Detailed Project Report on pet recycling unit (2000 kg/day)

PET RECYCLING UNIT
[CODE NO. 3086]


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.

COST ESTIMATION

Plant  Capacity                                :       2000.00 Kgs./day                                        
Land & Building (3000 Sq.MT)    :    Rs. 1.50  Cr
Plant & Machinery                          :    Rs. 1.05  Cr
Working Capital for 1 Month         :    Rs. 26.00 Lacs
Total Capital Investment                 :    Rs. 2.92 Cr
Rate of Return                                  :    18%
Break Even Point                              :    65%


INTRODUCTION    
HISTORY OF PET    
PROPERTIES & CHARACTERISTICS    
USES AND APPLICATION OF PET    
RECYCLING OF PET BOTTLES    
CLEAR PET FLAKE – BOTTLE SPECIFICATION    
MARKET SURVEY    
FUTURE PROSPECT FOR PET RECYCLING    
US RECYCLED PLASTIC DEMAND, 2006-16    
MARKET SURVEY OF PRODUCTS MADE FROM RECYCLED PET    
PRODUCTION AND INSTALLED CAPACITY OF POLYSTER STAPLE FIBRE
   IN INDIA    
CONSUMPTION OF POLYSTER STAPLE FIBRE IN INDIA    
EXPORT DATA OF PET FLAKES    
FINISHED PRODUCTS THAT CAN BE MADE FROM PET RECYCLED
   GRANULES OR FLAKES    
MARKET POSITION OF INDIAN PLASTICS    
OVERVIEW OF PLASTIC RECYCLING1
ADDRESSES OF PET RECYCLING UNIT    
MANUFACTURERS/SUPPLIERS OF PET GRANULES    
ADVANCEMENT AND PRACTICES IN PET RECYCLING    
POST CONSUMER PET WASTE    
PROCESS OF PET RECYCLING UNIT    
SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT    
MANUFACTURING PROCESS IN DETAILS    
PROCESS FLOW DIAGRAM    
LOWERING THE COST OF PET RECYCLING THROUGH BETTER
   LABEL TECHNOLOGY    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
ADDRESSES OF CONSULTANT    
SUPPLIERS OF PLANT AND MACINERIES    
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)    
SUPPLIERS OF RAW MATERIAL    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS  
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET