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7/27/2019 Pp Project Rtrsl 75 _650_ - Cam 5525-2
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R.R PLAST EXTRUSION PVT.LTD.
MUMBAI
PROJECT PROFILE(RRSL 75 (650) /CAM TFM 5525- 2)
PRODUCT - Plastic Disposable Cups and Glasses
INTRODUCTION
The Plastic Industries in India plays a very important and key
role in Industrialization. A wide spectrum of Plastic Articles
manufactured by this Industries have touched the life of every
Indian in many ways. Now we have entered into another era
of Plastic consumer goods, which is continuously replacing
the traditional items.
Disposable cups, glasses, plates and other plastic packing
containers are used in daily life. In addition to that, these are
largely used at hournies, parties and other functions also.
The use of Disposable containers is increasing day by day
because of better hygienic conditions, Low cost, easy
usability and impressive appearance .
Disposable cups and glasses are largely used for Tea, coffee,
juices and other milk-products.
MARKET With rapid urbanization in recent years and growth in
OUT-LOOK consumerism, a study growth is taking place in the Indian
consumer products market. By the end of 10th
plan period
urban population will cross 400 millions, this will lead to
further in continuous growth in consumer products in future.
As far as the question of Cups and Glasses are concerned, ithas gained great importance because of many reasons. The
Disposable cups and glasses are mostly used at Railway
stations, moving restaurants, travels and Sports-Centre.
.ContP/2
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Page 2
With increasing urbanizations and sifting thrust of Society
For time oriented has increased the use of Disposable
Containers.
In addition to that the Disposable containers are also used
In packaging of Dairy and Food products which has a verybright future and steady growth.
MANUFACTURING The basic material for thermoforming is sheet in rolls and
PROCESS therefore, the first process of manufacturing is Extrusion
where the granules mixed with master batch of required
colour are extruded into sheet in roll form. The sheets are
extruded in various thickness and width to match with the
product to be thermoformed. The extrusion of P.P. is to be
done with minimum orientation. The sheet rolls are then fed
into thermoforming station, where it is to be softened at the
required temperature with infra red heaters and then with the
help of dies and moulds, air pressure, pre-forming plug, the
sheet is Thermoformed into desired shape of containers, and
punched out on station. The formed containers are separated
here and the punched web (sheet) in rolls are taken to grinder
machine where it is converted into Flakes and refilled into the
Extruder along with the virgin granules.
The containers after Thermoforming are checked, counted
and pocked on polythene sleeves and then in corrugated
boxes and made ready for despatch.
SAILENT (a) Thermoformed containers being the lightest packing materials
FEATURES save packing cost and freight.
(b) Cold as well as hot drinks can be served easily.
U S E S Thermoformed containers can be of various shapes and sizes
To cater to the demand of a cross-section of the food, catering
and dairy industries.
.Cont.P/3
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Page 3
RAW MATERIAL Raw material for the Disposable containers are either
& High impact polystyrene (HIPS or PP) and colouring
CHEMISTRY masterbatch granules. Polypropylene is a thermoplastic
polymer with good resistance to chemicals and mineral
acids and having high impact strength and good toughnessand very easy in processing. It has gained wide acceptance
in application ranging house-hold items and food-packaging.
Masterbatch consists of 80%pigments and 20% polypropylene.
Polypropylene is manufactured by dissolving an Unsaturated
rubber in polypropylene monomer and polymerizing the
monomer in a solution or mass-suspension process. The rubber
generally polybutadiene is dispersed on the form of discrete
particles and then the polymerization is taking place, which
gives the strength to the polymer.
What is PP?
Polypropylene (PP) is a long chain polymer made from
Propylene (C3) monomer
Heat, Pressure
C3 PPCatalyst
.
Propylene Monomer
CH2 = CH
CH3
Polypropylene Polymer
CH2-CH-CH2-CH
CH3 CH3 x
Polymerization Process
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FLOW CHART
ECONOMICS OF THERMOFORMING
.
