MANUFACTURING OF BIODEGRADABLE PLASTIC GRANULES/PELLETS FROM CORN STARCH (CAP: 30 TPD)
[EIRI/EDPR/4778] J.C. 2998BDT, 2998INR
Bioplastics are biodegradable materials that come from renewable sources and can be used to reduce the problem of plastic waste that is suffocating the planet and contaminating the environment. Does it make any sense to continue using packaging that can take centuries to disappear to pack products that only last days or months?
Plastic is the third most commonly used petroleum derivative in the world; each year 200 million tons of plastic are consumed on the planet. It comes from a non-renewable source (petroleum), it is contaminating and non-biodegradable (it can take more than 1000 years to decompose).
That is why countries such as Bangladesh have prohibited traditional plastic bags (they jam the sewage pipes and cause flooding), Africa has baptized them as a new 'national flower' because they are so visible all over the landscape and Europe has considered taxing them. In addition, this waste is the cause of the death of marine species and fowl that ingest them (whales, sea turtles, albatross, etc.) and pose a serious environmental problem, such as garbage patches (islands of garbage).
The term “Biodegradable” refers to anything or substances that can be degraded by the natural forces and micro-organisms and Bio-degradable plastics refer to those plastics that can be decomposed by the micro-organisms and also natural factors such as rain, sunlight, etc. and these plastics broaden the options for waste management treatment options over traditional plastics. The most favorable disposable options for these plastics are the municipal composting areas instead of the landfills. Hence, the biodegradable plastics can make significant contributions to material recovery options, reduction of landfill, and utilization of the natural resources.
COST ESTIMATION
Plant Capacity 30Ton/Day
Land & Building (12000 sq.mt.) Rs. 2.39 Cr
Plant & Machinery Rs. 4.51 Cr
Working Capital for 2 Month Rs. 18.40 Cr
Total Capital Investment Rs. 25.83 Cr
Rate of Return 38%
Break Even Point 42%
CONTENTS
INTRODUCTION
FIG.: BIODEGRADABLE PLA PELLETS
MARKET POTENTIAL
INDUSTRIAL SCENERIO
PRODUCT USES:
ADVANTAGES OF BIOPLASTICS:
USES OF BIOPLASTICS:
RAW MATERIAL REQUIREMENT
MANUFACTURING PROCESS
FIG.: SCHEMATIC DIAGRAM OF THE MANUFACTURING PROCESS
INDUSTRY OVERVIEW
BIO PLASTICS MARKET DYNAMICS:
ADVANTAGES:
BIO PLASTICS MARKET BY PRODUCT:
BIODEGRADABLE BIOPLASTICS
NON-BIODEGRADABLE BIO-PLASTICS
BIO PLASTICS MARKET BY APPLICATION:
KEY PLAYERS ANALYSED IN INDIA BIO PLASTICS MARKET:
TRENDS INFLUENCING THE BIODEGRADABLE PLASTICS MARKET SIZE
DRIVERS FOR THE BIOPLASTICS MARKET
GROWTH IN INDIA
CHALLENGES FOR BIOPLASTICS
GLOBAL PRODUCTION CAPACITIES OF BIOPLASTICS 2021-2026
COMPARATIVE ADVANTAGE OF BIOPLASTICS
POPULAR VARIANTS OF BIOPLASTICS
STARCH INDUSTRY
BYPRODUCTS FROM MAIZE
STARCHES
NATURAL STARCHES
CEREAL STARCHES
BRIDGING THE GAP WITH STARCH COMPOSITE GRANULES
SUBSTITUTE FOR TRADITIONAL PLASTIC GRANULES
