MANUFACTURING OF rPET CHIPS & SSP PLANT
[EIRI/EDPR/4708] J.C.: 2928XL
INTRODUCTION
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 consumption of bottled water has been increased very much in the past few years. Plastics are significant and make a positive contribution with regards to packaging in various ways. By sorting and processing plastic packaging that is found in predominantly homogeneous streams, the value and market availability is maximized for the collected plastic packaging industry. Plastic bottles, plastic tubs, and plastic bags all have the potential to be recycled. One of the fastest growing types of collected plastic materials for recycling is polyethylene terephthalate ("PET") from postconsumer beverage and water bottles. For beverages and other juices, plastic bottles are used more preferably. The growing utilization of plastics in industrial and consumer applications, combined with increased consumer awareness surrounding solid waste recycling, has led to an increased demand for recycled plastic resins and products. One of the fastest growing types of collected plastic materials for recycling is polyethylene terephthalate ("PET") from post-consumer beverage and water bottles. Replay Plastics will capitalize on the opportunities in the recycled resin.
Recycled Polyethylene Terephthalate (RPET) is simply a plastic made from repurposed waste PET from businesses and consumers. It’s also the material used most commonly by manufacturers to help meet their sustainability goals.
Because PET is so widely recyclable, bottles, food packages and other PET containers are taken and repurposed to create RPET, PCR and other plastics that can be used to make new products without damaging ecosystems and ending up in landfill sites.
Every year, an estimated 7.7 billion plastic water bottles are used in the UK, and 38 billion bottles of water are thrown away annually across the United States – not to mention the 4.9 billion tonnes of plastic waste produced globally already.
Unfortunately, most of these plastic bottles end up in landfill sites and oceans across the globe. This increases the drive to use sustainable RPET materials when manufacturing new products.
rPET has many benefits, including:
More environmentally friendly – than alternative plastics, because it’s made from recycled plastic. rPET leaves a significantly reduced carbon footprint compared with manufacturing new plastic and can be used again in other products. This also helps to reduce the amount of plastic that populates landfill sites and oceans worldwide.
Durability – rPET is highly resistant to chemicals and heat – making it an ideal material to store food and for use in microwaves, fridges and freezers.
Hygienic and low-hassle – Because of its glossy surface, rPET repels water and dirt – making it easy to clean.
Cost-effectiveness – rPET has low production costs. Developing recycled plastic uses little water and energy. The end product is also lightweight, reducing transportation costs and carbon emissions.
Encouraging use of recycled content
Establishing recycled content minimums for PET would send a signal to the markets that demand for recycled material will be consistent, which would help to stabilize its value. A number of markets have introduced directives setting targets for including recycled content in PET bottles.
In the European Union, the Single-Use Plastics Directive incorporates recycled content mandates for plastic beverage containers, setting a 25% target for recycled content in PET bottles by 2025 and 30% for all plastic bottles by 2030.
COST ESTIMATION
Plant Capacity 24 MT/Day
Land & Building (2 Acres) Rs. 12.01 Cr
Plant & Machinery Rs. 115.10 Cr
Working Capital for 1 Month Rs. 2.56 Cr
Total Capital Investment Rs. 130.18 Cr
Rate of Return 2%
Break Even Point 94%
CONTENTS
INTRODUCTION
RPET HAS MANY BENEFITS, INCLUDING:
ENCOURAGING USE OF RECYCLED CONTENT