Procurement of
Raw MaterialMaterial Quality Assurance
Raw Material
Inventory / StockComputer Inventory Control (RM)
Material Transfer to
Work Station/ Extruder Inventory
Control
Sheet/ Roll
Stock
Thermoforming
Forming
Inspection
Printing
Final Product
Inspection
Scrap Transfer
To Warehouse
Scrap Recovery
Grinding/ Identification
Packaging, Labeling
Finished Product Transfer
To WarehouseInventory Control (FP)
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INSTALLED RATED CAPACITY OF THERMOFORMING MACHINESPRODUCTION
CAPACITY Stroke - 30 Strokes / mints
Avg.Stroke - 26 Strokes / mints
Cavity - 12 Cavity Mould
Per day Production/ Machine - 26 X 12 X60 X22
4, 11, 840 pcs / day
Considering the average weight - 1.65 gm/ pc
For all the products = 4, 11, 840 X 1.65 gm/ pc
= 663.00 Kgs/ day + 2.5% packing scrap(16 kgs)
THERMOFORMING: Selected for two machines
CAPACITY Monthly Thermoforming production = 663 X 2 =1326.0 kgs
= 1326 kgs X 26/ Month
= 34.0 ton / Month
EXTRUSION : Working hrs per shift - 7.33 hrs
CAPACITY No. of shift per day - 3
Working hrs per day - 22 hrs
No. of Extruders - 1
No. of working days - 26 days
Machines rated
Capacity per hours - 130 kgs / hrs
Monthly Extrusion
Capacity - 22 X 130 X 26 = 68,640 Kgs/
Month_ _ _ _ _ _ _ _ _ _
PLANT ECONOMICS: Installed plant capacity = 34.0 Mts/ Month
No. of Working days = 26 days / Month
LAND & BUILDING: Total Land area 4,000 Sq. ft. 4,00,000.00
@ Rs. 100/- P/ Sq. ft.
Building 4,000 Sq. ft. 8,00,000.00
@ Rs. 200/- P/ Sq. ft.
TOTAL 12, 00, 000.00
Cont.... P / 5
.
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Page - 5
PLANT AND The Estimated cost of Plant and MachineriesMACHINERIES -
1. Sheet-Extruder 1 No Rs. 28.50 Lacs
75-Mono-Extruder2. Thermoforming -5525-PP 2 Nos Rs. 27.00
3. Thermoforming Mould 3 Nos Rs. 10.00
4. Scrap Grinder 1 No Rs. 2.75
5. Air Compressor-100 CFM 1 No Rs. 5.50
6. Water Cooling Tower-50 TR 1 No Rs. 0.50
7. Air receiver 1m3
1 No Rs. 0.40
8. Chilling Plant -10 TR 1 No Rs. 5.50
80.15 LAKHS
9. Electrical system H.T. Lines
of 230 KVA 415 V withElectrical Panels - Rs. 9.75
Taxes & Duties Rs. 9.50
Rs. 99,40,000
OTHER FIXED ASSETS
1. Office Equipment, Furniture Rs. 25, 000.00
2. Installation Cost for Water,Air, electricity etc. Rs. 1, 50, 000.00
3. Weighted Scales Rs. 25, 000.00
4. Tools and tackles Rs. 25, 000.00
5. Fire Freighting Equipments Rs. 30, 000.00
6. Pre operative & Preliminary Expenses Rs. 20, 000.00
Rs. 2, 75, 000.00
FIXED CAPITAL
1. Land and Building Rs. 12, 00, 000.002. Plant and Machinery Rs. 99,40,000.00
3. Other Fixed Assets Rs. 2, 75, 000.00
Rs. 1,14,15,000.00
Contd.P/6
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REQUIREMENT OF PERSONNEL & COST
ADMINISTRATIVE STAFF -
1. Plant Manager - 1 No - Rs. 12, 000. 00
Shift In-charge - 1 Nos - Rs. 6, 000. 00
Staff add Store - 1 Nos - Rs. 5, 000. 00Keeper
Security Personnel - 2 Nos - Rs. 6, 000. 00
5 Nos Rs. 29, 000.00
FACTORY PERSONNEL
1. Skilled - - 3 Nos Rs. 30, 000. 00
2. Semi Skilled - - 6 Nos Rs. 12, 000. 00
3. Un-Skilled - - 20 Nos Rs. 50, 000. 00(FLOATING LABOUR)
29 Nos Rs. 92, 000.00
GRAND TOTAL= -- 34 Nos Rs. 1,21,600.00
Consider Annual Benefit @ 10% to Add 12,160.00
to the Staff
Total Rs. 1,33,760.00
Electrical Power
UTILITIES & OTHER
OVERHEADS
Connected Load
a) Sheet Plant - One No. 77. 0 KW
b) TFM 2NOS Two Nos. 86. 0 KW
c) Air Compressor One No. 23.00 KW
d) Grinder One No. 11. 25 KW
e) Water Pump One No. 2. 25 KW
f) Lighting -------- 3. 0 KWg) Water Cooling tower One No. 3. 75 KW
h) Chilling plant One No. 15.0 KW
221. 0 KW
.
