pp project rtrsl 75 _650_ - cam 5525-2

7/27/2019 Pp Project Rtrsl 75 _650_ - Cam 5525-2

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R.R PLAST EXTRUSION PVT.LTD.

MUMBAI

PROJECT PROFILE(RRSL 75 (650) /CAM TFM 5525- 2)

PRODUCT - Plastic Disposable Cups and Glasses

INTRODUCTION

The Plastic Industries in India plays a very important and key

role in Industrialization. A wide spectrum of Plastic Articles

manufactured by this Industries have touched the life of every

Indian in many ways. Now we have entered into another era

of Plastic consumer goods, which is continuously replacing

the traditional items.

Disposable cups, glasses, plates and other plastic packing

containers are used in daily life. In addition to that, these are

largely used at hournies, parties and other functions also.

The use of Disposable containers is increasing day by day

because of better hygienic conditions, Low cost, easy

usability and impressive appearance .

Disposable cups and glasses are largely used for Tea, coffee,

juices and other milk-products.

MARKET With rapid urbanization in recent years and growth in

OUT-LOOK consumerism, a study growth is taking place in the Indian

consumer products market. By the end of 10th

plan period

urban population will cross 400 millions, this will lead to

further in continuous growth in consumer products in future.

As far as the question of Cups and Glasses are concerned, ithas gained great importance because of many reasons. The

Disposable cups and glasses are mostly used at Railway

stations, moving restaurants, travels and Sports-Centre.

.ContP/2


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With increasing urbanizations and sifting thrust of Society

For time oriented has increased the use of Disposable

Containers.

In addition to that the Disposable containers are also used

In packaging of Dairy and Food products which has a verybright future and steady growth.

MANUFACTURING The basic material for thermoforming is sheet in rolls and

PROCESS therefore, the first process of manufacturing is Extrusion

where the granules mixed with master batch of required

colour are extruded into sheet in roll form. The sheets are

extruded in various thickness and width to match with the

product to be thermoformed. The extrusion of P.P. is to be

done with minimum orientation. The sheet rolls are then fed

into thermoforming station, where it is to be softened at the

required temperature with infra red heaters and then with the

help of dies and moulds, air pressure, pre-forming plug, the

sheet is Thermoformed into desired shape of containers, and

punched out on station. The formed containers are separated

here and the punched web (sheet) in rolls are taken to grinder

machine where it is converted into Flakes and refilled into the

Extruder along with the virgin granules.

The containers after Thermoforming are checked, counted

and pocked on polythene sleeves and then in corrugated

boxes and made ready for despatch.

SAILENT (a) Thermoformed containers being the lightest packing materials

FEATURES save packing cost and freight.

(b) Cold as well as hot drinks can be served easily.

U S E S Thermoformed containers can be of various shapes and sizes

To cater to the demand of a cross-section of the food, catering

and dairy industries.

.Cont.P/3


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RAW MATERIAL Raw material for the Disposable containers are either

& High impact polystyrene (HIPS or PP) and colouring

CHEMISTRY masterbatch granules. Polypropylene is a thermoplastic

polymer with good resistance to chemicals and mineral

acids and having high impact strength and good toughnessand very easy in processing. It has gained wide acceptance

in application ranging house-hold items and food-packaging.

Masterbatch consists of 80%pigments and 20% polypropylene.

Polypropylene is manufactured by dissolving an Unsaturated

rubber in polypropylene monomer and polymerizing the

monomer in a solution or mass-suspension process. The rubber

generally polybutadiene is dispersed on the form of discrete

particles and then the polymerization is taking place, which

gives the strength to the polymer.

What is PP?

Polypropylene (PP) is a long chain polymer made from

Propylene (C3) monomer

Heat, Pressure

C3 PPCatalyst

.

Propylene Monomer

CH2 = CH

CH3

Polypropylene Polymer

CH2-CH-CH2-CH

CH3 CH3 x

Polymerization Process


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FLOW CHART

ECONOMICS OF THERMOFORMING

.

