pp disposable
TRANSCRIPT
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25 PPDISPOSABLE
PLASTIC
CUPS/GLASSES
cups arc
now fast rcplacing
conventional ups. ce-crcamand other dairy
products
arc
packed
n disposablc
Besidcs cc-crcam ndustry hotels, restaurants, antecnsetc. have
been ncreasingly
using disposable
cups as
convc'ntional
lass-warcs
r ccramic cups. Disposable
ups are mainly used or food items
and are madc
out of
or
polystlrcne
sheets. he disposable ups arc
gaining popularity
due
o
attractivc ook,
low weight for
casc
ol transportationand low impcrmeability.
Organizations
ike Railways,
Airlincs are
using disposable
for scrving col-lce, ea etc. now-a-days.
Potential
ilbstylcs and attitudes, here has been an increasedmarket for the thermoformedproducts.The
are
hc
major scctors
n which these ind
application.
Food Industry
hrdustry s onc
ofthc lar5cstuscrsof Thermoformed
ackaging.
Their main application s for
processed
ood and
scrving
packaging.
ndustry
Ampoulcs, Diagnostic Kits etc., are
packed
n thermoformed
packaging.
Electronics ndustry
components an be individually form packedand protcctedagainstdamagedue o handling.
Industry
arc many applications
o
pack
fruits and
vegetablesor
bulk
and consumcr
pack.
The thermoformed
articlesare
grcen
house as secd
rays
and
flower
pots
etc.
Carc Products.& Cosmetics
ndustry
ogues mply shorter
ife spanofproducts. Costly
ooling s neededor inje'ctionmouldedcontainer/
ackaging.
packs
are cheaper,
astcr to make and
the
process
has higher output rates making
quick
changes n
economically
'easible.
ndustry
and
rolls of appropriate
material can be formed and
used as an excellent barrier against water seepage
n
etc. Many
other
products
ike
bathroom
accessories,
omes,
panelling,
ceiling etc can be made.
Automobile
ndustry
sized hick
wallcd thermoformed
products
like door liners, dash
boards, frbnt
grills
are
widely
used n
the
automobile
differs from injection
molding, blow molding,
rotational
molding, and other forms ofprocessing
plastics.
hermoforming
s
primarily
the
manufactureofdisposable
cups, containers,
ids, trays, blisters, clamshells,
* If you want to know more about detail project, contact WILLFORCE.
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products
for the food, medical, and
general
etail industries.Thick-gauge
hermofbrming
ncludcsparrs
as
as vehicledoor and
dash
panels,
efrigerator
iners, utility vehicle
beds,and
plastic
pallets.
are the advantages f thermoformed
products
n
packing
rotection o the product packed.
and convenient
placement
of the
product
due to
contoured orming.
ost of
packing.
packing.
visual inspectionwithout
opening he whole
package.
proof packaging.
moisture Resistantpackaging.
nert to many chemicals.
formed
as transparent,Printed,
Opaque etc.
ostsare comparatively ower
and high volumes
can
be
produced
within
a very
shorr time.
of the reasons or thermoformed
PP
packaging's
mmense
popularity
are
asily ecyclability.
of Rigidity
/
flexibility
in
packing.
at
sub-zero
cmperatures.
moisture
barrier
properties.
suitable for micro-wave
ovcns.
contact clarity
(Clarified
PP).
Capacity
proposed
production
s estimated
o be
of
two
t1pes, ea/coffee
ups of 65
-80
ml and
water/juice
glasses
of I lio
. The ollowing
table details
he
production
plan.
Particulars
Per
Hour
Production
Estimated
Daysof
Prodn
Working
hours I day
Total
Annual
Production
65-80
ml
of tea
/ coffee
cups
84000000
8 hours
84000000
180
ml
of
water
/
juice
glasses
Total
168,000,000
unit
has
been
assumed
o
operate
at
80oA,90o/o
nd
onwards
of
its
operation
with
8 workinq
hours/dav
100%
of
its
nstalled
apacity
n
rh e
i.e.1
hif tand
300
workins
davs n
first,
second
nd
hird
year
a
year.
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i )
Process,
Plant& Machinery
Deta i ls
L is t o f
Machinery
uppl iers)
Manufactur ing
rocess
thc urcst conrrnon
rsthod ot high-volume,
contilluous hemrolbrming of thin-gauge
products, plastic
sheet s li'd
roll or l iorrr rr cxtrudcr
nto a sct of indexing llains
hat ncorporate
ins,
or
spikes,
hat
picrce
he sheet
nd
thioLr .irrrrovcn l irr
hcating o fbrming cmpcraturc.
fhe
hcated heet hen
ndexes nto
a ftrrm statit,n
nrttingnrtrld nd
prcssLrre-bor
loscon
thc
sheet,
ith vacu[m thenapplicd o remove rapped ir and o
pull
nto or orrto hemoldaiong
with
prcssurizcd
ir to fbrm
hc
plastic
o the
detailed hapc
fthc mold.
Pluil-
typicallyused
n atlditiur o vacuum
n thc
casc
of tallcr,dceper-drawbnned
parts
n ordcr o
provide l lc
listribrrtion
nd hicknessesn
the inished arts.)
a short
irrnr cyclc.
a burst of revcrscair
prcssurc
s actuatcd rom thc racuum sideof
the
mold as
thc lbrrn
opcns, orlnronly
cl 'crrcd
o
as air-cjcct,
o brcak hc vacuunlandassisl
tle bnned
parts
off of, or out oi, tl,c
platc rrxy alsobc uti l izcdon
thc molclas it opcnS br tjection of more detailed
arts
or thoscwilh
rn(icrcul rcas.
Thc shcctcontainilg
hc lbrmctl
parts
hen ndcxes nto a trirn stationon
thc sar'lre
hcrc a dic
ctrts hc
parts
rom
the remaining hcetweb, or
indcxcs nto a se paraterim
press
u,here lre
trts are rirnllrcd.
lrcshcetweb remaining
lier the brmedpartsare rimmed s typicallywoundontoa takJ-
p
rcelor t'ecl
nto an nline
granulatorbr recycling.
hcnnolorrning
onrpaniesecyclc
heirscrapand
waste
plastic,
eitherby cor:rpressing
n a balingmachinc r l.y
ntoa
glanulator
grindcr)
nrl
producing
round
lakc, br salc
o reproccssingompaniesr
re-usen thcir oun
irequentiy,
scrap
and wastc
f,lastic
iorn
the thermotbrming
process
s convertedback into
extrudedsheet irr
gain.
Plantand
Machinery
hc mqr)r
cqllipl-Itcnt
cclui l 'ecl
v
thc unit
fbr
rnanufactr"rriug
lastic
disposablc
cups
are as fbllows:
Autolnlltic
thennofbnning
machlne
Dic
Punch
ibr
clrps
Othcr
acccssor ics
Air
colnpressor)
Shcet
cxtrudcr
and scrap
grinder
T'estiug
quiplncnt
) Plant
and
Machinery
upPl iers
arc
he
plant andmachinery
lrppliers
or
the
projt:ct.
I
S t x o
Name
M/s
Klockner
Windsor
ndia
Ltd.
Mis
Wonderpack
ndustries
.Ltd.
72,lst
floor,
Shivalaya
ansion,
Hamington
Road,
Mumbai-
400 008
Mi s
Isimat
India Scrcen
Machinery
Pvt. Ltd.
Printing
Cl , /510,
GIDC,
Gundlav,
__l :stt.
Valsad,Gujarat-396
35
29,
Apurva
ndustrial
Estate,
Makvana
Road,
Andheri
Kurla
Road,
Andheri
East),Mumbai
400 059
Communication
Address
E-6
-
UZ
Road,Thane
ndustrial
Estate,
Thane
400
604
i M/s Solex
Machincs
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Material
& Util ities
Requirement
raw rnatcrial
required for the
project
would be
polypropylerre
which is as follorvs.
