DPR of ABC Inc.

ABC Inc.

DETAILED PROJECT REPORT

Manufacture of Blow Moulding &

Injection Moulding Articles

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TABLE OF CONTENTS
Chapter Description Page No.
PROJECT AT A GLANCE 3
1 Introduction 4
2 Promoter(s) 5
3 Product(s) 6
4 Plant Location 9
5 Plant Capacity 10
6 Market Potential 11
7 Manufacturing Process & PFD 19
8 Plant & Machinery 21
9 Plant Layout & Land Requirement 25
10 Estimated Project Cost 26
11 Raw Materials & Utilities 27
12 Waste Management 28
13 Employment Generation 33
14 Project Implementation Schedule 34
15 SWOT Analysis 35

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PROJECT AT A GLANCE
Sl. No. Name of the Company ABC Inc.
1 Constitution Partnership Firm

2 Registered and Corporate ----------------

address

3 Date of Incorporation 2019

4 CIN No. / Registration No. NA

5 Name of Proprietor / 1.
Partners / Directors 2.
6 Proposed Location -------------
7 Area required 0.22 acre (972 sq m)

8 Product(s) made Manufacture of Blow Moulding &

Injection Moulding Articles
9 Plant capacity per year 450 MT
10 Estimated Project Cost: Rs 180.00 Lakhs
11 Means of Finance: 33.33% Equity
66.66% Bank Loan
12 Raw Materials PET Granules (Virgin)
13 Manpower Requirement Managerial – 1; Skilled – 4;
Unskilled - 10
14 Fuel consumption per As per requirement
month
15 Water required, kL / day 5000 Liters per day
16 Power required 60 HP
17 Time needed for 12 months from the date of
implementation infrastructure availability

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1 Introduction

In almost all walks of life, starting from household utensils, clothes,

furniture etc. to automobiles to space aircrafts, plastics are
extensively use. Some of the things are provided by nature as such
while most of the others are fabricated from natural resources by the
people of different skills.

A plastic bottle is a bottle constructed from high-density plastic.

Plastic bottles are typically used to store liquids such as water, soft
drinks, motor oil, cooking oil, medicine, shampoo, milk, and ink. The
size ranges from very small sample bottles to large carboys.
Consumer blow molded containers often have integral handles or are
shaped to facilitate grasping.

Plastic was invented in the 19th century and was originally used to
replace common materials such as ivory, rubber, and shellac. In the
21st century, this once-celebrated invention has become almost like
a disease that has spread to a significant number of commodities sold
today, including plastic beverage bottles. They were first used
commercially in 1947 but remained relatively expensive until the
early 1950s when high-density polyethylene was introduced. They
quickly became popular with both manufacturers and customers
because of their lightweight nature and relatively low production and
transportation costs compared to glass bottles. However, the biggest
advantage plastic bottles have over their glass counterparts is their
superior resistance to breakage, in both production and
transportation. Except for wine and beer, the food industry has
almost completely replaced glass bottles with plastic bottles.

Giving further boost to industrial sector in the State, Government has

initiated measures on following four fronts: making the state a
business-friendly state, created dedicated cells for facilitating

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investment projects, providing various kinds of incentives to

encourage the first-generation entrepreneurs in the State and
providing additional incentives to SCs, STs and Women-owned
enterprises.

2 Promoter

The brief background of the key partner is given below:

Name of the Proprietor [Name]

Father’s Name ---------
Age ----- Years
Address ---------------------------------
---------------------------------
------------------------------
Educational Qualifications ---------------
Experience --- Years
Present Occupation ---------------
Achievements
Contact Details
◼ Phone ------------------
◼ Email ------------------
Annual Turnover Rs ……. Lakhs

The main partner has ….. years’ experience in different fields. After
through study of the market demand of plastic granules, he is keen
to setup the unit at [Area_Name], [Location_Name], ………… District,
……….. The firm needs about …….. Acre for manufacturing Blow
Moulding & Injection Moulding Articles.

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3 Products

M/s. ABC Inc. was incorporated as a proprietary concern in ….…… with

an objective to carry on the business of manufacture of Plastic
Containers, Bottles, Blow moulded Articles etc.

PET which stands for polyethylene terephthalate, is a form of polyester

(just like the clothing fabric). It is extruded or molded into plastic
bottles and containers for packaging foods and beverages, personal
care products, and many other consumer products.