Procurement of

Raw MaterialMaterial Quality Assurance

Raw Material

Inventory / StockComputer Inventory Control (RM)

Material Transfer to

Work Station/ Extruder Inventory

Control

Sheet/ Roll

Stock

Thermoforming

Forming

Inspection

Printing

Final Product

Inspection

Scrap Transfer

To Warehouse

Scrap Recovery

Grinding/ Identification

Packaging, Labeling

Finished Product Transfer

To WarehouseInventory Control (FP)


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INSTALLED RATED CAPACITY OF THERMOFORMING MACHINESPRODUCTION

CAPACITY Stroke - 30 Strokes / mints

Avg.Stroke - 26 Strokes / mints

Cavity - 12 Cavity Mould

Per day Production/ Machine - 26 X 12 X60 X22

4, 11, 840 pcs / day

Considering the average weight - 1.65 gm/ pc

For all the products = 4, 11, 840 X 1.65 gm/ pc

= 663.00 Kgs/ day + 2.5% packing scrap(16 kgs)

THERMOFORMING: Selected for two machines

CAPACITY Monthly Thermoforming production = 663 X 2 =1326.0 kgs

= 1326 kgs X 26/ Month

= 34.0 ton / Month

EXTRUSION : Working hrs per shift - 7.33 hrs

CAPACITY No. of shift per day - 3

Working hrs per day - 22 hrs

No. of Extruders - 1

No. of working days - 26 days

Machines rated

Capacity per hours - 130 kgs / hrs

Monthly Extrusion

Capacity - 22 X 130 X 26 = 68,640 Kgs/

Month_ _ _ _ _ _ _ _ _ _

PLANT ECONOMICS: Installed plant capacity = 34.0 Mts/ Month

No. of Working days = 26 days / Month

LAND & BUILDING: Total Land area 4,000 Sq. ft. 4,00,000.00

@ Rs. 100/- P/ Sq. ft.

Building 4,000 Sq. ft. 8,00,000.00

@ Rs. 200/- P/ Sq. ft.

TOTAL 12, 00, 000.00

Cont.... P / 5

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PLANT AND The Estimated cost of Plant and MachineriesMACHINERIES -

1. Sheet-Extruder 1 No Rs. 28.50 Lacs

75-Mono-Extruder2. Thermoforming -5525-PP 2 Nos Rs. 27.00

3. Thermoforming Mould 3 Nos Rs. 10.00

4. Scrap Grinder 1 No Rs. 2.75

5. Air Compressor-100 CFM 1 No Rs. 5.50

6. Water Cooling Tower-50 TR 1 No Rs. 0.50

7. Air receiver 1m3

1 No Rs. 0.40

8. Chilling Plant -10 TR 1 No Rs. 5.50

80.15 LAKHS

9. Electrical system H.T. Lines

of 230 KVA 415 V withElectrical Panels - Rs. 9.75

Taxes & Duties Rs. 9.50

Rs. 99,40,000

OTHER FIXED ASSETS

1. Office Equipment, Furniture Rs. 25, 000.00

2. Installation Cost for Water,Air, electricity etc. Rs. 1, 50, 000.00

3. Weighted Scales Rs. 25, 000.00

4. Tools and tackles Rs. 25, 000.00

5. Fire Freighting Equipments Rs. 30, 000.00

6. Pre operative & Preliminary Expenses Rs. 20, 000.00

Rs. 2, 75, 000.00

FIXED CAPITAL

1. Land and Building Rs. 12, 00, 000.002. Plant and Machinery Rs. 99,40,000.00

3. Other Fixed Assets Rs. 2, 75, 000.00

Rs. 1,14,15,000.00

Contd.P/6


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REQUIREMENT OF PERSONNEL & COST

