Detailed Project Report on adult diaper and sanitary napkin (fully automatic plant)

ADULT DIAPER AND SANITARY NAPKIN (FULLY AUTOMATIC PLANT)

 [CODE NO.4355]  

Sanitary Napkins and Diaper (Kids and Adult) have got tremendous demand in India and abroad. The global market for absorbent hygiene products is over US$ 50 bn (including wipes). The evolution of hygiene products in Europe and the North America has taken 4 to 5 generations. Feminine care was introduced over 100 years ago. Baby diapers were invented 60 years ago. Adult incontinence products appeared 30 years ago.

Feminine hygiene (lady napkins) is hygiene absorbent products engineered to absorb and retain body fluid without causing any leakage. The user should always feel dry and comfortable. It consists of an absorbent pad sandwiched between two sheets of nonwoven fabric.

There are 3 major types of products, viz, (a) Thick sanitary napkins. (b) Ultra thin sanitary napkins. (c) Panty liners being used in the market. The size of each and their content vary from market to market.

The menstrual cycle starts for young women between the ages 11-17, frequently around 12-13 years. On average a woman experiences a period every 28th day, 12 -13 times in a year. A menstrual period normally lasts 3-7 days. The loss of fluid in a period is on average half a cup or 65-80 ml. The menstrual pattern is influenced by giving birth and contraceptive methods. Menstruation lasts until menopause at the age 45-55. The feminine hygiene products market has evolved over more than 100 years to a more than US$ 17 bn in the following category worldwide.

Disposable diapers are designed to absorb and retain urine and faeces while keeping the skin dry and healthy and to be easily and hygienically disposed of in household solid waste. Diapers are available in a wide range of sizes.

A diaper or nappy is a type of underwear that allows the wearer to defecate or urinate without the use of a toilet, by absorbing or containing waste products to prevent soiling of other clothing or the external environment when diapers become soiled, they require changing, generally by another person.

The structure of typical samples is given below:

Product designs, full size pads:

1. Top sheet: nonwoven or aperture film.

2. Absorbent core: pulp (Thick core either fluff core with SAP or Air laid core with SAP.

3. Back sheet: film.

Product designs, Ultra thin pad:

1. Top sheet - nonwoven or aperture film.

2. Transfer layer

3. Absorbent Layer

4. Absorbent Core

5. Back sheet film

Product shape can be either flat or curved with/without wings to secure the pad in place and add additional leak protection. It is available in various pattern designs with perfume (deodorant) added to cover or absorb odour. Packaging is done either folded or single wrapped or packed flat and unwrapped.