PET is a polymer of ethylene glycol and terephthalic acid. Pellets of

PET resin are heated to a molten liquid, which can be easily extruded
or molded into almost any shape. PET was first synthesized in the U.S.
during the mid-1940s by DuPont chemists searching for polymers that
could be used to make new textile fibers.

PET is a highly valued packaging material because it is strong yet

lightweight, non-reactive, economical, and shatterproof. PET's safety
for food, beverage, personal care, pharmaceutical and medical
applications is recognized by health authorities around the world.

PET containers are popular for packaging sodas, water, juices, salad
dressings, cooking oil, peanut butter, shampoo, liquid hand soap,
mouthwash, pharmaceuticals, even tennis balls. Virtually all single-
serving and 2-liter bottles of carbonated soft drinks and water sold in
the U.S. are made from PET. Special grades of PET are used for carry-
home prepared food containers that can be warmed in the oven or
microwave.

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Uses for PET

1. PET is the clear, lightweight form of polyester that is extruded or

molded into plastic bottles and containers for packaging foods and
beverages, personal care products, and many other consumer
products. Like glass, PET is hygienic, strong, resistant to attack by
micro-organisms, does not react with foods or beverages, and will not
biologically degrade. Its safety for food and beverage use is recognized
by health authorities around the world. But unlike glass, PET is
extremely lightweight, simple to transport and won't break, which is
why it's preferred for packaging many foods and beverages.

2. PET bottles are cleared for both single and repeated use by the FDA
and other world health-safety agencies. It's a common misconception
that refilling or reusing a PET bottle will somehow cause the bottle to
degrade or to release harmful substances. PET is a stable, inert
material that doesn't biologically or chemically degrade with use, and
is resistant to attack by micro-organisms. Regulatory authorities have
tested PET bottles and found no harmful substances in either new or
re-used PET bottles.

3. Although PET bottles are approved for both single and repeated
use, the refilling and re-use of any bottle first requires careful
cleaning. Always use soap and hot water. Dry thoroughly to make sure
it is free of any moisture that might promote bacterial growth.
Consumers should avoid re-using any bottle that has been scratched
inside, since bacteria can become lodged in scratches.

4. PET plastic containers are identified by the #1 recycling code -- the

triangular chasing arrows symbol with the number 1 in the center and
the acronym PET or PETE underneath. PET is a biologically inert
material that doesn't react with foods or beverages and is resistant to

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attack by micro-organisms. It's been thoroughly reviewed and

approved as safe for contact with foods and drinks by the FDA, Health
Canada, the European Food Safety Authority and other health-safety
agencies. It has also been used by consumers around the world for
more than 30 years without any known adverse effects. Extensive
testing of PET and PET packaging has repeatedly shown it to be safe.
PET itself is biologically inert if ingested.

5. It depends on the shelf-life requirements. The grades of PET used

for soft drinks don't quite have the oxygen barrier properties needed
to maintain a beer's optimum taste quality over its typical shelf-life.
However, beer packaged in single-serving PET bottles is becoming
more and more popular at concerts and sporting events. Because the
beer is bottled specifically for these events and consumed on the
premises, there's no time for beer quality to deteriorate. New
technology to meet the longer shelf-life needs of beer and wine
continues to be introduced into the marketplace.

6. Special grades of PET are used for take-out food containers and
prepared food trays that can be warmed in the oven or microwaved.
These "dual ovenable" trays and containers have the same basic
chemical formula as PET bottles and jars, but have special additives
that crystallize and toughen the PET so it can withstand the much
higher temperatures of oven and microwave heating. Ovenable PET is
approved as safe by the FDA and other health-safety agencies around
the world.

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4 Plant Location

[Location_Name] is a Village in ------------------- in -------------------

-- District of --------------- State, India. It belongs to ----------- region.
It is located ------- KM towards -----from District headquarters -------
---------- ---- KM from --------------.

Connectivity

------------ is the nearest town to [Location_Name]. ---------- is ----

km from [Location_Name]. Road connectivity is there from -----------
to [Location_Name].

Map

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5 Plant Capacity

PRODUCTION CAPACITY PLANNED

The plant capacity is planned as 450 MT per year worth of Blow

Moulding & Injection Moulding Articles (Containers, bottles etc.)
manufacture.

