PET RECYCLING TO MANUFACTURE POLYESTER STAPLE FIBER
[EIRI/EDPR/4269] J.C.: 2450XL
INTRODUCTION
Nowadays, PET bottles are the global number one in beverage packaging. More than 400 billion plastic bottles come on the market every year and PET is becoming increasingly valuable as a recyclable raw material used in the production of beverage bottles. Thus, it is important that all of the production steps applied for the manufacture of your PET bottles is made sustainable for the future.
The gentle treatment of resources and economical use of materials are a must when it comes to sustainable production. Valuable raw materials such as PET must be processed as efficiently as possible while still tapping into every way of saving costs. The PET manufacturing and production process allows for the application of a sustainable approach which can optimally combine environmental awareness and cost effectiveness: the bottle-to-bottle recycling concept.
Bottle-to-bottle recycling plant efficiently recycles used PET bottles and the recyclate is then reused in the food and beverage industry as recycled PET (rPET). The complete process comprises the cleaning of the used PET bottles and the treatment of the recyclate so that the end product - which could come in the form of flakes, pellets or preforms - can meet the highest quality requirements after the recycling process. European and American certificates (e.g. FDA) and a number of different corporate approvals, all confirm the high quality of the recyclate for direct use in containers which come into direct contact with foodstuffs.
COST ESTIMATION
Plant Capacity 50 MT/Day
Land & Building (16,000 sq.mt.) Rs. 8.39 Cr
Plant & Machinery Rs. 14.00 Cr
Working Capital for 2 Months Rs. 8.91 Cr
Total Capital Investment Rs. 31.67 Cr
Rate of Return 24%
Break Even Point 54%
CONTENTS
INTRODUCTION
PRINCIPLE OF POLYCONDENSATION
HISTORY OF PET
POLYESTER FIBRES
PET BOTTLES
PROPERTIES & CHARACTERISTICS OF PET
DIFFERENT TYPES OF POLYMER STRUCTURE
PET, AMORPHOUS
PET, PARTLY CRYSTALLINE
PET IS A SUITABLE MATERIAL FOR THE PRODUCTION OF BEVERAGECONTAINERS BECAUSE IT IS:
CHARACTERISTICS OF POLYESTER FIBERS
USES AND APPLICATION OF POLYESTER STAPLE FIBER
USES AND APPLICATION OF PET
RECYCLING OF PET BOTTLES
RECYCLING OF PET-BOTTLES
DEPENDING ON THE TYPE OF RAW MATERIAL THREE TYPES OF RECYCLING IS POSSIBLE:
TABLE DESCRIBES THE PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES
PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES OF PET-BOTTLE WASTE
CLEAR PET FLAKE – BOTTLE SPECIFICATION
MARKET OVERVIEW OF RECYCLED POLYESTER STAPLE FIBER
SOLID FIBER
HOLLOW FIBER
APPAREL
HOME FURNISHING
AUTOMOTIVE
PERSONAL CARE & HYGIENE
NORTH AMERICA
LATIN AMERICA
GROWTH FACTORS OF THE RECYCLED POLYESTER STAPLE FIBER MARKET
FUTURE PROSPECT FOR PET RECYCLING
INDIA’S RECYCLING INDUSTRY
USD 80 BILLION WORLDWIDE AND IS GROWING BY 5% TO 6% EACH YEAR
MARKET POSITION OF PRODUCTS MADE FROM RECYCLED PET
CONSUMPTION OF POLYSTER STAPLE FIBRE IN INDIA
EXPORT DATA OF PET FLAKES
FINISHED PRODUCTS THAT CAN BE MADE FROM PET RECYCLED GRANULES OR FLAKES
ADDRESSES OF PET RECYCLING UNIT
MANUFACTURERS/SUPPLIERS OF PET GRANULES
RECYCLED POLYESTER STAPLE FIBER
MANUFACTURING PROCESS OF RECYCLED POLYESTER STAPLE FIBER
PROCESS FLOW DIAGRAM
POST CONSUMER PET WASTE
SORTING
PROCESSING FOR SALE
FURTHER TREATMENT
PROCESSING DETAILS OF PET RECYCLING UNIT
SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT
OPERATION IN PET RECYCLING
METHOD OF OPERATION
PRE-SORTING
DRY LABEL SEPARATION
SIZE REDUCTION
THE WASHING MODULE
WATER CASCADE
PARCIVAL FILTRATION SYSTEM
THE DECONTAMINATION MODULE CLOSE
AUTOMATIC PROCESSES AND QUALITY SURVEILLANCE CLOSE
QUALITY "TRAFFIC LIGHT"
PET BOTTLE CONVERT TO RECYCLED POLYESTER GARMENT
PROCESS OF RECYCLED POLYESTER
POLYESTER STAPLE FIBER LINE
WASH AND DRY
EXTRUDER AND QUENCHING
WINDER
CAN UNIT
CREEL STAND
STRETCHER
STACKER AND CRIMPER
RELAX AND HEATING SETTER
BALER / PACKAGING
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
ADDRESSES OF CONSULTANT
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)
SUPPLIERS OF RAW MATERIAL
SUPPLIERS OF PET BOTTLES WASTE
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)