminates* Tablecover laminates* Chopped strand mat

* Backing/stabilizer for machine embroidery

* Packnaging - to sterilize medical products

* Insulation 9fiberglass batting)

* Pillows, cushions, and upholstery padding* Batting in quilts or comforters

* Consumer and medical face masks

* Mailing envelopes

* Tarps, tenting and transportation (lumber, steel) wrapping

* Disposable clothing (foot coverings, coveralls)

11



Nonwovens are typically manufactured by putting small fibers together in the form of a sheet or web (similar to paper on a paper machine), and then binding them either mechanically (as in the case of felt, by interlocking them with serrated needless such that the inter-fiber friction results in a stronger fabric), with an adhesive, or thermally (by applying binder (in the form of powder, paste, or polymer melt) and

melting the binder onto the web by increasing temperature).

Staple Nonwovens

Staple nonwovens are made in 2 steps. Fibers are first spun, cut to a few centimeters length, and put into bales. These bales are then dispersed on a conveyor belt, and the fibers are spread in a uniform web by a wetlaid process or by carding. Wetlaid operations typically use 1/4" to 3/4" long fibers, but sometimes longer if the fiber is stiff or thick. Carding operations typically use ~1.5" long fibeAED Rayon used to be a common fiber in nonwovens, now greatly replaced by PET and PP. Fiberglss is wetlaid into mats for use in roofing and shingles. Synthetic fiber blends are wetlaid along with cellulose for single-use fabrics. Staple nonwovens are bonded by using either resin or thermally. Bonding can be throughout the web by resin saturation or overall thermal bonding or in a distinct pattern via resin printing or thermal spot honding. Conforming with staple fibers usually

refers to a combination with meltblown, ofter used in high-end textile insultations. Melt Blown non wovens are produced by extruding melted polymer fibers through a spin net or die consisting of up to 40 holes per inch to form long thin fibers which are stretched and cooled by passing hot air over the

fibers as they fall from the die. The resultant web is collected into

rolls and subsequently converted to finished products. The extremely

fine fibers typically polypropylene differ from other extrusions

particularly spun bond in that they have low intrinsic strength

but much smaller size offering key properties. Often melt blown is

added to spun bond to form SM or SMS webs, which are strong and

offer the intrinsic benefits of fine fibers such

as fine filtration, low pressure drop as used in face masks or filters and physical benefits such as acoustic insulation as used in dishwasheAED One of the largest users of SM and SMS materials is the disposable diaper and feminine care industry.

12



Spunlaid Nonwovens

Spunlaid nonwovens are made in one continuous process. Fibers are spun and then directly dispersed into a web by deflectors or can be directed with air streams. This technique leads to faster belt speeds, and cheaper costs. Several variants of this concept are available, but the leading technology is the REICOFIL machinery. PP spunbonds run faster and at lower temperatures than PET spunbonds, mostly due to the difference in melting points. Spunbond has been combined with meltblown nonwovens, conforming them into a layered product called SMS (spun-melt- spun). Meltblown nonwovens have extremely fine fiber diameters but are not strong fabrics. SMS fabrics, made completely from PP are water-

repellent and fine media, being able to capture very fine particles. Spunlaid is bonded by either Resin or thermally. Regarding the bonding of spundlaid, Rieter has launched a new generation of nonwovens called Spunjet. In fact, Spunjet is the bonding of the Spunlaid filaments thaks to the hydroentanglement.

Air-Laid Paper

Air-laid paper is a textile-like material categorized as a nonwoven fabric made from wood pulp. Unlike the normal papermaking process, air-laid paper does not use water

as the carrying mediaum for the fibre. Fibres are carried and formed to the structure of paper by air.

Other

Nonwovens can also start with films and fibrillate, serrate or vacuum-form them with pattened holes. Fiberglass nonwovens areof two basic types. Wet laid mat or "glass tissue" use wet-chopped, heavy denier fibers in the 6 to 20 micrometre diameter range. Flame attenuated mats or "batts: use discontinuous fine denier fibers in the 0.1 to 6 range. The latter is similar, though run at much higher temperatures, to meltblown thermoplastic nonwovens. Wet laid mat is almost always wet resin bonded with a curtain coater, while batts are usually spray bonded with wet or dry resin. An unusual process produces polyethylene fibrils in a Freon-like fluid, forming them into a paper-like product and then calendering them to create

Tvvek.