APPLICATIONS

By end use type, the global plastic caps and closures market is
segmented as follows:

• Food
• Beverage
• Personal & Home Care Products
• Pharmaceutical
• Industrial chemicals
• Others (Automotive etc.)

By product type, the global plastic caps and closures market is

segmented as follows:

• Screw Caps
• Dispensing Caps
• Other Plastic Caps

By raw material, the global plastic caps and closures market is

segmented as follows:

• Polypropylene
• Polyethylene
• Polystyrene
• Other Resins
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6 Market Potential

The global plastic bottles and containers market was valued at USD
140.107 billion in 2017, and is expected to reach a value of USD
192.048 billion by 2023, at a CAGR of 5.31%, during the forecast
period (2018-2023). Plastic packaging has been witnessing growing
inclination from consumers over other products, as plastic packages
are lightweight and easier to handle. Similarly, even the major
manufacturers prefer to use plastic packaging solutions, owing to their
lower cost of production. There are a wide variety of innovative, cost-
effective and sustainable packaging solutions emerging in the market.
The non-availability of raw materials has been a restraining factor for
the industry, over the last decade. The increasing awareness about
environmental concerns over usage of plastic remains the major
constraint for the growth of the plastic industry.

Growing Demand from the Packaging Industry is driving the

growth of this Market

Consumers are demanding products with extended shelf life and easy
usage. This has necessitated companies to develop alternative
packaging solutions. Shelf life is an important aspect of the product.
Shelf life can be increased by protecting the products from potential
deteriorating agents, such as moisture, oxygen, and microbes. In
order to protect products, companies need a cost-effective and safe
packaging solution. Plastic packaging has superior barrier capabilities
and can effectively protect the product from moisture and oxygen.
Changing lifestyles and the consequent dependence of consumers on
processed, packaged, and pre-cooked food is increasing the sales of
plastic packaging in all its formats (bottles, cans, tins, glass, and
plastic containers); this is visibly giving way to plastic

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bottles/containers owing to its convenient format, superior barrier

properties, prudent use of material resources and high-quality
printability. Plastic bottle packaging is a major contributor to the
plastic packaging market, across the world.

Beverage segment to remain dominant market

The beverage segment will remain by far the single largest cap and
closure market. Gains will be supported by the continued popularity of
single-serving beverages and the widening presence of plastic bottles
in markets once dominated by metal cans.

However, preventing faster gains will be the maturity of several large

beverage applications such as beer and carbonated soft drinks. Also
moderating demand growth will be continued competition from
closureless packaging options, such as aluminum beverage cans,
peelable lidding, and pouches. Furthermore, a significant deceleration
in bottled water growth due to environmental concerns will also
moderate cap and closure prospects, as will the commodity nature of
most beverage closures.

Opportunities in the food market will benefit from demand for

dispensing and other value-added closures such as non-drip flip top
pourer caps, boosted by convenience advantages. In terms of
materials, plastic will continue to account for the largest share of cap
and closure demand and will also see the fastest increases. Plastic
containers, which typically use plastic closures, will continue to gain
market share.

Developing regions to see fastest growth in demand

Overall, the most rapid increases in cap and closure demand will occur
in the world’s developing regions. The Asia/ Pacific region (especially

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developing Asian countries) will post fast gains and remain the biggest
market due to its large food and beverage industries. The highest
growth rates are expected in India and China, with Indonesia, Brazil,
Russia, and Mexico also expected to see robust advances. In contrast,
market maturity in developed countries (as well as market saturation
in bedrock applications such as bottled beer, water, and carbonated
soft drinks) will moderate overall growth.

The rising demand for the plastic caps and closures are an important
part of packaging and containers such as bottles, canisters, tubes,
cans and beverages cartons. Plastic is gradually replacing the
traditional materials such as aluminium, tinplate etc. With competition
going up and evolving high-tech enlargements, plastics caps and
closures, has become ever more important in the global caps and
closures market. With large market potential and growing preference
of consumers, the global plastic caps and closures market is likely to
observe a substantial growth in the near future.

Plastic products are anticipated to lift their share up in the global cap
and closure market. The growing market of caps and closures has
been undergoing a phase of new product development and
technological advancements due to greater demand. The
manufacturers are making high investments in the production and
launch of innovative caps for diverse range of product types.