ENVIRONMENTAL BENEFITS AND REDUCED DEPENDENCY ON TRADITIONAL PLASTICS
APPLICATIONS OF STARCH PLASTIC COMPOSITE GRANULES
FUTURE PROSPECTS OF STARCH PLASTIC COMPOSITE GRANULES
TOP BRANDS LIST BIOPLASTIC COMPANIES IN INDIA
LEADING BIOPLASTIC COMPANIES IN INDIA
OVERVIEW OF MAIZE GLOBALLY
MAIZE MARKET TRENRS (GLOBAL)
INCREASE IN DEMAND FOR ANIMAL-BASED PROTEIN SOURCES
DEMAND- WORLD WIDE
CORN SCENARIO IN BANGLAGESH
BANGLADESH’S PRODUCTION, SUPPLY, AND DISTRIBUTION OF CORN
PRODUCTION
PRICES
CORN PRICE RISES
TRADE
CORN IMPORTS DECLINE
INDIA IS THE PREFERRED EXPORTER
CONSUMPTION
FEED AND RESIDUAL USE
FEED DEMAND SHRINKS DUE TO HIGH PRICES
FSI CONSUMPTION
STOCKS
CONSTITUENTS AND VARIETY OF MAIZE
SPECIFICATION OF CORN STARCH
CORN STARCH SPECIFICATION
USES OF STARCH:
STARCH HAS MANY INDUSTRIAL APPLICATIONS. THESE INCLUDE:
A) TEXTILE INDUSTRY:
B) FOOD INDUSTRY:
C) PAPER INDUSTRY:
D) PHARMACEUTICAL INDUSTRY:
E) MANUFACTURE OF GLUCOSE AND DEXTROSE BY HYDROLYSIS:
F) MANUFACTURE OF MODIFIED STARCHES, SUCH AS:
G) MISCELLANEOUS OTHER USES:
IN ADDITION TO THESE USES, BY PRODUCTS OF STARCH ARE ALSO OBTAINED DURING THE WET MILLING OF MAIZE.
A) CONCENTRATED STEEP LIQUOR:
B) GERM OIL AND GERM AND CAKE:
C) GLUTEN:
PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
COMPONENTS OF YELLOW DENT CORN
QUALITY CONTROL
FINAL PRODUCTS PHOTOGRAPHS
LIST OF LAB TESTING EQUIPMENTS
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
UTILITIES
UTILITIES
STEAM
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY
SUPPLIERS OF LAB TESTING EQUIPMENT
MANUFACTURERS AND SUPPLIERS
STARCH
OTHER RAW MATERIALS SUPPLIERS
LIST OF SOME STARCH PROCESSING INDUSTRIES
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR PROCESSING MACHINE
IMPORTED COMPLETE PLANT & MACHINERY SUPPLIERS
FOREIGN COLLABORATORS
SUPPLIERS OF PLANT & MACHINERY
STARCH MAKING PLANT AND EQUIPMENTS
TANKS
TRAY DRIER
DISINTEGRATORS
PULVERISER/GRINDER
INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER
LABORATORTY EQUIPMENTS MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS
WEIGHING BREIDGE MANUFACTURER
TURNKEY CONSULTANT FOR SETTINGUP MAIZE PROCESSING PLANT
OTHER MANUFACTURER OF BIODEGRADABLE PLASTIC RAW MATERIALS
RAW MATERIAL SUPPLIERS
GRANULATORS
MIXER
OXO BIODEGRADABLECARRY BAGS MANUFACTURE IN INDIA
TESTING FACILITIES/CERTIFICATIONS
PACKAGING MACHINE
EXTRUDER MACHINE MANUFACTURERS (GLOBALLY)
WEIGHING BREIDGE MANUFACTURER
PLANT LOCATION COUNTRY BANGLADESH
ORGANIZATION STRUCTURE
IMPLEMENTATION SCHEDULE
PLANT LAYOUT
SWOT ANALYSIS
PLANT & MACHINERY
FIG.: HAMMER MILL
FIG.: PULPING MACHINE
FIG.: MIXING TANKS
FIG.: INDUSTRIAL FERMENTATION SYSTEM
FIG.: JACKETED REACTION VESSEL
VACUUM CRYSTALLIZER:
FIG.: VACUUM CRYSTALLIZER
FIG.: POLYMERIZATION REACTOR
SMR (STATIC MIXER REACTOR) OR THE PLUG FLOW REACTOR:
FIG.: PLUG FLOW REACTOR
VACUUM DEGASSER:
FIG.: VACUUM DEGASSING SYSTEM
PELLETIZER MACHINE:
FIG.: UNDERWATER PELLETIZER
PLASTIC PELLETS PACKAGING MACHINE.
FIG.: PELLET PACKING MACHINE
FIG.: HEAT EXCHANGER
FIG.: CENTRIFUGAL PUMPS
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)