13



Bonding

Both staple and spunlaid nonwovens would have no mechanical resistance in and of themselves, without the

bonding step. Several methods can be used:

* Thermal bonding:

* BUsing a large oven for curing

* Calendering through heated rollers (called spundbond

when combined with spunlaid), calenders can be smooth faced for an overall bond or pattened for a

softer, more tear resistant bond

* Hydro-entanglement: mechanical intertwining of fibers by

water jets (called spunlace)

* Ultrasonic pattern bonding, ofter used in high-loft or

fabric insulation/quilts/bedding

* Needlefelt: mechanical interwining of fibers by needles

* Chemical bonding (wetlaid process): use of binders (such as

latex emulsion or solution polymers)to chemically join

the fibers

*

A more expensive or solution polymers) to chemically join the fibers

* A more expensive route uses binder fibers or powders that soften and melt to hold other non-melting

fibers together

* One type of cotton staple nonwoven is treated with sodium hydroxide to shrink bond the mat, the caustic causes the cellulose-based fibers to curl and shrink around one

another as the bonding technique

* Meltblown is very weakly bonded from the air attenuated fibers intertangling with themselves during web

formation as well as the temporary tackiness when they are forming

* One unusual polyamide spunbond (Cerex) is self-bonded with gas-phase acid

14



MARKET SURVEY

Nonwoven PP bags are made out of oil - but other than this

initial position, they are a very sustainable choice for the

modern retailer. They promote reuse, they use a resource that

exists as a result of other production (i.e. derivatives - the

4% of world crude oil left over after fuel production), and

provide they are reused and recycled they have an extremely low

impact on the environment.

Non woven poly bags are liquid resistant and offered in

variety of patteAED These can be used for regular purpose and

manufactured to meet the requirements of the clients. They are

designed in variegated patterns and following the latent trends to

satisfy the end useAED

Now a day’s government has banned use of polythene bags

because of environment concerns. Nonwoven bags are fast replacing

polythene bags in the retail sector. With availability of bags in

the local market, the retail segment would gradually shift to

nonwoven bags. Creation of market for nonwoven depends upon the

entrepreneur’s ability to push the same in the market. Apart from

retail segment, the nonwoven bags are being widely used as fancy

bags, gift bags and Tote bags.

In a small township with 500,000 populations, the use of

carry bags by retailers could be to the tune of 10000 pcs per day.If the nonwoven bags take 20% of that market potential the use

could be 2000 bags per day.

15



DEMAND SUPPLY GAP OF GCC COUNTRIES

(Lakh Nos.) ---------------------------------------------------------------- YEAR DEMAND SUPPLY GAP ----------------------------------------------------------------

2005-06 700 620 80

2006-07 850 750 100

2007-08 1000 895 105

2008-09 1200 1050 150

2009-10 1400 1200 200

2010-11 1600 1350 250

2011-12 1800 1500 300

2012-13 2000 1650 350

2013-14 2200 1800 400

2014-15 2400 1950 450

2015-16 2600 2100 500

2016-17 2800 2250 550

2017-18 3000 2400 600

2018-19 3200 2550 650

2019-20 3400 2700 700

----------------------------------------------------------------

Based on GPCA Plastic Summit, Dubai

17



PRESENT MANUFACTURERS

List of some of the suppliers of different type of Bags in UAE (Importers Included)

East Eagle General Trading L.L.C. Mr. Ayub Khan Airport Road, Al Garhoud,

Dubai, United Arab Emirates http://www.east-eagle.com Telephone : 971-55-6695910 Fax : 971-50-5256714

B.B.M CREATION FOR FASHION & GIFTS &

ANTIQUES LLCP.O. Box :112440, Plot # 10,

M20 - Al Mussaffah Industrial Area,

Abu Dhabi, United Arab Emirates

Tel: 97125535700

Mob: 971504411296 Fax: 971-2-5535703

http://www.bbmfashion.com

SHIKMOS INTERNATIONAL ADVERTISING & CORPORATE GIFTS L.L.C Al Yousuf Baker Street, Ameena Jaseera Building. Office No: 15 Deira, Dubai

http://www.shikmo.com

Tel: 97142284611Mob: 00971504662513

Fax: 971-4-2284662

H&A Media Al Garhoud, Dubai, United Arab Emirates

http://hagifts.com

http://handamedia.com Tel: 971042395377

Mob : 00971 50 3475767Fax: 971-04-2395373

D'CRUSH

Dubai, United Arab Emirates Tel: 971-55-6551194

http://www.dcrush.com

KOSHYS FZE Hamriya Free Zone, Sharjah, United Arab Emirates Tel: 971-55-4175453

http://www.fptuae.com

MIR HOSPITALITY SUPPLIES LLC

17-3B, JVT, Dubai, United Arab Emirates Tel: 971-50-2531924

http://www.miruae.com 18

http://www.shikmo.com/


http://hagifts.com/

http://hagifts.com/

http://handamedia.com/


http://www.dcrush.com/


http://www.fptuae.com/


http://www.miruae.com/






http://hagifts.com/




List of some of the exporters of different type of Nonwoven Bags in UAE from India

PRINT PROCESS

7.B.B. Road,

Chennai, Tamil Nadu - 600039

Tel: 91-044-25514696 Mob: 091 9600014597 Fax: 91-044-25512090 Website: http://www.cottonbagindia.com

PEALS GLOBAL INDIA 3605, Main Road B.H Rao(Back Side)

Delhi-110006 Tel: 23512062, 23622826, 26385312

Mob:- +91- 9311999595 +91- 9810109595 +91- 9212709595

Email: [email protected];

[email protected]

ISPA EXIM PVT. LTD B 304 Patel Commercial Premised, Veera Desai Industrial Layout, Off Link Load, Andheri West, Mumbai, Maharashtra - 400 053 Tel: +(91)-(22)-42667627

Colours Polymers Dharmraj Industries, Unit No. A - 5, Lake Road, Bhandup West, Mumbai – 400078 Phone: +(91)-(22)-25946955

Mahavir Packaging No. 17, Jamnadas Industrial Estate, Dr. R. P.