A GROWING APPETITE FOR RPET PLASTIC
PRODUCTS AND ITS APPLICATION
A PILE OF USED PET BOTTLES AT A WASTE TRADER
FIBER MADE FROM RECYCLED PET BOTTLES; INDIAN CRICKET TEAM T-SHIRTS MADE FROM RECYCLED PET BOTTLES
MARKET INSIGHTS
MAJOR COMPANIES GLOBALLY
MAJOR RAW MATERIAL S
WHY RECYCLE
RECYCLING TIPS
PET SAFETY FACTS
APPLICATIONS
RPET FLAKES APPLICATIONS
RPET SSP GRANULES
B.I.S. SPECIFICATION
PROMOTION
INDIAN ASSOCIATIONS
MANUFACTURING PROCESS
PET FLAKES
HARMONIZED SYSTEM (HS) FOR PET FLAKES:-
USES OF PET FLAKES
PET FLAKES GRADES
SOME GRADES ARE:
TYPES OF PET FLAKES
RECYCLING PROCESS OF PET FLAKES
THE RECYCLING PROCESS TAKES PLACE IN FOLLOWING STEPS: -
1. MANUAL SORTING:
2. SHREDDING :
3. BELT CONVEYOR:
4. WASHING TANK:
RECYCLING PROCESS OF PET FLAKES
DIFFERENCE BETWEEN PET FLAKES AND PET CHIPS
MARKET IN INDIA
SCOPE IN INDIA
ADVANTAGES
THEY HELP CONSERVE RAW MATERIALS IN MANY DIFFERENT INDUSTRIES
DISADVANTAGES
PET BOTTLE TO BOTTLE RECYCLING PROCESS
WASHING LINE
PELLETIZING PROCESS
CONTINUOUS SSP PROCESS
DETAILED VALUE CHAIN OF PET
TRENDS IN USAGE OF RECYCLED PET RESIN IN INDIA
RAW MATERIALS USED
GENERATION OF PLASTIC WASTE
YEAR WISE DATA FOR PLASTIC WASTE GENERATION AS PER CPCB ANNUAL REPORTS
INDUSTRYOVERVIEW
1. GLOBALPLASTICMARKET-MARKETPERFORMANCE
1.1. MARKET BREAKUP BY MATERIAL TYPE - VALUE TRENDS
TRENDS IN ASIA PACIFIC:
GLOBAL PET MARKET - MARKET PERFORMANCE
GLOBAL PLASTIC WASTE MARKET - MARKET PERFORMANCE
TRENDSINASIAPACIFIC:
1.1. MARKET BREAKUP BY MATERIAL TYPE
PET WASTE HIGHLIGHTS:
1.1. MARKETBREAKUPBYUSEOFPLASTICWASTE
MISMANAGEDWASTE:
INCINERATION:
RECYCLING:
PETWASTEMARKETBREAKUPBYUSE
COUNTRY WISE COMPARISON OF RECYCLING RATE BY MATERIAL TYPE
1.1. TRENDS ON INCREASING PENETRATION OF RECYCLED MATERIAL USED FOR PET APPLICATIONS
GLOBALREGULATIONS:WASTECOLLECTION
INDIAPLASTICCONSUMPTION–MARKETPERFORMANCE
VOLUMETRENDS
PLASTICCONSUMPTIONBYTYPE
VALUE TRENDS
PET:
INDIANPETMARKET
VOLUMETRENDS:
1.1.1. VALUETRENDS
VOLUMETRENDS
VALUETRENDS
INDIANPETPACKAGINGMARKET
VALUETRENDS
INDIAPLASTICWASTEGENERATION
VOLUMETRENDS
PLASTIC WASTE GENERATION BY STATES
INDIANREGULATIONSSUPPORTINGPLASTICWASTECOLLECTION&RECYCLING
PLASTICWASTEMANAGEMENTRULES:
TIMELINEOFPLASTICWASTEMANAGEMENTRULESININDIA
CATEGORIES,TARGETS,ANDTIMELINES
ASPERPLASTICWASTEMANAGEMENT(AMENDMENT)RULES,2022,THECLASSIFICATIONOFPLASTICSISDEFINEDBELOW:
GUIDELINESONEXTENDEDPRODUCERRESPONSIBILITY(EPR)FORPLASTICPACKAGING
INDIAWASTEPLASTICRECYCLINGMARKET
MARKETOVERVIEW
VOLUMETRENDS
RECYCLINGPLASTIC:BREAKUPBYSTATES
INDIAPETWASTEMANAGEMENT(VOLUMETRENDS)
GLOBAL RPET MARKET
MARKETOVERVIEW
TRENDSFORINCREASINGUSEOFRPET
LARGECORPORATIONSHAVINGSUSTAINABILITYMANDATES
NUMBEROFBOTTLESCONSUMEDININDIA(VOLUMETRENDS)
INDIA RPET MARKET
MARKET OVERVIEW
VOLUME TRENDS
VALUETRENDS
MARKETBREAKUPBYAPPLICATION
VOLUMETRENDS
VALUE TRENDS
BENEFITSOFUSINGRECYCLEDMATERIALSOVERVIRGINPLASTIC
LISTOFINDIANKEYPLAYERS
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:
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. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
UTILITIES
INDIAN MANUFACTURING INDUSTRY
INTRODUCTION
MARKET SIZE
INVESTMENT
SOME OF THE MAJOR INVESTMENTS AND DEVELOPMENTS IN THIS SECTOR IN THE RECENT PAST ARE:
GOVERNMENT INITIATIVES
ROAD AHEAD
PLANT AND MACHINERY MANUFACTURERS
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
RPET PROCESSOR/MANUFACTURERS IN INDIA
WEIGHING BREIDGE MANUFACTURER
WEIGHING MACHINES
PACKAGING MACHINE
LABORATORTY EQUIPMENTS MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS
ELECRICAL GOOD & SWITCH MANUFACTURE
EXTRUDER MACHINE MANUFACTURERS (GLOBALLY)
SS PIPE & TUBE MANUFACTURER
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
LICENCE OF PLASTIC WASTE IMPORT
DOCUMENTS REQUIRED ARE:-
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
SWOT ANALYSIS
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
ORGANIZATION CHART
PLANT LATOUT
IMPLEMENTATION SCHEDULE
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)