Plastic Caps and Closures Market: Drivers & Restraints

The global plastic caps and closures market is expected to grow due
to several factors such as continual inroads by plastic containers into
various applications as well as the growing popularity of plastic
closures on other container types, such as gable top & aseptic cartons
and stand-up pouches that are expected to rise the global plastic caps

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and closures. There is an existing virtual domination of plastic closures

in the aseptic & gable top cartons and stand-up pouches.

The global plastic caps and closures market growth will also be
supported by the rising technological developments and
improvements in the processes such as hot- fill processing that is
expected to positively influence the demand of plastic containers
resulting in the expansion of its presence in markets which were once
dominated by glass and metal containers.

The better availability of raw materials such as resins and advanced

machinery is also expected to positively influence the demand for
plastic caps and closure market.

Although, the beer market will remain highly reliant on glass bottles
and metal cans which either use metal closures or don’t use separate
closures. The growing use of dispensing plastics closures are also
rising the value of the global plastic caps and closures market.

The global plastic caps and closures market is also facing some
challenges such as the regulatory framework for caps and closures
which can restrain the market growth.

On the other hand, the growing usage of packaging layouts without

closures and concepts like blister packaging will also act as restraint
obstructing the growth of the global plastic caps and closures market.

Plastic Caps and Closures Market: Segmentation

By end use type, the global plastic caps and closures market is
segmented as follows:

• Food
• Beverage
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• Personal & Home Care Products

• Pharmaceutical
• Industrial chemicals
• Others (Automotive etc.)

By product type, the global plastic caps and closures market is

segmented as follows:

• Screw Caps
• Dispensing Caps
• Other Plastic Caps

By raw material, the global plastic caps and closures market is

segmented as follows:

• Polypropylene
• Polyethylene
• Polystyrene
• Other Resins

Plastic Caps and Closures Market: Region-wise Outlook

The plastic caps and closures market is expected to register a

favourable growth for the forecast period, 2016?2026. The Asia Pacific
is projected to endure control on the global plastic caps and closures
market due to its flourishing end user industries.

Some of the other fastest growing regions in plastic caps and closures
market are Latin America, Middle East and Africa. The North America
and Western Europe are expected to register a moderate growth rate
owing to the saturation of end use markets in the regions. The Eastern
Europe is expected to depict a high growth in the future ahead.

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Plastic Caps and Closures Market: Key Players

The key players in the global plastic caps and closures are Blackhawk
Molding Company Incorporated, Amcor, BERICAP holdings, Global
Closure Systems, Crown Holdings, Siligan Holdings, Reynolds Group
Holdings, Closure Systems International, Oriental Containers, Guala
Closures Group, Berry Plastics, Pelliconi, Premier Vinyl Solution, etc.

Overview of the global pharmaceuticals’ caps and closures

market

Technavio’s market research analysts predict that the global

pharmaceuticals caps and closures market will grow at a CAGR of more
than 5% by 2020. The growing use of child-resistant and tamper-
evident packaging has gained huge popularity in the market which has
encouraged vendors to use superior quality plastics such as cyclic
olefin copolymer (COC) as a raw material in the manufacturing of
pharmaceutical caps and closures because of their exceptional barrier
properties. COCs are clear amorphous copolymers and have a unique
combination of properties like low density, high transparency, and
resistance to aqueous and polar organic media. Also, these materials
are halogen-free and environmentally-friendly. Other plastic
materials, such as High-density polyethylene (HDPE), polyester, and
PP, are also being used as raw materials in the construction of caps
and closures because of their flexibility, lightweight, and corrosion
resistance.

Some of the companies have also introduced hot-fill polyethylene

terephthalate (PET) containers with metal closures. Consumers benefit
by having the same quality product but in a light-weight PET bottle.
These varieties of packaging are expected to increase the demand for
pharmaceutical caps and closures in the forecast period.

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7 Manufacturing Process

Caps & Closures

Bottle caps can be manufactured both form thermosetting material

(UF & PF) as well as thermoplastic material (PP, HIPS, HDPE etc.) the
present scheme envisages setting up of a unit comprising of a
compression moulding and injection moulding sections.

However, many a time more than one conversion techniques may be

employed in the same unit in order to cover a wider range of products.