ADMINISTRATIVE STAFF -

1. Plant Manager - 1 No - Rs. 12, 000. 00

Shift In-charge - 1 Nos - Rs. 6, 000. 00

Staff add Store - 1 Nos - Rs. 5, 000. 00Keeper

Security Personnel - 2 Nos - Rs. 6, 000. 00

5 Nos Rs. 29, 000.00

FACTORY PERSONNEL

1. Skilled - - 3 Nos Rs. 30, 000. 00

2. Semi Skilled - - 6 Nos Rs. 12, 000. 00

3. Un-Skilled - - 20 Nos Rs. 50, 000. 00(FLOATING LABOUR)

29 Nos Rs. 92, 000.00

GRAND TOTAL= -- 34 Nos Rs. 1,21,600.00

Consider Annual Benefit @ 10% to Add 12,160.00

to the Staff

Total Rs. 1,33,760.00

Electrical Power

UTILITIES & OTHER

OVERHEADS

Connected Load

a) Sheet Plant - One No. 77. 0 KW

b) TFM 2NOS Two Nos. 86. 0 KW

c) Air Compressor One No. 23.00 KW

d) Grinder One No. 11. 25 KW

e) Water Pump One No. 2. 25 KW

f) Lighting -------- 3. 0 KWg) Water Cooling tower One No. 3. 75 KW

h) Chilling plant One No. 15.0 KW

221. 0 KW

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Therefore total connected load = 221. 0 KW (Say)

Consider 70% of the total connected load as average consumption per month.

Cost of total nos. of Units consumed per month = 160.00 KW (SAY)

Considering the rate of Unit as Rs. 6. 00 / Unit.

= 160 X 550 = 88,000/- x Rs. 6.00 = Rs. 5, 28,000. 00 / Month

2. Maintenance Spare Parts -- -- 4,500. 00 /

3. Telephone & Postage -- -- 3,000. 00 /

4. Stationery -- -- 3,000. 00 /

5. Conveyance & Transportation -- -- 5,000. 00 /

6. Miscellaneous -- -- 5,000. 00 /

Total: - 5,48,500.00 / Month

RAW MATERIAL REQUIREMENT

As total plant capacity is 34. 0 Mts / Month, the raw

Material requirement = 34000 Kgs. / month.

Present Rate is @ Rs. 100. 00 / Kg

Cost of total Raw Material ---- --- --- Rs. 34,00,000. 00 / Month

Packing material -a) P P Film

b) Packing Box

c) BOPP Tape

d) Strap & Clip.

Considering average rate of Rs. 6. 00 / Kg for the total production of34 M.Tons --- --- Rs. 2, 04, 000.00 / MonthTOTAL WORKING CAPITAL / MONTH

1) Raw Material Rs. 34,00,000. 00

2) Packing material Rs. 2, 04, 000. 00

3) Salary and Wages Rs. 1,33,760.00

4) Utilities and Overheads Rs. 5,48,500.00

Rs. 42, 86, 260. 00

Cont.P/8

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TOTAL CAPITAL INVESTMENT

1) Fixed Capital Rs. 1,14,15, 000. 00

2) Working Capital Rs. 42,86,260. 00

Rs. 1, 57,01,260. 00

PROFIT & LOSS ACCOUNT

1. Cost of Production per Month

a) Cost of Raw Materials Rs. 34,00,000. 00

b) Cost of Packing Materials Rs. 2,04, 000. 00

c) Salary & Wages Rs. 1,33,760.00

d) Utilities and Overheads Rs. 5,48,500.00

e) Interest @ 12% on TCI Rs. 1,57,012. 00f) Considering the depreciation

@ 15% on Fixed Assets Rs. 1, 42, 687. 00

Rs. 45,85, 959. 00

TURN OVER PER MONTH:

By Sale of 34. 0 Mts Glasses and Cups

At average rate of Rs. 1, 65, 000. 00 / Mts

At the present market rate total sale Rs. 56,10, 000. 00/ Month

Profit = Receipts Cost of Production

= 56,10, 000. 00- 45,85,959. 00

= RS. 10, 24, 041. 00 / MONTH

PROFIT(%) / MONTH :-

Profit / Sales X 100

= 10,24,041. 00/56,10,000. 00X 100 = 18.25%

** The Profitability of the Plant will be more Viable if production is matchedwith marketing strategy and demand.

FOR,

R.R. PLAST- MUMBAI

pp project rtrsl 75 _650_ - cam 5525-2

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