PLASTIC RECYCLING UNIT
[CODE NO.4263]
A plastic is any one of a large and varied group of materials which consists of an essential ingredient combinations of carbon with oxygen, hydrogen, nitrogen and other organic and inorganic elements. While solid in the finished state, at some stage in its manufacture it has been or can be formed into various shapes by flow-usually through the application singly or together of heat and pressure.
Plastic Classification:
Plastics are classified in several ways. The most accepted division that covers the entire field is by the behaviour pattern.
(1) Thermoplastic
(2) Thermosetting plastics
In this report we are only concerned with Thermoplastics.
Thermoplastics are those which soften under heat and again harden when cooled and this process can be repeated a number of times without any appreciable was in the physical properties.
Plastics today have a prominent place in the spectrum of materials frequently used by materials engineers and designers. They have earned this placed on the basis of performance at a price, plus the apparently unlimited ability of the plastics industry to develop new plastics or new grades of older plastics to meet specific needs of modern industry. With this status and the tremendous growth of new uses has come an important need for meaningful data on fundamental plastics behaviour under realistic stresses and strains, couched in engineering terms, in short, engineering properties as contrasted with data sheet properties. Needed are engineering criteria for rigidity, strength, endurance and temperature range, which are common to nearly all plastic applications, as well as more specialized performance characteristics that are important only in certain types of special product (eg. electrical properties).
Among the plastics the various industrial grade plastic waste available, the following are the materials like A.B.S. (Acrylonitrite Butadiene) styrones, polypropylene, HIPS, L.D.P.E., L.I.D.P.E. Polystyrene, Opp. OPS and Acrylic. In this report we have considered Ten Industrial grade plastic waste material and for that plastic granules will be prepared.
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 are 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.
• Food-grade PET flakes and pellets
Recycling plant produces food-grade PET. With it, returned PET bottles can be reused to make new PET bottles. The use of recyclate has clear economic and ecological benefits.
• Flakes, pellets or performs
The procedure gives you the freedom to decide which end product you wish to create. The decontamination step required for the material's later contact with foodstuffs is only ever performed with flakes. Afterwards, the flakes are either used directly or are made into pellets. Another extremely energy-efficient use for the decontaminated flakes is the direct feeding of the material into an extrusion process –
Worldwide, PET-bottles more and more replace glass bottles in the beverage and food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages.
On the one hand, the production of PET is less expensive and energy consuming than the production of glass. Secondly, the light weight of the PET-bottle makes it easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers more or less the same material properties as glass regarding hygiene, taste and gas impermeability.
The negative impacts of PET-bottles in recent years result from their use as nonreturnable beverage containers leading to a dramatic increase of beverage container waste. But even here, changes are on the move, particularly in industrialized countries, where PET-bottles enter more and more the existing returning and refilling schemes. Apart from returning and refilling, recycling of used PET-bottles is also possible and will be an interesting option especially for developing countries, where refilling schemes are not in place or economically unfavourable.