For the manufacture of UF/PF bottle caps hydraulic type compression

moulding process is employed. The thermosetting material is put in
the cavities of a preheated mould and pressed between the two
platens of the press. The combined effect of heat and pressure causes
cross linking in the material leading to formation of micro- molecules.
This causes the compound to fill the cavity of mould and harden. After
a certain time, the mould is opened and the moulding are removed.

For the manufacture of bottle caps from thermoplastic material the

process involves the following steps:

1. Fixing of requisite dies in the die head

2. Feeding of raw materials in the hopper
3. Injecting molten material into the die
4. Cooling and opening of the moulds
5. Ejection of moulding piece and
6. Finishing

Plastic Bottles

A plastic bottle is a container constructed of plastic, with a neck that

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is narrower than its body and an opening at the top. The mouth of the
bottle is normally sealed with a plastic bottle cap. Plastic bottles are
typically used to store liquids such as water, soft drinks, cooking oil,
medicine, shampoo, milk, and ink.

The most-common plastic bottle we see nowadays is the soda bottle.

It is made from polyethylene terephthalate, also known as PET. PET is
used for 14 percent of all plastic containers and 43 percent of soda
bottles. It was developed in 1941, but it wasn't used for soda bottles
until the 1970s.

Before the Bottle is Made

Before a plastic bottle can be manufactured, the PET must be made.

PET is a polymer that is made from petroleum hydrocarbons. It comes
from a reaction between terephthalic acid and ethylene glycol. The

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process to make PET is called polymerization.

Making the Bottle

The process to make PET bottles is called stretch blow molding. PET
pellets are injection-molded in a thin-walled plastic tube. The tube is
then cooled and cut into shorter lengths. Each length of tube is
inserted into a mold that is shaped like the bottle the manufacturer
wants to create. A steel rod is inserted into the tube and blows out
highly pressurized air. This pushes the plastic and PET against the
inner sides of the mold. Under this high pressure and high
temperature, the molecules in the PET polarize, in essence, crystallize,
which give the bottle its strength. The consistent pressure also
ensures a uniform thickness to the PET. The bottle bottom is made
from a separate mold during the process and attached later.

Finishing the Bottle

The mold is then cooled quickly to keep any of the PET from flowing
inside the mold. The bottle is then removed from the mold and
trimmed to remove and PET that leaked through cracks in the mold.
The bottles are then packaged and sent to the company that ordered
them. Lids and labels are made in an entirely separate process.

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Process Flow Diagram

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8 Plant & Machinery

The following machinery is proposed as listed below:

The following machinery is proposed as listed below:

Sl. Name of Machine Quantit

No. y
1 Injection Moulding Machine 1 No.

2 Blow Moulding Machine 1 No.

3 Mixer 1 No.

BLOW MOULDING MACHINE:

A Blow Moulding Machine is usually used to manufacture the body of

a plastic bottle or the bottom part of the plastic bottle. It has a mould
with a pre-carved shape within the cavity so as to get the desired
shape of the bottle. The machine also blows air into the plastic material
so as to expand the interior of the bottle or in other words to obtain
interior space. The opening where the raw materials are introduced is
called the Hopper.

From there the materials pass through a barrel called the Heater. As
the name itself suggests, here the raw materials are heated, but at
different stages and at different temperatures, gradually from lower
temperatures to higher temperatures. The screws are contained in the
heater.

They help in the easy movement of the raw materials. Then the liquid
(or the semi liquid) flows into the mould, where the plastic is moulded
to the desired shape.

After it is moulded, air is blown into the plastic. Now the plastic bottle
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is ready. In this way the base of the bottle is ready.

Extrusion Blow Moulding

Extrusion blow moulding can be used to process many different

polymers including polyethylene, polyvinyl chloride, polypropylene
and more. The process begins with the conventional downward
extrusion of a tube. When the tube reaches the desired length the
mould is closed catching and holding the neck end open and pinching
the bottom end closed. Then a blow-pin is inserted into the neck end
of the hot tube to form the threaded opening and inflate the tube
inside the mold cavity.

When the mould is completely cooled it is opened to eject the bottle

and the excess plastic is trimmed from the neck and bottom areas.