Road, Mulund, Mumbai - 400 080 Phone: +(91)-(22)-25609511

RAHIL AIRBUBBLE PVT. LTD. Survey No. 34, Plot No. 2-B, N.H.8-B,

Shapar (Veraval), Rajkot - 360002, Gujarat

Wintex Apparel Limited E - 307, Kailas Industrial Complex, Veer Savarkar Marg, Park Site, Vikhroli West, Mumbai - 400 079 Phone: +(91)-(22)-65619684

Akrishna Bags Company Unit No. 204 - 205, Shankala Industrial Estate, Gogate Wadi, Behind Thomas School, Goregaon East, Mumbai - 400 063 Phone: +(91)-(22)-29275619

19



MANUFACTURING PROCESS

Range of non wove nbags are manufactured With good quality propylene material which is environmental friendly. Bags are used to serve various purposes. These bags are 100% recycled And are manufctured with a durable, liquid

resisting and dehumidifying fabric which can be recycled.

PP non woven bags are available in d ifferent And unique colors with a variety of designs and dimensions. These are also custom made as per the specifications of the client; These bags can be printed in accordance to the customer's designs and logos. These bags are perfect for the purpose of shopping,

gifts, promotional items and packaging.

Nonwoven Loop Hadle Bag w/Rectangle Bases

This loop handle bag is made from Nonwoven fabric instead of plastic. It has the same style as the plastic loop handle bag, but it's environment friendly and can be reusable. It has a rectangle base, can offer various colors of such bag, and can produce any size. It's very great for shoppin,

gifts, makeups, favors, parties, jewellery, and much more.

Name: Nonwoven Loop Handle Bag w/Rectangle Bases Size: 28 * 30 + 10 * 20 Pack: 10 pcs per pack, 100 pcs per box

Fabric: NOnwoven fabric

Nonwoven Punch Bag W/Bottom Gusset

This Punch bag is made from nonwoven fabric instead of plastic. It has the same style as the plastic punch bag, but it's environment friendly and can be reusable. It has a bottom gusset and customized printing on both sides. Your logos can also be printed. The edge is heat cut and sealed, no stitching, offer various colors of such bag, and can produce any size. It's very great for shoppin, gifts, makeups, favors,

parites, jewellery, and much more.

Name: Nonwoven Punch Bag w/ Bottom Gusset Size: 27 * 36 + 27 * 6 cm Pack: 10 pcs per pack, 100 pcs per box

Fabric: Nonwoven fabric, edge heat cut & sealed, no stiching

20



Nonwoven Pouch W/ Gold Printing

This pouch is made from nonwoven fabric, which is environment friendly. It has gold printing on 1 side. Your logo can also be printed on it. It can be produced in any other colors and sizes. It's great for gifts, makeups, keys, favors,

parties, jewellery, and much more.

Name: Non-woven Bag Black and White Size: 10 + 5 * 10 inch Thickness:100 GSM Pack: 100 pcs per box

Material: Non-woven fabric with snap

Nonwoven T-Shirt Bag

This is not a plastic t-shirt bag, it's made from nonwoven fabric, which is environment-friendly. Logo can be printed on it. Sizes and colors can all be customized. It's widely used for shopping, fashion, gifts,and more.

Name: Nonwoven T-shirt Bag Blue Size: 12 + 7 * 22 inch Thickness:70 GSM Pack: 100 pcs per box

Material: Non-woven fabric

Non-Woven Bag Pink W/Snap

It's made from PP non-wovenfabric with vivid and clear printing. It has self material handles at top. It also has a snap for opening. It can be printed and can be Made in any other coloAED It's widely used for shopping or to pack gifts,

favors, soaps, candles, jewelry, clothes, and more.

Name: Non-woven Bag Pink w/ Snap Size: 9.5 + 3 * 8.5 inch

Thickness:100 GSM Pack: 100 pcs per box

Material: Non-woven fabric with snap

21



Plain Nonwoven Bag

This bag is made from nonwoven fabric, which feels like cloth, but much cheaper than the cloth fabric and pretty strong. Unlike plastic bags, this bag is degradable and environment- friendly. Printing can be done on it . More colors are available. It's great for shopping, picnic, or to carry or

pack any items you like.