COST ESTIMATION
Plant Capacity 5 MT/Day
Land & Building (4000 sq.mt.) Rs. 1.44 Cr
Plant & Machinery Rs. 1.72 Cr
Working Capital for 1 Month Rs. 63.88 Lac
Total Capital Investment Rs. 4.03 Cr
Rate of Return 30%
Break Even Point 62%
INTRODUCTION
PLASTIC CLASSIFICATION:
THE MATERIAL
PRINCIPLE OF POLYCONDENSATION
POLYMERIZATION OF PET
RECYCLING OF PET BOTTLES
RECYCLING OF PET-BOTTLES
DEPENDING ON THE TYPE OF RAW MATERIAL THREE TYPES OF RECYCLING ARE POSSIBLE:
TABLE DESCRIBES THE PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES
CLEAR PET FLAKE – BOTTLE SPECIFICATION
PROPERTIES AND ADVANTAGE OF PET
CRYSTAL CLEAR
PURE
SAFE
GOOD BARRIER
LIGHTWEIGHT
NO LEAKAGE
DESIGN FLEXIBILITY
RECYCLABLE
GOOD RESISTANCE
LONG SHELF-LIFE
CSD -- CARBONATED SOFT DRINKS
WATER -- THE CLEAR STORY
JUICE -- HOT FILL QUALITIES
BEER -- A NEW MARKET WITH NEW REQUIREMENTS
RESOURCES OF PLASTIC WASTE
PLASTIC RECYCLING AND ITS IMPORTANCE
THE FOLLOWING ARE THE 6 COMMON TYPES OF PLASTICS
CHALLENGES FOR PLASTIC RECYCLING INDUSTRY
B.I.S. SPECIFICATION
TYPES OF RECYCLABLE PLASTICS
POLYSTYRENE –
POLYPROPYLENE –
LOW-DENSITY POLYETHYLENE –
POLYVINYL CHLORIDE (PVC) –
HIGH-DENSITY POLYETHYLENE (HDPE) –
POLYETHYLENE TEREPHTHALATE (PET) –
NUMBER 1: PETE (OR PET) – POLYETHYLENE TEREPHTHALATE
NUMBER 2: HDPE – HIGH-DENSITY POLYETHYLENE
NUMBER 3: PVC – POLYVINYL CHLORIDE
NUMBER 4: LDPE – LOW-DENSITY POLYETHYLENE
NUMBER 5: PP – POLYPROPYLENE
NUMBER 6: PS – POLYSTYRENE
OVERVIEW OF PLASTIC RECYCLING
STAGES IN PLASTIC RECYCLING PROCESS
1. COLLECTION
2. SORTING
3. WASHING
4. SHREDDING OR RESIZING
5. IDENTIFICATION AND CLASSIFICATION OF PLASTIC
6. COMPOUNDING OR EXTRUDING
SEQUENCES IN PLASTIC RECYCLING
● COLLECTING
● SORTING
● SHREDDING
● WASHING
● MELTING
● PELLETIZING
DETAILS OF PLASTIC RECYCLING PROCESS
THE PLASTIC RECYCLING PROCESS STEPS
1. COLLECTION + DISTRIBUTION
2. SORTING + CATEGORIZING
3. WASHING
4. SHREDDING
5. IDENTIFICATION AND SEPARATION OF PLASTICS
6. EXTRUDING + COMPOUNDING
PROCESS OF MANUFACTURE TO PRODUCE COLORLESS TRANSPARENT PLASTIC GRANULES FROM WASTE
SORTING
SMASHING
WASHING
CONCENTRATION OF BLENDING
SOLVENT ADDITION
REMOVAL OF COLOUR TO OBTAIN TRANSPARENT GRANULES BY ACTIVATED CARBON TREATMENT
FILTERATION
DISTILLATION
COOLING AND DEHUMIDIFYING
GRANULATION
WEIGHING, FILLING AND PACKING
MANUFACTURING PROCESS FLOW SHEET FOR PLASTIC GRANULES FROM PLASTIC SCRAP
PLASTIC RECYCLING PLANT
TECHNICAL SPECIFICATION
A EXTRUDER
GENERAL PROCESS OF MANUFACTURING:-
SORTING:-
SMASHING & WASHING:-
CONCENTRATE & BLENDING:-
SECTION EXTRUDING IST STAGE:-
FILTRATION:-
SECTION EXTRUDING IIND STAGE;-
DRAWING & PELLETIZING:-
COOLING AND DEHUMIDIFYING:-
PACKING & STORAGE:-
MANUFACTURING PROCESS FLOW CHART
RECYCLING POLYETHYLENE TEREPHTHALATE (PET)
RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:
PET COLLECTION AND SORTING
PET RECYCLING IN INDIA
STEP 1: REACHING THE WASTE STREAM, GETTING COLLECTED
STEP 2: SORTING AT THE KABADIWALLAHS
STEP 3: AT THE PET RECYCLERS—SORTING (ONCE AGAIN), CLEANING, FLAKING
PROCESS OF PET RECYCLING UNIT
SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT
PROCESS FLOW DIAGRAM OF PET RECYLING
EXISTING POLICY AND REGULATION FOR PLASTIC RECYCLING INDUSTRY IN INDIA
TABLE: CIRCULARITY IMPLICATIONS OF LEGISLATIVE AND REGULATORY FRAMEWORK FOR PLASTICS IN INDIA
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:
IMPLEMENTATION SCHEDULE
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
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
SUPPLIERS OF PLASTIC RECYCLING PLANT
COMPLETE PLANT SUPPLIERS FOR PLASTIC GRANULES FROM WASTE
SUPPLERS OF PLANT & MACHINERY
SUPPLERS OF REACTION VESSEL
SUPPLERS OF GRANULATORS
SUPPLERS OF MIXER
WASTE RAW MATERIAL SUPPLIERS ADDRESSES
PLASTIC PROCESSING MACHINERY SUPPLIER IN INDIA
MACHINETY AND PROCESS KNOW HOW
PLASTIC TESTING LABS IN INDIA
LIST OF PLSTIC SUTLI MANUFACTURE AND TRADERS
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)
