BIODEGRADABLE CUPS AND PLATES FROM SUGARCANE BAGASSE, WOOD PULP OR BAMBOO PULP
[CODE NO.3209]
Today consumption of Disposable products is breaking records. Disposable products are easy to handle, economical and can be disposed easily. With the changing lifestyle of Mankind, the use of disposable products is raising like anything. Plastic Disposable products are very popular because it can be carried easily and very low in prices too.
This is 100% BIODEGRADABLE & COMPOSTABLE tableware, which is widely used in various functions ,restaurants , festivals as ECO FRIENDLY single time (Use & throw) crockery , it’s produce by Plant extract or residue like Sugarcane Bagasse (SCB) etc., which is Proven Environment friendly 100% Biodegradable and Compostable and not harmful for food, human , soil and Nature. This is becoming more popular due to environment awareness ,climate change & NGT/State govt. bans on recyclable plastics. This can be use in microwave and refrigerator also.
10 inch Bagasse Round Regular Plate
Disposable products are made of various materials such as dry leaves, pulp, papers and plastic etc.
Thermoformed fiber is a material made by forming paper fibers or other natural fiber in a mold. The end product can be made into almost any shape for any type of solution. In the process of making thermoformed fiber, the product begins with a process similar to transfer molding. During the process of thermoforming fiber, the product is transferred to a set of heated metal molds that dry the fiber under intense pressure and heat, making an extra drying process unnecessary. The process of thermoforming the pulped fiber delivers parts that have a smooth finish on both sides of the thin and dense walls of the product. There are many advantages to having a thermoformed fiber product with smooth walls. They include: reduced freight and storage costs and the ability to use mechanical denesting. The use of thermoformed fiber is very desirable when visual appearance is preferred.
140ml Bagasse Cup
The process of pulp thermoforming is employed to develop sturdy and smooth packaging. This type of packaging can be used in various industrial and commercial uses. Thermoformed pulp is a desirable alternative to petroleum-based products. American Fiber Packaging has invested in the latest equipment technology and has developed a process to manufacture high-quality thermoformed fiber solutions. Through this process we are able to deliver environmentally responsible products to our customers.
Thermoformed molded fiber products can be customized to specifications and can include clamshells, trays, inserts, and many other types of packaging. Thermoformed pulp is a great alternative to petroleum-based foam products like expanded polystyrene (EPS) for protecting and positioning products inside packaging.
Range & Variety
The present project report is fully based on biodegradable cups and plates from Sugarcane bagasse, wood pulp. These products have got good demand in throughout the country. The project many be setup in small scale sector. All the required plant & equipments and Raw materials are easily available in India.
The plastic industry in India plays a very important and key role in Industrialization. Wide spectrums of plastics and articles manufactured by the industry have touched the life of every Indian in many ways through consumer plastics. Now we have entered into another era of plastic consumer goods continuously replacing the traditional items. The items cover from furniture to medical sciences from lutchen equipment to daily use articles.
Biodegradable cups and plates from Sugarcane bagasse, wood pulp or bamboo pulp are used in daily life now a day. In addition to be used at home these are largely used during at hournies, parties and other functions.
The use of disposable items is increasing day by day because of better hygienic conditions, low cost, easy usability and impressive appearance.
MARKET POSITION
The foodservice disposables market is estimated to expand at a CAGR of >5.1% from 2015 to 2021, to account for US$ 27,187 Mn by 2021. The market was valued at US$ 19,200 Mn in 2014. Asia-Pacific and the Middle East & Africa are projected to be the fastest-growing markets over the next six years. The growth of the Asia largely depend upon the market of India. Plastics and such other material cant be sustain more in food packaging. As Indian youth population life style going to upgrade and demand is growing fast, so demand of disposables will be continue in increasing tread.
The Indian and Global foodservice disposables market is experiencing rapid growth. Increasing consumer concern regarding hygiene is the most important factor driving the growth of the disposable food Crockery. For a better understanding and analysis of the disposables found 100% biodegradable and compostable is best choice. The foodservice disposables market is estimated to expand at a CAGR of >5.1% from 2015 to 2021, to account for US$ 27,187 Mn by 2021. The market was valued at US$ 19,200 Mn in 2014. Asia-Pacific and the Middle East & Africa are projected to be the fastest-growing markets over the next six years. The growth of the Asia largely depend upon the market of India. Plastics and such other material cant be sustain more in food packaging. As Indian youth population life style going to upgrade and demand is growing fast, so demand of disposables will be continue in increasing tread.