Name: Plain Nonwoven Bag Size: 30 * 40 cm Thickness:60-200 GSM Pack: 1000 pcs per box

Fabric: Nonwoven fabric with handle

Nonwoven Tote Bag W/O Stitching

This nonwoven tote bag is heat cut & strongly sealed on edges, no stiching. So, it looks neater and is more durable than the stitched ones. Customized logos can be printed on both sides. Sized & colors can also be customized. It's widely used for shopping or to pack gifts, favors, soaps,

candles, jewelry, clothes, and more.

Name: Nonwoven Tote Bag w/o Stiching Size: 30 * 38 * 8 cm Thickness: 80 GSM Pack: 100 pcs per box

Material: PP

22



PRINCIPLES OF PLANT LAYOUT

Some of the guiding principles for detailed Plant layout

will be discussed for the benefit of those Making layout decisions for the first time.

Storage Layout: Storage facilities for raw materials and

intermediate and finished products may be located in isolated

areas or in adjoining areas. Hazardous materials become a decided

menace to life and property when stored in large quantities and

should consequently be isolated. Storage in adjoining areas to

reduce materials handling may introduce an obstacle toward future

expansion of the plant. Arranging storage of materials so as to

facilitate or simplify handling is also a point to be considered

to design. Where it is possible to pump a

single material to an elevation so that subsequent handling can be accomplished by gravity into intermediate reaction and storage units, costs may be reduced. Liquids can be stored in small containers, barrels, horizontal or vertical tanks and vats, either indoors or out of dooAED

Equipment Layout: In making a layout, ample space should be

assigned to each piece of equipment; accessibility is an important

factor for maintenance.

It is extremely poor economy to fit the equipment layout too closely into a building. A slightly larger building appears necessary will cost little more than one that is / that crowded. The extra cost will indeed be small in comparison with the penalties that will be extracted if, in order to iron out the kines, the building must be expanded.

The operations that constitute a process are essentially a

series of unit operations that may be carried on simultaneously.

These include filtration, evaporation, crystallization,

separation, and drying. Since these operations are repeated

several times in the flow of materials, it should be possible to

arrange the necessary equipment into groups of the same kinds.This sort of layout will make possible a division of operation

labor so that one or two operators can be detailed to tend all

equipment of a like nature.

23



The relative levels of the several pieces of equipment and

their accessories determine their placement. Although gravity flow

is usually preferable, it is not altogether necessary because

liquids can be transported by blowing or by pumping, and solidscan be moved by mechanical means. Gravity flow may be said to cost

nothing to operate, whereas the various mechanical means of

transportation involve the first cost of the necessary equipment

and the cost of operation and maintenance. But material must be

elevated to a level where gravity flow must start. However,

gravity flow usually means a multistory layout, whereas the

factors favoring a single-story plant may largely, if not

entirely, compensate for the cost of mechanical transportation.

Access for initial construction and maintenance is a

necessary part of planning. For example, overhead equipment must

have space for lowering into place, and heat-exchange equipmentshould be located near access areas where trucks or hoist can be

placed for pulling and replacing tube bundles. Thus, space should

be provided for repair and replacement equipment, such as cranes

and forked trucks, as well as access way around doors and

underground hatches.

Safety: A great deal of planning is governed by local and national

safety and fire code requirements. Fire protection consisting of reservoirs, mains, hydrant, hose houses, fire pumps, reservoirs, sprinklers in building, explosion barriers and directional routing of explosion forces to clear areas, and Dikes

for combustible-product storage tanks must be incorporated to protect costly plant investment and reduce insurance rates.

Plant Expansion: Expansion must always be kept in mind. The question of multiplying the number of units or increasing the size of the prevailing unit merits must be studied. Suffice it to say that one must exercise engineering judgement; that as a penalty for bad judgement, scrapping of present serviceable equipment constitutes but one phase, for shutdown due to

remodeling may involve a greater loss of money than that due to

rejected equipment. Nevertheless, the cost of change must

sometimes be borne, for the economies of larger units may, in the

end, make replacement imperative.

24



Floor Space: Floor space may or may not be a major factor in the design of a particular plant. The value of land may be a considerable item. The engineers however, follow the rule of

practicing economy of floor space, consistent with good housekeeping in the plant land with proper consideration given to line flow of materials, access to equipment, space To permit working on parts of equipment that need frequent servicing, and

safety and comfort of the operatoAED

Utilities Servicing: The distribution of gas, air, water, steam, power, and electricity is not always a major item, in as much as the flexibility of distribution of these services permits designing to meet almost any condition. But A little regard for the proper placement of each of these services, practicing good design, aids in of operation, orderliness, and reduction in costs of maintenance. No pipes should be laid on the floor or between the floor and the 7-ft. level, where the operator must pass or work. Chaotic arrangement Of piping invites chaotic operation of the plant. The flexibility of standard pipe fittings and power-transmission mechanisms renders

this problem one of minor difficulty.