Stretch Blow Moulding

The main applications of stretch blow moulding includes jars, bottles,

and similar containers because it produces items of excellent visual
and dimensional quality compared to extrusion blow moulding. The
process first requires the plastic to be injection moulded into a
'preform' with the finished necks (threads) of the bottles on one end.
The preform is then heated above its glass transition temperature and
blown, using high pressure air, into bottles using metal blow molds.
At the same time the preform is stretched with a core rod to fill inside
of the mould.

INJECTION MACHINE:

Injection molding is the most commonly used manufacturing process

for the fabrication of plastic parts. A wide variety of products are
manufactured using injection molding, which vary greatly in their size,

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complexity, and application.

The injection molding process requires the use of an injection molding

machine, raw plastic material, and a mold. The plastic is melted in the
injection molding machine and then injected into the mold, where it
cools and solidifies into the final part.

Blow Moulding Machine

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Injection Moulding Machine

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9 Plant Layout and Land Requirement

The principal factors to be considered are:

• Economic consideration: construction and operation cost.

• The shop requirement

• Convenience of operation

• Convenience of maintenance

• Safety

• Future expansion

Based on the requirements of unit and machinery layout, the areas

for various buildings of the plant are as under:

Sl. No. Main Buildings Unit Area %

1 Main Shed Sq. M 300 30.86%
2 Water Tank Sq. M 10 1.03%
Transformer &
3 Sq. M 50 5.14%
Panel Room
4 DG Set Sq. M 25 2.57%
5 Stores Sq. M 25 2.57%
6 RM Storage Sq. M 50 5.14%
7 FG Storage Sq. M 50 5.14%
8 Office Sq. M 100 10.29%
9 Canteen Sq. M 50 5.14%
10 Restrooms Sq. M 25 2.57%
11 Parking Sq. M 110 11.32%
12 Road Sq. M 80 8.23%
13 Greenery Sq. M 97 9.98%
Total Sq. M 972 100.00%

The total built up area required is estimated as 972 sqm or about

0.22 acre.

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10 Estimated Project Cost

The project cost is estimated as under:

Total Cost,
Description
Rs. Lakh
Land and Land Development 45
Civil Works Buildings 40
Plant & Machinery 50
Misc. Fixed Assets 10
Provision for Contingencies 5
Prelim. & Pre-Op Expenses 5
Interest During Construction (IDC) 10
Margin WC 15
Total 180

Means of Finance

The project is to be funded through a mix of Equity and Debt. The

means of finance for the project is presented below.

S. No. Sources of Funds Rs. Lakhs

1 Equity from Promoters 60.00

2 Term Loan from Banks 120.00

TOTAL, Rs. Lakhs 180.00

The Debt Equity Ratio is: 2.00: 1.

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11 Raw Materials & Utilities

Raw Materials

A plastic bottle made of polyethylene terephthalate has the resin

identification code 1. Also known as PET, PETE or polyester, it is
often used for carbonated beverages, water and food products
because it is strong and light. Like most plastics, PET is made from
petroleum hydrocarbons, formed as a reaction between ethylene
glycol, a colorless viscous hygroscopic liquid, and terephthalic acid,
an organic compound. During the production process, PET
polymerizes to form long molecular chains.

Power

Power requirement for the unit is estimated at 60 HP, which will be

drawn from the state grid of state electricity board through a 11-kV
line. Keeping in view of the future demand MP proposes to install a
75-kVA transformer.

Sl. No. Description Value

1 Power Requirement from 75 kVA
APTRANSCO
2 Contracted Maximum Demand 60 kVA
3 Required Power Supply Line 11 kV
4 Voltage Rating at which Supply 433 V
Required
5 Connected Load 60 HP
6 Load Factor 80%

Water

The ground water is available in Malkhan through TSIIC Ltd. and it

will be sufficient to meet the requirements for usage in the unit and
other purposes by the staff. About 5 m3/day is the requirement.

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12 Waste Management

Plastics are an inseparable part of modern society. However, their

safe disposal is a big and highly challenging issue. Plastics are used
globally in industries like packaging, construction and medical
equipment among others. This is because plastics are durable,
water-proof, lightweight and versatile.

Waste management is all the activities and actions required to

manage waste from its inception to its final disposal. This includes
amongst other things, collection, transport, treatment and disposal
of waste together with monitoring and regulation. It also
encompasses the legal and regulatory framework that relates to
waste management encompassing guidance on recycling etc.