Demand for serviceware -- which includes cups, dinnerware, utensils, and other products -- is forecast to increase at the second fastest annual rate through 2017. Below average value gains will result from a moderation in material prices along with growing competition from Asian imports in some segments. Nonetheless, prospects will be supported by a favorable outlook for limited service restaurant and retail establishment foodservice revenue growth, along with steady demand in the institutional and other markets. Also supporting gains will be the increased focus on gourmet coffee and specialty cold drinks by quick service restaurants and convenience stores and increased catering activity by restaurants. Robust advances are anticipated for degradable or compostable packaging and serviceware from a relatively small base, the result of the heightened prominence of environmental concerns, efforts by foodservice establishments to differentiate themselves, and growing local bans on foamed polystyrene disposables.
PROPERTIES & CHARACTERISTICS
- Disposable
- Microwave safe
- Eco-friendly & renewable
- Can be refrigerated and frozen
- 100% biodegradable & compostable
- Clean design
- Rigid Construction
- Impermeable grease resistant surface
Raw Material
Dishware made out of Bagasse/wood pulp/bamboo pulp is a substitute for disposable paper dishware. Bagasse/wood pulp/bamboo pulp dishware is often marketed as biodegradable or compostable.
Pros
- Bagasse/wood pulp/bamboo pulp products are produced from a renewable resource.
- Bagasse/wood pulp/bamboo pulp products are made from a secondary waste product of making sugar and therefore do not impact food supply.
- Bagasse/wood pulp/bamboo pulp products are made with less energy and water than their paper counterparts.
Cons:
- If Bagasse products break down in the landfill, they do so without oxygen, and they release methane, a potent greenhouse gas that contributes to global warming. The landfills where Portland’s waste goes do capture methane and use it to generate electricity, but some methane still escapes into the atmosphere.
MANUFACTURING PROCESS OF BIODEGRADABLE CUPS AND PLATES
For the manufacture of biodegradable cups and plates, the first step is to soak the sugarcane bagasse or other pulp in water and mix them until the right consistency of pulp is achieved. No waste water is generated in the manufacturing process, all excess water either evaporates during manufacturing or is returned in the system.
The pulp part is formed to shop by custom designed tools. The tools are powered into pulp mixture and the water is pulled through the mesh with a vacuum. The upper tools press into the lower tools to help shape the piece suction from the vacuum helps bind the fibers. After forming, the parts are wet and need to be dried.
PROCESS OF MOLDED PULP
To create molded pulp you must begin with a fiber. The fiber used will be based on the end product desired. For example, when creating a stabilizer or cushion you can use recycled corrugated and Kraft materials. This will result in a thick, dark-colored pulp. You would most likely use the Thick-Walled manufacturing process with this kind of pulp. Virgin material rather than recycled material has been proven to be stronger as well. With molded pulp, the shape and size of the molded piece will play a large part in how strong the piece will be.
In manufacturing, fiber is mixed with water in a giant blender. As it mixes, a slurry is formed. The slurry has the same consistency and thickness of pancake batter and is also quite heavy. If additives are to be used, they would be mixed into the slurry. An additive could be used to make the product stronger, printable, smoother, or to add color or bleach the slurry.
BAGASSE PULP PLATE MAKING MACHINE
Bagasse is the newly developed material for the production of tableware. Compared with other raw material, bagasse tableware has better appearance and longer life span, compared with polyester, bagasse is more environmental friendly, which can be recycled or absorted easily. The production of bagasse tableware is similar with egg tray production. Bagasse pulp, which can be obtained from paper making plants, is used as raw material, after pulping, molding & drying section, the tableware will go through sterilization and edge trimming section before packaging. As the profit margin is much higher than other consumable tableware, it‘s another excellent choice for entrepreneurs who wants enter the local market.
COST ESTIMATION
| Plant And Capacity | 19200.00 Pieces/day |
|---|---|
| Land & Building (700 sq.mtrs) | Approx. Rs. 1.05 Cr |
| Plant & Machinery | Rs. 1.80 Cr |
| Working Capital for 2 Months | Rs. 17.00 Lacs |
| Total Capital Investment | Rs. 3.10 Cr |
| Rate of Return | 19% |
| Break Even Point | 66% |