25



Building: After a complete study of quantitative factors,

the selection of the building or buildings must be considered. Standard factory buildings are to be desired, but, if none can be found satisfactory to handle the space and process requirements of the chemical engineer, then a competent architect should be consulted to design a building around the process - not a beautiful structure into which a process must fit. It is fundamental in chemical engineering industries that the buildings should be built around the process, instead of the

process being made to fit building of conventional design.

In many cases only the control area requires housing, with

the process equipment erected outdooAED This is known as outdoorconstruction and such layouts should be considered for many types of plants. What consideration must be given to buildings depends upon conditions. If the designer must adapt his design to fit an old building or building space already erected, his problem is cut out for him and he has limiting conditions. However, the selection of the design of a new building to meet the requirements of the process is more scientific. In this case, one finds before him practically all types of standard building, built in units, interlocking or otherwise, ready for

shipment and erection.

26



Throughout chemical industry, much thought must be given to

the disposal of waste liquors, fumes, dusts, and gases.

Ventilation, fume elimination, and drainage may require the

installation of extra equipment. This may involve the design of the

individual pieces of operating equipment, or it may require the

installation of isolated equipment. If the latter be the case, the

location of such equipment where it will not interfere with the flow

of materials in process should be practiced. The selection of the

proper piece of equipment for doing this service is also an important point; the less attention the ventilating, fume, or waste-elimination systems require, the better service they may render. Sometimes air conditioning of the plant is called for and may require an elaborate setup. But the installation of such equipment, when needed, pays in better service from operators, less discomfort, greater production, and a better morale than when such conditions are left to nature.

It must be recognized that there is not only one solution to the problem of layout of the equipment. There are many rational designs. Which plant to adopt must be decided upon after exercise of

engineering judgement and after striking a balance between the

advantages and disadvantages of each possible choice.

27



PLANT LOCATION FACTORS

Factors which generally apply to the economic and operability aspect of plant site location are classified into two major groups. The primary factors listed apply to choice of a region, whereas the specific factors looked at in choosing an

exact site location within the region. All factors are important

in making a site location selection.

Primary Factors

1. Raw-material supply:

a. Availability from existing or future suppliers

b. Use of substitute materials

c. Distance

2. Markets:

a. Demand versus distance

b. Growth or decline

c. Inventory storage requirements

d. Competition - present and future.

3. Power and fuel supply:

a. Availability of electricity and various type of fuel

b. Future reserves

c. Costs

29



4. Water supply:

a. Quality - temperature, mineral content,

bacteriological content

b. Quantity

c. Dependability - may involve reservoir construction

d. Costs

5. Climate:

a. Investment required for construction

b. Humidity and temperature conditions

c. Hurricane, a tornado, and earthquake history

Specific Factors

6. Transportation:

a. Availability of various services and projected rates

1. Rail - dependable for light and heavy shipping

over all distances

2. Highways - regularly used for short distance and

generally small quantities

3. Water - cheaper, but may be slow and irregular

4. Pipeline - for gases and liquids, particularly

for petroleum products

5. Air - for business transportation of personnel

30



7. Waste disposal:

a. Regulations laws

b. Stream carry-off possibilities

c. Air-pollution possibilities

8. Labor:

1. Availability of skills

2. Labor relations - history and stability in area

3. Stability of labor rates

9. Regulatory laws:

a. Building codes

b. Zoning ordinances

c. Highway restrictions

d. Waste-disposal codes

10. Taxes:

a. State and local taxes

1. Income

2. Unemployment insurance

3. Franchise

4. Use

5. Property

b. Low assessment or limited term exemptions to attract

industry

31



11. Site characteristics:

a. Contour of site

b. Soil structure

c. Access to rail, highway, and water

d. Room for expansion

e. Cost of site

f. Site and facilities available for expansion on present

company-owned property

12. Community factors:

a. Rural or Urban

b. Housing costs

C. Cultural aspects - churches, libraries, theatres

d. School system

e. Recreation facilities

f. Medical facilities - hospitals, doctors

13. Vulnerability to wartime attack:

a. Distance important facilities

b. General industry concentration

14. Flood and fire control:

a. Fire hazards in surrounding area

b. Floor history and control

32



EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

This represents reduction in the utility and value of a

capital asset because of wear and tear, lapse of time,

obsolescence etc. The use of an asset helps in the generation of

revenue for the business. A part of the cost of the asset, estimated to be equal to the reduction in the utility and economic life of the asset, because of its use, is charged off by way of depreciation charge against such revenue to arrive at

the true profits.

2. FIXED ASSETS:

Represent those assets which remain permanently (till their

useful lives) with the business and are not meant for resale.

These assets are acquired for use in the operation of business and

help in the generation of revenue for the business. These include

land and building, plant and machinery etc.

3. WORKING CAPITAL:

This represents the total expenses on Raw materials,

utilities & overheads, and salaries & wages, for a specified

period of time.

33



4. BREAK-EVEN POINT:

This represents the level of output and sales at which the firm is able to recover all its expenses-both fixed and variable. In other words it indicates the level of output and sales at which the firm is neither making profit nor incurring any loss. Level of output more than the Break-Even Level generates

profit for the firm.