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Page - 7
Therefore total connected load = 221. 0 KW (Say)
Consider 70% of the total connected load as average consumption per month.
Cost of total nos. of Units consumed per month = 160.00 KW (SAY)
Considering the rate of Unit as Rs. 6. 00 / Unit.
= 160 X 550 = 88,000/- x Rs. 6.00 = Rs. 5, 28,000. 00 / Month
2. Maintenance Spare Parts -- -- 4,500. 00 /
3. Telephone & Postage -- -- 3,000. 00 /
4. Stationery -- -- 3,000. 00 /
5. Conveyance & Transportation -- -- 5,000. 00 /
6. Miscellaneous -- -- 5,000. 00 /
Total: - 5,48,500.00 / Month
RAW MATERIAL REQUIREMENT
As total plant capacity is 34. 0 Mts / Month, the raw
Material requirement = 34000 Kgs. / month.
Present Rate is @ Rs. 100. 00 / Kg
Cost of total Raw Material ---- --- --- Rs. 34,00,000. 00 / Month
Packing material -a) P P Film
b) Packing Box
c) BOPP Tape
d) Strap & Clip.
Considering average rate of Rs. 6. 00 / Kg for the total production of34 M.Tons --- --- Rs. 2, 04, 000.00 / MonthTOTAL WORKING CAPITAL / MONTH
1) Raw Material Rs. 34,00,000. 00
2) Packing material Rs. 2, 04, 000. 00
3) Salary and Wages Rs. 1,33,760.00
4) Utilities and Overheads Rs. 5,48,500.00
Rs. 42, 86, 260. 00
Cont.P/8
.
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Page - 8
TOTAL CAPITAL INVESTMENT
1) Fixed Capital Rs. 1,14,15, 000. 00
2) Working Capital Rs. 42,86,260. 00
Rs. 1, 57,01,260. 00
PROFIT & LOSS ACCOUNT
1. Cost of Production per Month
a) Cost of Raw Materials Rs. 34,00,000. 00
b) Cost of Packing Materials Rs. 2,04, 000. 00
c) Salary & Wages Rs. 1,33,760.00
d) Utilities and Overheads Rs. 5,48,500.00
e) Interest @ 12% on TCI Rs. 1,57,012. 00f) Considering the depreciation
@ 15% on Fixed Assets Rs. 1, 42, 687. 00
Rs. 45,85, 959. 00
TURN OVER PER MONTH:
By Sale of 34. 0 Mts Glasses and Cups
At average rate of Rs. 1, 65, 000. 00 / Mts
At the present market rate total sale Rs. 56,10, 000. 00/ Month
Profit = Receipts Cost of Production
= 56,10, 000. 00- 45,85,959. 00
= RS. 10, 24, 041. 00 / MONTH
PROFIT(%) / MONTH :-
Profit / Sales X 100
= 10,24,041. 00/56,10,000. 00X 100 = 18.25%
** The Profitability of the Plant will be more Viable if production is matchedwith marketing strategy and demand.
FOR,
R.R. PLAST- MUMBAI