COST ESTIMATION

Plant Capacity                                   384000 Pieces/Day

Land & Building (4000 sq.mt.)  Rs. 2.74  Cr

Plant & Machinery                             Rs. 15.10 Cr

Working Capital for 1 Month           Rs. 5.04  Cr

Total Capital Investment                  Rs. 23.64 Cr

Rate of Return                                    38%

Break Even Point                               46%

• INTRODUCTION
• THE STRUCTURE OF TYPICAL SAMPLES IS GIVEN BELOW:
• PRODUCT DESIGNS, FULL SIZE PADS:
• PRODUCT DESIGNS, ULTRA THIN PAD:
• USES AND APPLICATIONS
• SANITARY NAPKINS FOR LADIES
• PROPERTIES
• IMPORTANT PROPERTIES OF SANITARY NAPKINS:
• POTENTIAL PROBLEMS OF SANITARY NAPKINS
• HYGIENE RISK
• DISPOSABILITY:
• AFFORDABILITY
• STRUCTURE AND PERFORMANCE CHARACTERISTICS
• OF SANITARY NAPKINS
• STRUCTURE OF SANITARY NAPKINS:
• I. FLUID ACQUISITION LAYER:
• II. DISTRIBUTION COMPONENT:
• III. ABSORBENT STRUCTURE:
• IV. LIQUID IMPERVIOUS MEMBRANE:
• PERFORMANCE CHARACTERISTIC OF SANITARY NAPKIN:
• BARRIER LAYER
• FIG: MODEL OF ABSORBENT STRUCTURE
• RAW MATERIALS
• I. FLUID TRANSFER LAYER:
• II. ACQUISITION AND DISTRIBUTING LAYER:
• III. ABSORBENT LAYER:
• IV. BARRIER SHEET:
• MARKET OVERVIEW OF SANITARY NAPKIN
• MARKET DYNAMICS IN SANITARY PRODUCT MARKET
• MARKET GROWTH
• MARKET OVERVIEW OF ADULT DIAPER
• MAJOR PLAYERS
• OVERVIEW OF SANITARY NAPKIN IN INDIA
• LEAPING INTO GST
• MANUFACTURER/EXPORTERS AND SUPPLIER OF SANITARY NAPKINS
• DISPOSABLE DIAPERS
• B.I.S SPECIFICATION
• PREPARATORY PROCESSES FOR SANITARY NAPKINS
• OPENING
• THIRD STAND KIERING BLEACHING & WASHING:-
• BLEACHING:-
• STERILISATION:-
• DRY HEAT:-
• AUTO CALVING:-
• EXPOSURE TO ETHYLENE OXIDE:-
• HYDRO - EXTRACTING:-
• DRYING:-
• ALTERNATE MANUFACTURING PROCESS OF DIAPERS
• FORMATION OF THE ABSORBENT PAD
• PREPARATION OF THE NONWOVEN
• ASSEMBLY OF THE COMPONENTS
• BYPRODUCTS/WASTE
• QUALITY CONTROL
• RAW MATERIALS REQUIRED
• BABY DIAPER:-
• RAW MATERIALS FOR DIAPER
• RAW MATERIALS' DESCRIPTION & SPECIFICATIONS
• ROLL PULP:-
• NON-WOVEN FABRIC:-
• POLYETHLENE FILM:-
• TISSUE:
• HOT MELT AND POLYEXTRUDED ADHESIVE:
• PRESSURE SENSITIVE ADHESIVE
• SILICONE RELEASE PAPER:
• SPECIFICATIONS OF THE RAW MATERIALS
• WOOD PULP
• NON-WOVEN FABRIC:
• SILICONE RELEASE PAPER
• HOT MELT
• LACK OF AWARENESS ABOUT WOMEN’S HEALTH IN INDIA
• UNDERSTANDING MENSTRUATION CYCLE
• CREATING AWARENESS ABOUT MAINTAINING HYGIENE
• EDUCATING WOMEN
• EMPOWERMENT AND WELL-BEING OF WOMEN
• MANUFACTURING PROCESS OF DIAPER (ADULT AND BABY)
• THERE ARE THREE BASIC PROCESSES IN THE MANUFACTURING OF DIAPER.
• PROCESSING DETAILS OF DIAPER MANUFACTURE
• PREPARATION OF THE NONWOVEN
• ASSEMBLY OF THE COMPONENTS
• DETAILS OF COMPONENT FOR DISPOSABLE DIAPER
• AMONG ALL PARTS, FOUR ARE VERY ESSENTIAL LAYERS IN  A DIAPER (SHOWN IN FIG).
• FOUR IMPORTANT SECTIONS OF A DIAPER
• DIAPER PICTURE TOP VIEW
• POLYTHENE FILM (BACK SHEET):
• BREATHABLE/CLOTH-LIKE BACK SHEET:
• POLYPROPYLENE NONWOVEN (TOP SHEET AND LEAK GUARD):
• FIG-3: SPUN BONDED POLYPROPYLENE NONWOVENS
• ABSORBENT CORE - WOOD PULP FLUFF:
• FIG-4: DIAPER ABSORBENT CORE WOOD PULP FLUFF
• SUPER ABSORBENT POLYMER (SAP):
• FIG-5: SUPER ABSORBENT POLYMER (SAP)