5. OTHER FIXED EXPENSES:

These represent expenses which remain fixed irrespective of

changes in level of output. In other words these are the expenses

which the firm has to incur whether there is production or not.

These include expenses such as preliminary and Preoperative

expenses, Insurance and Freight, Technical Know-how and

Consultancy, Erection & Commissioning etc. building, insurance,

etc.

6. MARGIN MONEY:

This represents that part of the cost of project which the

promoter has to meet from his own resources. This is the

contribution which the promoter must make to the equity of the

project for becoming eligible for assistance from financial

institutions/Banks.

34



7. TERM LOANS:

Represent Loans which are repayable over a long period of

time. These loans are meant for meeting capital expenditure of the

project.

8. TOTAL LOAD:

It is the ratio of the maximum power consumed in KWH in a

particular period of time to the number of operating hours of the unit in that particular period.

Power Consumed in KWH Total Load = (-------------------------- ) in a particular

No. of operating hours of period of time

the unit

9. LAND AREA/MAN POWER RATIO:

It is the ratio of manpower utilised per unit area of land

required for operating the unit.

+ + | Land Area |

Land Area/Man Power Ratio = | ---------------- | | No. of persons | | Working on the unit|

+ +

35



SUPPLIERS OF RAW MATERIAL (INDIAN)

ALOK INDUSTIES LTD. Peninsula Towers, Peninsula Corporate Park, Ganpatrao Kadam Marg, Lowel Parel, Mumbai, Maharashtra - 400013 Tel: 91-22-24996200

BIYANI INDUSTIAL TEXTILES (P) LTD. 102, Amar Towers, 37 G.F. Scheme No. 54, Indore, Madhya Pradesh- 452010 Tel: 91-731-2574108 Fax: 91-731-2550459

Dasim Rexine House D R H No. 9, Dharamshi Street, No. 6, Aga Building,

Bhendi Bazar, Mumbai - 400 003 Phone: +(91)-(22)-23463180

Fibreweb Non Woven Private Limited 18, S. S. Mungekar Industrial Estate, No-4 , Off

Aarey Road, Opposite Acme Amay, Goregaon (East),

Mumbai - 400 063 Phone: +(91)-(22)-29275492

RAHIL AIRBUBBLE PVT. LTD. Survey No. 34, Plot No. 2-B, N.H.8-B, Shapar

(Veraval), Rajkot – 360002, Gujarat

Max Non Woven Private Limited C Type, 119/120/121, Golden Industrial Estate,

Behind Shapar Village, Shapar, Veraval, Rajkot -

360 001, Gujarat, India

Leenon Industries Survey No. 577, Part-1, B/h G.E.B. Sub Station,

Opp. Talav, Opp. Lajai Chokdi, Morbi Rajkot

Highway, Tankara, Rajkot – 363641

Enox Non Woven Private Limited Plot No. G-2106, Metoda Gidc, Ta- Lodhika,

District Rajkot, Rajkot - 360 021

36



SUPPLIERS OF RAW MATERIAL

REAL TECHNITEX Morbi-Rajkot Highway, At Tankara, Morbi - 363650, Gujarat, India

Orange Polyfab Industries, Rajkot - Jamnagar Highway, Survey No. 228, At. Rampar, Taluka - Paddhari, Rajkot - 360 110, Gujarat, India Phone: +(91)-(2820)-290291

Macon Incorporation No. 327, Plenary Arcade Building, Besides Bombay Petrol Pump, Gondal Road, Rajkot - 360 002 Phone: +(91)-(281)-2229404

AROMA FABRICS Bhimanath Mahadev Mandir Road, At Lajai, Tankara - 363650, Gujarat, India

Parvati Fabrics Ltd. Parvati House, Tower F, Shree Kuberji Textile Park, B/H Belgium Square, Delhi Gate, Ring Road, Surat - 395 002 Phone: +(91)-(261)-3270913

Vimlon Dyeing & Printing Mills Pvt. Ltd Vimlon House, No. 2/904, Hira Modi, Sagrampura,

Surat - 395 002, Gujarat, India Phone: +(91)-(261)-2398930

Mani TechniTex Plot No. 2, Block No. 137/138, At Tatithaiya, Tal Palsana Kadodra, Bardoli Road, Surat - 394 305, Gujarat, India Phone: +(91)-(261)-2570289

Jadvani Manufacturing Company Hotel Krishna Park Compound, Village, Kathodara,Post Vav, Between Kamrej & Kadodra, N. H. No. 8,

Surat - 394 326, Gujarat, India Phone: +(91)-(2621)-295200

Wovlene Tec Fab India No. 122 - 125, Ajanta Diamond Industrial Estate,

Opposite Himson Mills, A. K. Road, Near Umiya

Mata Chowk, Surat - 395 004, Gujarat, India

Phone: +(91)-(261)-2480101

37



SUPPLIERS OF PLANT & MACHINERY (INDIAN)