The term usually relates to all kinds of waste, whether generated

during the extraction of raw materials, the processing of raw
materials into intermediate and final products, the consumption of
final products, or other human activities, including municipal
(residential, institutional, commercial), agricultural, and social
(health care, household hazardous wastes, sewage sludge). Waste
management is intended to reduce adverse effects of waste on
health, the environment or aesthetics.

Disposal solutions

Landfill Incineration

Incineration is a disposal method in which solid organic wastes are

subjected to combustion so as to convert them into residue and
gaseous products. This method is useful for disposal of residue of
both solid waste management and solid residue from waste water
management. This process reduces the volumes of solid waste to 20
to 30 percent of the original volume. Incineration and other high
temperature waste treatment systems are sometimes described as
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"thermal treatment". Incinerators convert waste materials into heat,

gas, steam, and ash.

Incineration is carried out both on a small scale by individuals and

on a large scale by industry. It is used to dispose of solid, liquid and
gaseous waste. It is recognized as a practical method of disposing
of certain hazardous waste materials (such as biological medical
waste). Incineration is a controversial method of waste disposal, due
to issues such as emission of gaseous pollutants.

Incineration is common in countries such as Japan where land is

more scarce, as these facilities generally do not require as much
area as landfills. Waste-to-energy (WtE) or energy-from-waste
(EfW) are broad terms for facilities that burn waste in a furnace or
boiler to generate heat, steam or electricity. Combustion in an
incinerator is not always perfect and there have been concerns about
pollutants in gaseous emissions from incinerator stacks. Particular
concern has focused on some very persistent organic compounds
such as dioxins, furans, and PAHs, which may be created and which
may have serious environmental consequences.

Recycling

Recycling is a resource recovery practice that refers to the collection

and reuse of waste materials such as empty beverage containers.
The materials from which the items are made can be reprocessed
into new products. Material for recycling may be collected separately
from general waste using dedicated bins and collection vehicles, a
procedure called kerbside collection. In some communities, the
owner of the waste is required to separate the materials into
different bins (e.g. for paper, plastics, metals) prior to its collection.
In other communities, all recyclable materials are placed in a single
bin for collection, and the sorting is handled later at a central facility.
The latter method is known as "single-stream recycling."

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The most common consumer products include aluminium such as

beverages cans, copper such as wire, steel from food and aerosol
cans, old steel furnishings or equipment, rubber tyres, polyethylene
and PET bottles, glass bottles and jars, paperboard cartons,
newspapers, magazines and light paper, and corrugated fiberboard
boxes.

PVC, LDPE, PP, and PS (see resin identification code) are also
recyclable. These items are usually composed of a single type of
material, making them relatively easy to recycle into new products.
The recycling of complex products (such as computers and electronic
equipment) is more difficult, due to the additional dismantling and
separation required.

The type of material accepted for recycling varies by city and

country. Each city and country has different recycling programs in
place that can handle the various types of recyclable materials.
However, certain variation in acceptance is reflected in the resale
value of the material once it is reprocessed.

Re-use

Biological reprocessing

Recoverable materials that are organic in nature, such as plant

material, food scraps, and paper products, can be recovered through
composting and digestion processes to decompose the organic
matter. The resulting organic material is then recycled as mulch or
compost for agricultural or landscaping purposes. In addition, waste
gas from the process (such as methane) can be captured and used
for generating electricity and heat (CHP/cogeneration) maximising
efficiencies. The intention of biological processing in waste
management is to control and accelerate the natural process of
decomposition of organic matter.

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Energy recovery

Energy recovery from waste is the conversion of non-recyclable

waste materials into usable heat, electricity, or fuel through a
variety of processes, including combustion, gasification,
pyrolyzation, anaerobic digestion, and landfill gas recovery. This
process is often called waste-to-energy. Energy recovery from waste
is part of the non-hazardous waste management hierarchy. Using
energy recovery to convert non-recyclable waste materials into
electricity and heat, generates a renewable energy source and can
reduce carbon emissions by offsetting the need for energy from
fossil sources as well as reduce methane generation from landfills.
Globally, waste-to-energy accounts for 16% of waste management.