• ELASTICS:
• FIG-6A: ELASTICS AT WAIST AND LEG CUFFS, ADL
• FIG-6B: ELASTIC AT SIDE PANELS OF FASTENING TAPE
• QUICK WICKING LAYER/ACQUISITION AND DISTRIBUTION LAYER (ADL):
• FIG-7: QUICK WICKING LAYER/ACQUISITION AND DISTRIBUTION LAYER (ADL)
• HOT MELTS ADHESIVE:
• FIG-8: HOT MELT GLUING OF LYCRA ELASTIC WITH POLYPROPYLENE NONWOVEN
• FASTENING TAPES:
• FIG-9: HOOK & LOOP FASTENERS
• FIG-9A: HOOK SYSTEM ENLARGED
• FIG-9B: LOOPING SYSTEM ENLARGED
• MOISTURIZING AND FRAGRANT LOTIONS:
• FIG-10: A TYPICAL DISPOSABLE DIAPER WITH ITS SIGNIFICANT PARTS LABELED
• DISPOSABLE DIAPER MANUFACTURING TECHNOLOGY
• CELLULOSE PULP
• CELLULOSE WADDING
• NONWOVEN
• POLYETHYLENE
• SUPERABSORBENT POLYMER
• ELASTIC BANDS
• HOT MELT GLUES
• DEFIBRATION
• MAT FORMATION
• DEBULKING AND SHAPING
• CROSS CUTTING
• NONWOVEN, POLYETHYLENE AND ELASTIC BOND COUPLING
• ADDING OF SELF ADHESIVE TAPE TABS
• NONWOVEN, POLYETHYLENE SHAPING
• LONGITUDINAL FOLDING AND TRANSVERES FOLDING
• QUALITY CONTROL
• COUNTING AND STACKING
• BASIC PRODUCTION PROCESS FOR SANITARY NAPKIN
• STEP 1: PULVERISATION:
• MACHINES USED:
• STEP 2: CORE FORMATION:
• STEP 3: COVERING LAYER:
• STEP 4: ACCESSORIES FORMATION
• STEP 5: STERILIZING
• STEP 6: PACKAGING:
• QUALITY CONTROL
• PRODUCTION METHOD OF SANITARY NAPKIN
• (A)  PREPARATION OF COTTON LINT SLIVER:
• (1) COTTON OPENING:
• (2) SCUTCHING OR LAPPING:
• (3) CARDING:
• (4) DRAW FRAME:
• (5) TISSUE PAPER WRAPPING:
• B) MANUFACTURE OF SANITARY NAPKINS:
• 1) CONE WINDING:
• 2) KNITTING & INSERTION OF TISSUE PAPER WRAPPED SLIVER:
• 3) CUTTING & LOOPING OF BOTH ENDS OF SANITARY NAPKINS:
• 4) PACKING:
• PROCESS DESCRIPTION FOR SANITARY NAPKIN WITH AUTOMATION
• FLOW SHEET
• RAW MATERIAL CALCULATION
• RAW MATERIAL FOR APPROXIMATE 8 GM REGULAR SANITARY NAPKIN
• PLANT LAYOUT
• PERFORMANCE TEST OF SANITARY NAPKIN
• TESTS TO EVALUATE PERFORMANCE:
• ABSORBENCY TEST:
• FLUID RETENTION CAPACITY:
• LIQUID STRIKE THROUGH TEST:
• WICKING EXPERIMENTS:
• CONSULTANT FOR SETTINGUP THE SANITARY NAPKINS AND DISPOSABLE ADULT & KIDS DIAPER PROJECTS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF ADHESIVE (CHEMISTICK):-
• SUPPLIERS OF LINT TISSUE PAPER:
• SUPPLIERS OF POLYTHENE FILM
• SUPPLIERS OF TISSUE PAPER
• SUPPLIERS OF RELEASE PAPER
• MANUFACTURERS OF NON WOVEN FABRIC
• MORE INFORMATION ON MACHINERY
• INSTALLATION, TRAINING, TECHNOLOGY TRANSFER
• MANAGING
• PRODUCTION LINE OPERATOR:
• PACKING WORKER:
• THE SPECIFICATIONS AND MAIN PARAMETERS:
• PRODUCTION COST & PROFIT ANALYSIS OF WINGSHIELD SANITARY NAPKIN
• MACHINERY STRUCTURE
• POWER CONSUMING
• MACHINERY SIZE:
• GRINDER SET:
• FORMING AND WRAPPING SYSTEM SET:
• EMBOSSER, ADH. APPLYING, FINISHED PRODUCTS SET:
• CONVEYOR SET:
• EXPORT PACKING SIZE
• THE SIZE OF THE SANITARY PAD (NAPKIN):
• NAME AND SPECIFICATION OF THE RAW MATERIAL OF THE SANITARY PAD (NAPKIN):
• PRODUCTION PROCESS
• THE PROPERTY OF THE RAW MATERIALS
• THE FOLLOWING TYPES ARE MULTI-FUNCTION LINES: YOU CAN SHIFT THE FUNCTION TO THE DIAPER FUNCTION
• RELEASE PAPER: GOOD RELEASE, WIDTH 19-50MM (STANDARD)
• MAIN PARAMETERS:
• OPTIONS:
• MAIN FEATURES:

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)