Raw Material Requirement
Mil l i l i tre
Wt
in
gms Total in I \ IT
65-80
ml tcalcoffee ups
80
1 032
7
4 .30
180
200
ml
watcr
uice
cups
200 2 .s8
1 0 8 . 3 6
Total Raw Material
Reqd
including3'h wastage
r8 8 . 1
has beenassumed o operate
at
807o
and 90% of its installedcapacity n the first and
second
ear andat I
009'o
rom third
year
and onwardsof
its
operation.
utilities required are
power
and water Around 220 KW of Power and 450 KLPA of water a-^
--^"i--'r
Land
&
Built-up Area Requirement
land area s 500 sq metresand the built up area
s
300 sq mt.
ManpowerRequirement
manpower equiredwould be
l3 Nos
of which
administrative s 4
and lactory staff is 9.
Personnel
Nos
Works Manager
1
I
Accountant-cum-Store
Keeper
I
Admini
trativc
ssistant
Cl"tk
Ski l l .d
/ , . , tk .^
S"- i St
l lc . lW"rk.^
P."t/ Vrrcl'rr.r',rn
I
I
I
5 - -
t--
Total
l 3
Project
CosU
Fixed
CapitalRequirement Meansof Finance
been consideredas a
part
of the
project
cost
because
t has been considcrcd o
bc taken on lease
as
Charges
have
been aken as
part
of
tlrc Project
Cost.
Also,
Special
Chargesand an Annual
ServiceCharge
have
been considered s
part
of operatingcost.
fhe
project
cost
199.87 akhs s as ollows.
Sl
No
Particulars
Rs
n l ,akhs
Site
Devclopn-rent
os t
r . 0 0
Building
Plant
andMachinery
Miscellaneous
ixed
Assets
Preliminary
nd Pre-Operativc
.xpcnses
Margin
Money
on Working iapital
Contingencics
24.00
i :s i
9. 1_s
2 .0 0
iq
oo
Total
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Means of
Finance
Rs n
lakhs
Equity
49.97
Dcbt
r49.90
Total
199.87
prolect
cost
may
be
financed at a debt
equityratio
of 3:1
as
follows.
WorkingCapitalRequirement
working
apital
equirement
s
given
elow:
Sl
No
Particulars
Years of Operation
I
2
3
4
5
I
Net Working
Capital
76.00
85.50
95.00
95.00
9s.00
2
Available
Bank
Finance
57.00
64. r2 71 25
71 .25
7
.25
.\
J
Margin
Money
19.00
2 t . 3 7
23.7
23.7
23.1
Operating
Expenses
annual
perating
xpenses
stimated
t
Rs 177.02
akhs
80%
apacity
tilization)
s
given
elow:
Sl
No
Particulars
Rs
in Lakhs
I
Annual
Land Charges
0 . 1 2
2
Raw
materials
101
73
1
-)
Uti l i t ies
1
. 1 3
4
Wagcs&
Salanes
9.00
5
Overheads
3.53
6
Sell ing
expenses
0.67
7
Packing
expenses
8.06
B
lntcrest
on
temt
loan
22.49
9
Interest n
llank
Financc
or Working
Capital
8 .5 5
l 0
Depreciation
5 .74
Total
r77.02
Profitability
Estimates
SI
No
Particulars
Year
Y r
- l
Yr-2
Yr
-3
Yr
-4
Yr-5
Production/Sales
InstalledCapacity(inakh
nos)
I 680 I 680 l 680 1680 I 1680
Capacity
Utilization
80%
90%
l00Yo
r00%
r00%
E,stimated
roduction
in
lakh
nos)
t344
I512
1680
1
680
1680
I
Gross
Sales
Revenue
4 0 3
|
4 0 3 _ l
4 0 3
1 3 5
1 3 5
1 3 5
Expense
108
I2 l
aw
Material
ConsumPtion
utilities
1 1
1 1
1 l
u
1 1
Administrative
Overheads
4
4
4
4
4
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-
:s:try_-------
--
l
--i-
i--i-I-r
i
j
i t , a c k i n s q p g l r . l _ _ _ _
_ l
s
_ i
e
i
r o
I
r o
i
r o
i t . , ' r ' R . ' p r , ' . n t
i
0
i
3 l
[ - 3 7 -
|
l z
'
n
I
.
-
, .
i - . .
t .casc
cnrals
I
rr": 0. r
- i -d
t2
----r i
Lz i i r r i
T'otal
'i
146
i
I
qq
I
Ztl
t,
214
,
214
i
'
Gros1
j
Financia l xpenses
.
-
. - ; - -
i
lnler(st
On
T't'rn
Loutr
??
|
'"')
t
l ' l
I
l t
;
;:
i
Interest
Un I crnt Loun
22
- I
t,
Irtttrest
On Working
Cutrtitul i
q
: 2
|
n
r f l
i -
l ,
l ( ) ; l l l l
SubTor r l
i
3 l
i
. r t
I
:S
I
l t
l ( r
l _
. .
I
i
i
_ _
. .
, f ) r ' ^ . o , - i , r t i ^ n
i
- - - i . - | - n |
- -
| - -
l ) cp rec ia t ion
. i 7
i
- i , 7
I
_ tZ
|
_ ; .2
|
S ;
i l ) r o f l t B e f b r c J ' a x
I t r t t
I
t l a i t < K I r A r r A -
ndicators
Ilrcak Irvcn
Point
for
thc projcct
is
36(%.
I
Sales
Real isat ion
|. __
I
l.'ixed
Costs
i Salarrcs
L_____
F -
;d
S
'il | ng
L.
Ler,",*;
j
Depreciat ion SLM)
I
lrrr l )rsurau()n
)Llvr)
-
i
Rcpai rs
& Maintcnancc
Yr-2
Yr
-3
403
Yr
-rl
- - - - -
-l
i
Yr-5
,
I
I
l
--1-
- - - r
1_
t i l i t i cs
l ' ixed)
Admin.
Overheads
ncl
I"rcr..tffi
'-
Loan
l(cpayment
Total
Fixed
Costs
V*i"bt.
C"rt
i l l l l l
I -
- -
- -
l 4 i 1
|
- -
- l - - _
1 1 -
|
- -
|
- -
[-
--
-i--
r r
i
-
|
- ) t
l 6 0 l e e
L -
u
- I -
l _ _ 1
__
l + l + l +
i--i7-1--
rr--l--e--
i-ltl--.t
t-;--
I*--I- 2--[qt_-
I-- it-T-]:s T r35
awMaterials
r08 [lr r
Packing
8
9
l 0
l 0
t 0
Interest
On
Working
Capital
Loans
9
1 0
l t
11
l l
Total
Variable
Costs
124
t40
r55
155
155
Contribution
198
223
248
248
248
Breakeven
n
7o
300h
440h
380
360
340h
Average
Breakeven
In
7o
36"h
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thc
pro. icct
s27.4nh,
Average
OI is
86'% and average
SCR
s
3.0I.
Part iculars
Year
of
Operation
I
2
3
4
5
Revcnuc
323
363
403
403
403
Profit []cfbrc
Tax
1 3 9 .9 5
126.24
155.64
161.26
r66 .88
ProfitAftcr Tax 93.77 84.58 104.28 108.04 I 11 . 8 1
LT
Intcrcst
22.49
22.49
16 .86
Lt .24
5.62
Depreciation
5.74
5.74
5.74
s.74
5.74
LT Loan
Repayment
0.00
37
48
37.48
37.48
37
48
Return
n
Investment
%)
84(J 770h
890/.,
890h
89V"
AverageROI
86'Yo
Debt-Service
CoverageRatio
-
Debt
Service
22.49
59.96
54.34
48.72
4 3 . 1
-
Coverage
t 2 t . 9 9
r 1 2 .8 1
t26.8rl
t25.03
r 2 3 . r 7
DSCR
5.43 1.88 2.33
2.57
2.86
AverageDSCR
3.0