The energy content of waste products can be harnessed directly by

using them as a direct combustion fuel, or indirectly by processing
them into another type of fuel. Thermal treatment ranges from using
waste as a fuel source for cooking or heating and the use of the gas
fuel (see above), to fuel for boilers to generate steam and electricity
in a turbine. Pyrolysis and gasification are two related forms of
thermal treatment where waste materials are heated to high
temperatures with limited oxygen availability. The process usually
occurs in a sealed vessel under high pressure. Pyrolysis of solid
waste converts the material into solid, liquid and gas products. The
liquid and gas can be burnt to produce energy or refined into other
chemical products (chemical refinery). The solid residue (char) can
be further refined into products such as activated carbon.
Gasification and advanced Plasma arc gasification are used to
convert organic materials directly into a synthetic gas (syngas)
composed of carbon monoxide and hydrogen. The gas is then burnt
to produce electricity and steam. An alternative to pyrolysis is high
temperature and pressure supercritical water decomposition
(hydrothermal monophasic oxidation).

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Resource recovery

Resource recovery is the systematic diversion of waste, which was

intended for disposal, for a specific next use. It is the processing of
recyclables to extract or recover materials and resources, or convert
to energy. These activities are performed at a resource recovery
facility. Resource recovery is not only environmentally important,
but it is also cost effective. It decreases the amount of waste for
disposal, saves space in landfills, and conserves natural resources.

Resource recovery (as opposed to waste management) uses LCA

(life cycle analysis) attempts to offer alternatives to waste
management. For mixed MSW (Municipal Solid Waste) a number of
broad studies have indicated that administration, source separation
and collection followed by reuse and recycling of the non-organic
fraction and energy and compost/fertilizer production of the organic
material via anaerobic digestion to be the favoured path.

As an example of how resource recycling can be beneficial, many of

the items thrown away contain precious metals which can be
recycled to create a profit, such as the components in circuit boards.
Other industries can also benefit from resource recycling with the
wood chippings in pallets and other packaging materials being
passed onto sectors such as the horticultural profession. In this
instance, workers can use the recycled chips to create paths,
walkways, or arena surfaces.

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13 Employment Generation

The Firm will appoint a senior technical person experienced in plastic

units. He will look after the daily activities, production, operation and
maintenance. The required manpower with the required experience
will be appointed for the various sections from time to time as the
project execution starts.

After implementation of the project, about 15 personnel will be

employed. The requirement of manpower for spinning unit has been
listed below:

Sl. No Description - Cotton No.

1 Managerial 1
2 Skilled Workers 4
3 Un-Skilled Workers 10.
Total 15

The requirement of manpower is assessed in fair amount of detail

and the suggested manpower is sufficient for running the proposed
unit.

Indirect Employment

Indirect employment due to the plant will be about 20 to 30

considering the additional employment generation by way of
transportation of raw material and product apart from service
providers who will be rendering services on various counts for the
firm.

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14 Project Implementation Schedule

The most critical aspect regarding the successful implementation of

the project is to ensure the completion of the project as per
schedule. The COD for the project is estimated to be in ---- months.
The detailed implementation schedule is represented in the following
table:

Status Beginning Date Completed

Date
Company incorporation

Financial tie-ups

Water & power supply

Statutory Approvals

Recruitment of man power

Building construction

Supply of Machinery

Installation of new Machinery

Testing and trial runs

Commercial operations

A few activities can be simultaneously done along with other

activities.

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15 SWOT ANALYSIS

The strengths and weaknesses are tabulated below:

Strengths:

Promoters: Engineering graduate and financially sound youngsters

are promoting the firm. They have good exposure to technical,
market and regulatory issues affecting the industry.

Good Demand: The main strength of the project is the ready

demand for the product.

Opportunities:

Strong Industrial Growth: The state of ----------- under the

dynamic leadership of Sri ………………. is on a development spree.

Industrial Activity: There is a spurt in the industrial activity in this

area due to the vision and thrust of the governments, both, Central
and State.

Weaknesses:

Availability of skilled workmen: This is a fairly less competitive

industry and good operators are easily available.

Company`s perspective for Risk mitigation: The main partner

has drawn up a plan to recruit young and dynamic technically
qualified persons who can be trained in the nuances of plastic
granules manufacturing.

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Threats:

Price competition: New players will be at disadvantage to compete

with established companies. Competition from existing units is a
serious threat.

Company`s perspective for Risk mitigation: The firm plans to

establish competitive advantage by leveraging their technical skills
and low-cost manufacturing base by better capacity utilization.

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