M/S Shri Ram Filaments Mr. Raman Aggarwal Plot No. 65-66, Sector 21, Industrial Area Bhiwani, Haryana - 127021, India Telephone : +(91)-(1664)-329215 Mobile / Cell Phone : +(91)-9315607101

TOUCH C-42, Sector-6, Noida - 201301 Uttar Pradesh Tel: 0120-4253610/11/12/13 Mob: +91-9999030519, 9313873494, 9350107721, 9811092624 Fax: 0120-4253616/17 E-Mail: [email protected];

[email protected] Website: machinebaba.com

BEST INDUSTRIAL MACHINES

79, 1st floor, Mogappair

road, Mannurpet, Padi,

Chennai, Tamil Nadu - 600050 Tel: 91-44-26251803 Mob: 91119380784282 Fax: 91-44-296251016 Website: http://www.bestindustrialmachines.com

Next Impex Mr. Parag Dalal G - 4, Chitra AMI Apartment, Near Times Of India Ashram Road Ahmedabad - 380 009, Gujarat , India

Telephone : +(91)-(79)-26581627 +(91)-(79)-26581628

Mobile : +(91)-9375070093

Radiance India Mr. Nayan Thakkar (Director) No. 115, 1st Floor, Empire Estate Building

Surat - Gujarat, India Mobile : +(91)-9687611676/ 9099922260 Telephone : +(91)-(261)-6642006

38



SUPPLIERS OF PLANT & MACHINERY (CHINA)

RUITAI MACHINERY MFG. & EXP CO., LTD

Shangwang Industrial Area,

Wenzhou,

Zhejiang, 325200

China

Tel: [86] (577) 65785957

Fax: [86] (577) 65778777

Web Site: http://www.plasmachinery.com

RUIAN HUANA PLASTIC PACKAGING MACHINERY CO.,

LTD Jiusan industry Zone,

Ruian City,

Wenzhou,

Zhejiang - 325207

China

Tel: [86] (132) 82703060

Fax: [86] )577) 65163822

Website: http://www.rahuana.com

39



CHINA ELECTRONICS ZHEJIANG COMPANY

408 Wensan Road,

Hangzhou,

Zhejiang

China - 310012

Tel: (86 571) 88869558

Fax: (86 571) 88864844 / (86 571) 88864333 Website:

http://www.globalsources.com/cezic5.co

GUANGZHOU GUOYAN MACHINERY MAKIN CO. LTD.

No.3 Xibuxia,

Zhuji Road,

Jishan Village,

Tianhe District,

Guangzou,

Guangdong,

China

Tel: 86-20-32010458

Mob: 86-13719254118

Fax: 86-2032050470

Website: http://www.plastics007.com/showroom/Guoyan

This are just for your reference, we do not take any responsibility

of their products. This include suggested raw material supplier and

machinery suppliers (both foreign and domestic).

40



NON-WOVEN CARRY/SHOPPING BAGS [IPRI/BAGS/44A6] T.154

J.C. 9474 Page A- 1

PLANT ECONOMICS

Rated Plant capacity = 28800.00 NOS/day = 8640000.00 NOS/annum


Basis

No. of working days = 25 days/month

= 300 days/annum

No. of shifts = 1 per day

One shift = 8 hours

Production capacity of automatic machines = 20-120 pcs/min For calculation purpose = 60 pcs/min @ 40~41gms/pcs

Only simple carry bags are considered forcalculation purpose. However the capacity and

selling price vary as the type of bags vary.

Currency – AED (Dubai Dirham).

41




J.C. 9474 Page A- 2

LAND & BUILDING

As in this case there is no requirement of Land and Building as its being

rented. So, the cost of Land and Building is considered as Variable cost

(i.e. considered as working capital). However, the requirement of land and

building area is:

1. Land Area 250 Sq.Mts2. Building Area 150 Sq. Mts

42




J.C. 9474 Page A- 3

PLANT & MACHINERY

1. Complete Automatic Plant for

Making Non-Woven Bags Cap: 20-120

Bags/Minute 1No. AED 1,42,000.00

2. UPS 12 KVA 1No. AED 8,000.00

3. Automatic Printing Machine 1No. AED 25,000.00

4. Tools & Fixtures AED 3,500.00

5. Air Compressor 5 HP 1No. AED 4,000.00

6. Miscellaneous Equipments AED 3,500.00

------------------------ TOTAL AED 1,86,000.00

------------------------

43




J.C. 9474 Page A- 4

OTHER FIXED ASSETS

1. Office equipment, furniture plus

other equipment & accessories AED 6,000.00

2. Installation costs for water,

electricity, fuel etc. AED 8,000.00

3. Pre-operative & preliminary expenses AED 3,500.00

4. Electricals, Lightings etc. AED 3,500.00

5. D.G.Set 20 KVA AED 10,000.00

6. Miscellaneous AED 2,000.00

7. Computer, Printer, Laptop AED 6,000.00

------------------------ TOTAL AED 39,000.00

------------------------

44




J.C. 9474 Page A- 5

FIXED CAPITAL

1. PLANT & MACHINERY AED 1,86,000.00

2. OTHER FIXED ASSETS AED 39,000.00

------------------------ TOTAL AED 2,25,000.00

------------------------

45




J.C. 9474 Page A- 6

WORKING CAPITAL REQUIREMENT/MONTH

RAW MATERIALS

1. Non-Woven Fabrics 12,000 Kgs@ AED 8/- Per kg. AED 96,000.00

2. Printing Inks & other consumables AED 5,000.00

3. Packing Materials etc. AED 2,000.00

------------------------ TOTAL AED 1,03,000.00

------------------------

46




J.C. 9474 Page A- 7

SALARY & WAGES / MONTH

1. Manager cum Supervisor 1 No. AED 4,000.00

2. Marketing Executive 1 No. AED 2,500.00

3. Semi-Skilled Worker 1 No. AED 1,800.00

4. Un-Skilled Worker 3 No. AED 4,200.00

5. Accountant/Clerk 1 No. AED 2,000.00

6. Maintenance Staff 1 No. AED 2,500.00

------------------------ TOTAL AED 17,000.00

------------------------

PLUS PERKS @ 33% P.A. AED 5,610.00

------------------------ TOTAL AED 22,610.00

------------------------

47




J.C. 9474 Page A- 8

UTILITIES AND OVERHEADS

1. Power Consumption of 3000

Kwatt @ Fils 30 per Kwatt hr. AED 950.00

2. Water Consumption of 10

IG @ Fil 4.10 per IG AED 400.00

3. Stationery, Postage, Telephone etc. AED 500.00

4. Conveyance & Transportation etc. AED 1,000.00

5. Insurance Professional fees AED 500.00

6. Publicity & Sales Promotion AED 1,500.00

7. Repairs & maintenance AED 1,000.00

8. Miscellaneous AED 1,000.00

9. Fuel for D.G.Set etc. AED 500.00

10. Administrative Expensive AED 2,000.00

11. Building Rent AED 10,000.00

------------------------ TOTAL AED 19,350.00

------------------------

TOTAL LOAD IS 15 KWATTS (on an average)

48




J.C. 9474 Page A- 9

TOTAL WORKING CAPITAL/MONTH

1. RAW MATERIAL AED 1,03,000.00

2. SALARY & WAGES AED 22,610.00

3. UTILITIES & OVERHEADS AED 19,350.00

------------------------ TOTAL AED 1,44,960.00

------------------------

1. WORKING CAPITAL FOR 1 MONTHS AED 1,44,960.00

2. MARGIN MONEY FOR W/C LOAN (25%) AED 36,240.00

COST OF PROJECT

TOTAL FIXED CAPITAL AED 2,25,000.00

MARGIN MONEY AED 36,240.00

------------------------

TOTAL AED 2,61,240.00

------------------------

49




J.C. 9474 Page A- 10

TOTAL CAPITAL INVESTMENT

TOTAL FIXED CAPITAL AED 2,25,000.00

TOTAL WORKING CAPITAL FOR 1 MONTHS AED 1,44,960.00

------------------------

TOTAL AED 3,69,960.00

------------------------

50




J.C. 9474 Page A- 11

COST OF PRODUCTION/ANNUM

1. Working Capital for 1 Year AED 17,39,520.00

2. Interest @ 12.00% on T.C.I AED 44,396.00

3. Depreciation @ 10.00% on buildings AED 0,000.00

4. Depreciation @ 20.00% on Plant and Machinery AED 37,200.00

5. Depreciation @ 20.00% on office equipment & furnitures AED 2,400.00

------------------------ TOTAL AED 18,23,516.00

------------------------

51




J.C. 9474 Page A- 13

BREAK EVEN POINT (B.E.P)

Fixed Costs of the plant are as under -

1. Interests AED 44,396.00

2. Depreciation AED 39,600.00

3. 40.00% of Salaries AED 9,044.00

4. 40.00% of Overheads AED 7,740.00 ------------------------

TOTAL AED 1,00,780.00

------------------------

FIXED COSTS B.E.P. =

-------------X 100 FIXEDCOSTS + PROFIT

1,00,780.00 = ------------------------ X 100

1,00,780.00 + 1,19,424.00

=45.76%

53




J.C. 9474 Page A- 14

RESOURCES FOR FINANCE

1. Term loans from Financial institutions ( 65.00 % of fixed capital ) at @12.00% p.a rate of interest AED 1,46,250.00

2. Bank loans for 3 months ( 75.00 % of working capital ) at @ 12.00% p.a rate of interest AED 3,26,160.00

3. Self raised capital from even funds & loans from close ones to meet the margin money needs at a

@ 12.00% p.a rate of interest AED 1,87,450.00

--------------------------

TOTAL AED 6,59,880.00 --------------------------

nonwoven bags project report dubai

Documents