Detailed Project Report on plastic pet doors from waste pet bottles

PLASTIC PET DOORS FROM WASTE PET BOTTLES
 [CODE NO. 3055]


Polyethylene terephthalate
 
Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly abbreviated PET, PETE, or the obsolete PETP or PET-P), is a thermoplastic polymer resin of the polyester family and is used in synthetic fibers; beverage, food and other liquid containers; thermoforming applications; and engineering resins often in combination with glass fiber.

Depending on its processing and thermal history, polyethylene terephthalate may exist both as an amorphous (transparent) and as a semi-crystalline material. The semicrystalline material might appear transparent (particle size < 500 nm) or opaque and white (particle size up to a few microns) depending on its crystal structure and particle size. Its monomer (bis-B-hydroxyterephthalate) can be synthesized by the esterification reaction between terephthalic acid and ethylene glycol with water as a byproduct, or by transesterification reaction between ethylene glycol and dimethyl terephthalate with methanol as a byproduct. Polymerization is through a polycondensation reaction of the monomers (done immediately after esterification/transesterification) with ethylene glycol as the byproduct (the ethylene glycol is directly recycled in production).

Some of the trade names of PET products are Dacron, Diolen, Tergal, Terylene, and Trevira fibers, Cleartuf, Eastman PET and Polyclear bottle resins, Hostaphan, Melinex, and Mylar films, and Amite, Ertalyte, Impet, Rynite and Valox injection molding resins. The polyester industry makes up about 18% of world polymer production and is third after polyethylene (PE) and polypropylene (PP).

PET consists of polymerized units of the monomer ethylene terephthalate, with repeating C10H804 units. PET is commonly recycled, and has the number "1" as its recycling symbol.

PET (also abbreviated PETE) is short for polyethylene terephthalate, the chemical name for polyester.

PET is a clear, strong, and lightweight plastic that is widely used for packaging foods and beverages, especially convenience-sized soft drinks, juices and water. Virtually all single-serving and 2-liter bottles of carbonated soft drinks and water sold in the U.S. are made from PET.

It is also popular for packaging salad dressings, peanut butter, cooking oils, mouthwash, shampoo, liquid hand soap, window cleaner, even tennis balls. Special grades of PET are used for carry-home food containers and prepared food trays that can be warmed in the oven or microwave.

The basic building blocks of PET are ethylene glycol and terephthalic acid, which are combined to form a polymer chain. The resulting spaghetti-like strands of PET are extruded, quickly cooled, and cut into small pellets. The resin pellets are then heated to a molten liquid that can be easily extruded or molded into items of practically any shape.

PET was first synthesized in North America in the mid-1940s by DuPont chemists searching for new synthetic fibers. DuPont later branded its PET fiber as “Dacron.” Today, more than half of the world’s synthetic fiber is made from PET, which is called “polyester” when used for fiber or fabric applications. When used for containers and other purposes, it is called PET or PET resin.

PET is approved as safe for contact with foods and beverages by the FDA and health-safety agencies throughout the world. The safety of PET for food, beverage, pharmaceutical and medical applications has been repeatedly demonstrated through extensive studies, regulatory approvals, testing, and its widespread acceptance for more than 30 years. PET does not contain bisphenol-A (BPA) or phthalates (plasticizers).

Because of PET’s unique properties, it is rapidly becoming the world’s preferred packaging material for foods and beverages. Like glass, it is a very strong and inert material that does not react with foods, is resistant to attack by micro-organisms, and will not biologically degrade. But unlike glass, PET is extremely lightweight, easy and efficient to transport, and shatterproof.

PET is completely recyclable, and is the most recycled plastic in the U.S and worldwide. More than 1.5 billion pounds of used PET bottles and containers are recovered in the United States each year for recycling. PET can easily be identified by the #1 in the triangular “chasing arrows” code, which is usually found molded into the bottom or side of the container. No other plastic carries the #1 code.

PET can be commercially recycled by thorough washing and re-melting, or by chemically breaking it down to its component materials to make new PET resin. Almost every municipal recycling program in North America and Europe accepts PET containers.

Products commonly made from recycled PET include new PET bottles and jars, carpet, clothing, industrial strapping, rope, automotive parts, fiberfill for winter jackets and sleeping bags, construction materials, and protective packaging.

The current U.S. recycling rate for PET is 31%. This figure continues to grow, but notably lags behind Europe, which has a PET recycling rate of 52%.

Although recycling is the most environmentally responsible and efficient re-use of resources, PET bottles and containers that find their way to the landfill pose no risk of harm or leaching. Since the polymer is inert, it is resistant to attack by micro-organisms, and won’t biologically degrade. PET also takes up relatively little landfill space since it is easily crushed flat. According to the EPA, only 1% of U.S. municipal solid waste is due to PET containers.

PET is a very energy-efficient packaging material. Although its raw materials are derived from crude oil and natural gas, it enjoys a very favorable sustainability profile in comparison to glass, aluminum and other container materials.

Its sustainability jumps even higher when recycling is introduced, since approximately 40% of PET’s energy use is attributable to its “resource energy” – the energy inherently trapped in its raw materials that can be recaptured and reused through recycling.

The high strength of PET in comparison to its light weight is a major key to its energy efficiency, allowing for more product to be delivered in less packaging and using less fuel for transport. Ongoing advances in light-weighting technology continue to improve its energy efficiency even further. Life cycle studies of PET have consistently confirmed the environmental benefits of PET as a packaging material.

In the 60 years since PET was first synthesized, it has become one of the world’s most widely used, versatile and trusted materials.

Plastic doors are an important aspect of any home improvement  project. Front entry doors are the first thing  that visitors  to your home will see and you will want to make a  good impression.  One  way to be sure of doing that  is  with  Plastic doors.  Plastic door has several advantages over a wooden  door. There’s no  denying that a beautifully finished wooden  door  is appealing. The question is, how long will that wooden door retain its appeal? In many cases, you will have to replace or repair the wood within a few years, as wood is susceptible to weathering and rotting. And it doesn't take long for that lovely glossy exterior to become a peeling eyesore. If you live in a  listed  building, you  may  have  to  choose timber  doors  and  windows  for  your remodelling project.

The good news is that exterior home doors do not have to be white plastic.  Although that is the finish most commonly associated with vinyl exterior doors PVCU is now  available  in wood effect finishes.


COST ESTIMATION

Plant Capactiy                               :    300.00 Nos./day
Land & Building (1500 Sq.Mtr    :    Rs, 2.3 Cr
Plant & Machinery                        :    Rs. 1.95 Cr
Working Capital for 2 Months    :    Rs. 99.95 Lacs
Total Capital Investment             :    Rs. 5.05 Cr
Rate of Return                               :    18%
Break Even Point                           :    65%


INTRODUCTION    
PROPERTIES AND CHARACTERISTICS OF PLASTIC DOOR    
PROPERTIES AND CHARACTERISTICS OF PET    
USES & APPLICATION    
B.I.S. SPECIFICATION    
MARKET SURVEY    
PET BOTTLE RECYCLING    
PROCESSING GUIDELINES PET    
GLOBAL STATISTICS OF PET RECYCLING    
COMPOUNDING FORMULATION OF PET    
MANUFACTURING PROCESS OF PLASTIC PET DOOR
   FROM WASTE PET BOTTLES    
PROCESS FLOW DIAGRAM    
METHOD OF PET RECYCLING    
DATAILS OF PET BOTTLE RECYCLING    
METHOD OF PET DRYING    
PET INJECTION MOULDING PROCESSING CONDITION    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF PLANT & MACHINERY    
SUPPLIERS OF PLANT & MACHINERY (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