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APPENDICES

APPENDICES A PRODUCTION CAPACITY

PET Bottle Production (500mL) Machine: 1 2-Cavity Fully Automatic Stretch Blow Moulding Machine Output: 2800 pieces of bottle/ hour Runtime: 3826 hours X 3826 hours runtime = 10,712,800 pieces of 500mL

APPENDICES B ECONOMICS Initial Cost Land Cost Building/Infrastructure Cost Machineries and Auxiliary equipments Cost Office equipment/furniture Cost Installation Cost P 12,300,000 P 11,500,000 P 5,413,012 P 200,000.00 P 500,000.00 Initial Cost P 29,913,012

Operational Cost Raw Material Cost Weight of 500mL PET Bottle 10grams (Source:Huskys Guide to PET) =10,712,800 pieces of 500mL x 0.010 kg per piece of 500mL Total weight = 107,128 kilgrams

Price of 500mL PET Bottle resin 1000 kilogram = P 51,600 (Source: Alibaba.com) = 107,128 kilograms x = 5,527,804.5

Raw Material Cost = P 5,527,804.5 Electric Cost Price per kilowatt-hour = P 5.67 (Source: Meralco)

Injection Moulding Machine 46.9 KW x 3826 hours x P 5.67 = P 1,017,421.398 Washing and Capping Machine 4.23 KW x 3826 hours x P 5.67 = P 91, 763.17 Blow Moulding Machine 33 KW x 3826 hours x P 5.67 = P 715,882.86 Inkjet Printer 0.005 KW x 3826 hours x P 5.67 = P 108.47

Shrink Sleeve Machine 3 KW x 3826 hours x P 5.67 = P 65,080.26

Shrink Wrapping Machine 15 KW x 3826 hours x P 5.67 = P 325,401.3 P 1,535,657.5

Electric Cost = P 1,535,657.5 Fuel Cost Fuel Consumption Electrical Grid Price of Diesel fuel = 35 L/hr = 100 hrs = P 42.25/Liter

x 100 hours =P 147,875 Fuel Cost = P 147,875

Maintenance Cost Maintenance Cost = P 400,000 Wages Human Resource requirement Number of Monthly Salary Personnel ( Php) CEO 1 50,000 Manager/Engineer 2 42,000 Accountant 2 28,000 Human Resource 2 25,000 Operators 10 15,000 Helpers 5 12,000 Quality Control 2 17,000 Maintenance 3 11,000 Security Guards 2 13,000 Driver 2 9,000 Total 31 222,000

Annual Salary ( Php ) 650,000 1,092,000 728,000 650,000 1,950,000 325,000 442,000 429,000 338,000 234,000 6,838,000

Total Operational Cost = P 14, 449,337

Return of Investment Annual Income 10,712,800 pieces x P 6.00 per piece of 500mL Annual Income = P 64,276,800 Annual Gain from Investment = Annual Income Total Cost of Operation = P 64,276,800 P 14,449,337 Annual Gain from Investment = P 49,827,463

Return of Investment = = ROI = 66.57 % Payback Period Payback Period = = = 0.6 or 6 months

APPENDICES C OPERATIONAL CONSIDERATIONS TABLE PET Bottle Manufacturing Plant 300 days/year, No Sundays 500mL Production: 10,712,800 pieces Operating Schedule: 2 Shifts/day TOTAL TIME PLANNED DOWNTIME Electrical Grid Weather Scheduled Maintenance Shift Change TOTAL PLANNED DOWNTIME PRODUCTION TIME 100 hours ( 2.08% of Total Time) 300 hours ( 6.25% of Total Time) 150 hours ( 3.13% of total Time) 24 hours ( 0.50% of Total Time) 574 hours (Total Time Planned Downtime) = 4800 - 574 = 4226 hours UNPLANNED DOWNTIME No Raw Material Break Down of Equipment Injection Machine Washing/Capping Machine Blow Moulding Machine = 90 hours (1.875% of Total Time) = 100 hours(2.08% of total Time) = 90 hours (1.875% of Total Time) 0 4800 hrs

Shrink Sleeve Machine Shrink Wrapping Machine

= 60 hours (1.25% of Total Time) = 60 hours (1.25% of Total Time)

TOTAL PLANNED DOWNTIME RUN TIME

400 hours (8.33% of Total Time) (Production Time Unplanned Downtime) = 4226 400 = 3826 hours

TOTAL YEARLY DOWNTIME

(Planned + Unplanned Downtime) = 574 + 400 = 974 hours

SYSTEM UTILIZATION

(Run Time/Production Time) x 100% = (3826/4226) x 100% = 90.53%

AVERAGE HRS/DAY

(%Utilization x 16hrs/day) = (0.9053 x 16) = 14.4848 hours/day

APPENDICES D MACHINE FOUNDATION


INJECTION MACHINE L = 6.2m W = 1.5m H = 2m = 9000 kg Adding clearance: 1ft = 0.3048m L = 6.2m + (2 x 0.3048) m = 6.8096m W = 1.5m + (2 x 0.3048) m = 2.1096m H = 2m For : =LxWxH = 6.8096 x 2.1096 x 2 = 28.73 = 37.62 For : = = x Dc x 2406 = 28.73 x

= 69, 124.38 kg For 37.62 For 37.62 For sacks of cement: 37.62 x = 225.72 sacks of cement : x = 16.55 : x = 33.11

For weight of steel bar reinforcement: = 0.75% = 0.0075 x 69, 124.38 = 518.43 kg

BLOW MOLDING MACHINE L = 3.85m W = 2.3m H = 2m = 4000 kg Adding clearance: 1ft = 0.3048m L =3.85m + (2 x 0.3048) m = 4.4596m W = 2.3m + (2 x 0.3048) m = 2.9096m H = 2m For : =LxWxH = 4.4596 x2.9096 x 2 = 25.95 = 33.98 For : = = x Dc x 2406 = 25.95 x

= 62, 435.7 kg For 33.98 For 33.98 : x = 14.95 : x = 29.9

For sacks of cement: 33.98 x = 203.88 sacks of cement

For weight of steel bar reinforcement: = 0.75% = 0.0075 x 62, 435.7 = 468.27 kg

SHRINK WRAP PACKING MACHINE

L = 5.05m W = 3.3m H = 2.1m = 1200 kg Adding clearance: 1ft = 0.3048m L =5.05m + (2 x 0.3048) m = 5.6596m W = 3.3m + (2 x 0.3048) m = 3.9096m H = 2.1m For : =LxWxH = 5.6596 x 3.9096 x 2.1 = 46.47 =60.84 For : = = x Dc x 2406 = 46.47 x

= 111, 806.82 kg For 60.84 For : : x = 53.54

60.84 For sacks of cement: 60.84

= 26.77

= 365.04 sacks of cement

For weight of steel bar reinforcement: = 0.75% = 0.0075 x 111, 806.82 = 838.55 kg