Detailed Project Report (DPR) on kraft paper bags

KRAFT PAPER BAGS

[CODE NO.4184]  

Paper bags are the oldest types of packaging material and are very much prevalent in the modern days in various fields. In fact, paper bag is one of the most common and popular form of packaging. The handmade bags of paper have been a commodity of common use. However, for the manufacture of bags, the introduction of machines is of recent origin about the middle of 19th century. Since then the manufacture of paper bags has become an important industry in itself, paper bag is the cheapest form of packaging. Such paper bags have the specialty that they are light weight, free from any contaminants like dust and are, as well, free from shifting or 'puffing' which results in loss of contents. As for the share occupying these paper bags for general use require minimum possible space for storage and shipment, both before and after filling. However, one disadvantage of the paper bags is that they are not durable. Though the strength of the paper bags can be increased by lamination of the base paper with jute, scrim or other reinforcing materials, this however, increases the cost of the bag by making it more expensive.

   Paper bags are made from a variety of papers both bleached and unbleached. However for making of the paper bags for general use, kraft paper and initiation kraft paper are the most common papers used. Papers most commonly used for commercial and office envelopes include manila, brown wrapping paper or white papers. The type of paper used for bags depends upon the requirements of the product to be packed. Kraft paper used for bag making is usually of 20 to 40 lbs basis weight.

Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million people and contributes Rs 25 billion to the government's kitty. The government regards the paper industry as one of the 35 high priority industries of the country Due to tough economic times; most major food stuff manufacturers are becoming particular how they package their products. A casual glance at the isles at the supermarket will tell you that most food is packaged in plastic or paper bags. For decades, plastic bags have competed toe-to-toe with paper bags, from the manufacturing plants to the retail supermarkets. In many countries now especially the United States, shoppers at local super markets and retail chains offer their customers the option to have their products bagged in plastic or paper. While many customers still value plastic because of its durability, water-resistant nature and also the fact that it is extremely reusable, paper bags are also wildly popular. One of the reasons why paper bags are popular is because of safety. Plastic bags have been responsible for many deaths especially for small children. This is because children are fond of playing with plastic bags and one of the ways in which they do this is to place the bags over their heads. In the event that the child is unable to free themselves fast enough, death by suffocation can occur. This is one major reason why shoppers prefer paper bags to plastic bags.

Another reason why shoppers prefer paper bags is because they are easily disposable. While plastic bags have obvious advantages, they tend to litter the house because most people reuse them. This can cause an environmental issue especially it there are wrong disposal. If disposed of wrongly especially in areas with farm animals, these animals can swallow these bags and suffer health repercussions. One major disposal issue that environmental proponents fight about in regards to plastic bags is the way recycling plants handle them. While recycling has been welcomed by many as a safe way of getting rid of plastics that have outlived their use, it has since been discovered that they are incinerated thereby releasing harmful toxins into the atmosphere.

Paper bags are light, safe and can be easily discarded after they are used. They therefore pose no threat to small children or to the environment. Although the chances of paper bags causing a fire exist, the chances are slim compared to dry grass during summer.

When children play with paper bags, they end up shredding them and therefore they pose no imminent threat. Paper bags are also extremely cost effective for the retailer and in most supermarkets; they are free with any purchase. This may not necessarily be the case with plastic bags where in countries such as Ireland, pose such an environmental hazard that an additional charge is passed on to shoppers who want to carry their grocery purchases using plastic bags.

“The manufacturing process for a paper bag requires four times as much energy as the manufacturing process for a plastic bag. The production of paper bags creates 50 times more water pollutants than the production of plastic bags and 70 percent more air pollutants.

Additionally, it requires 98 percent more energy to recycle paper bags than it does to recycle plastic bags, but the recycling rate for paper is higher. “

 100% reusable, recyclable and biodegradable.

 Easier to carry than plastic bags.

 Holds more items than plastic bags = fewer bags to handle.

 Environmentally preferred.

 Contains 40% post-consumer recycled material.

 A renewable resource - comes from trees.

 High profit margin

COST ESTIMATION

Plant Capacity                                    50,000 Nos./Day

Land & Building (1000 sq.mt.)  Rs. 1.55 Cr

Plant & Machinery                               Rs. 7.97 Cr

Working Capital for 2 Months    Rs. 58 Lac

Total Capital Investment                   Rs. 10.37 Cr

Rate of Return                                     33%

Break Even Point                                51%

• INTRODUCTION
  
• TYPES OF PAPER BAGS
• 1. FLAT BAGS:
• 2. SQUARE BOTTOM (PINCH BOTTOM) BAGS:
• 3. SATCHEL-BOTTOM BAGS:
• 4. AUTOMATIC SELF-OPENING-SQUARE 9SOS0 BOTTOM BAGS:
• 5. WINDOW BAGS:
• 6. BALER BAGS:
• SIZE OF PAPER BAGS
• SIZES OF PAPER BAGS (FINISHED)
• USES AND APPLICATIONS
• B.I.S. SPECIFICATION
• QUALITY CONTROL AND STANDARDS
• FOR KRAFT PAPER
• PROPERTIES OF PAPER
• BURSTING STRENGTH:-
• INTERNAL TEARING STRENGTH:-
• FOR THE TEST
• SCENARIO OF PAPER BAGS IN INDIA
• INDIAN PACKAGING INDUSTRY
• PACKAGING & ALLIED INDUSTRIES – THE SOUTH INDIA SCENARIO
• GLOBAL PAPER BAGS MARKET
• FEW KEY MARKET PLAYERS ARE AS FOLLOWS:-
• PAPER INDUSTRY IN INDIA
• KEY FACTORS WHICH ARE FUELLING THE DEMAND OF THE 
• PAPER BAG MARKET IN INDIA
• PRESENT MANUFACTURERS/SUPPLIERS OF PAPER BAGS
• RAW MATERIALS
• REGISTRATION AND LICENSES FOR KRAFT PAPER BAGS
• TECHNIQUE AND PROCESSES OF PAPER BAG PRODUCTION
• 1) DESIGN
• 2) PROOFING
• 3) PRINTING
• 4) FILM
• THE COATING PROCESS AND BAG POINTS TO NOTE:
• 5) SURFACE FINISHING
• 6) DIE-CUTTING PROCESS
• PAPER BAGS SHOULD PAY ATTENTION TO THE DIE-CUTTING PROCESS:
• 7) PASTE BOX
• PROCESS OF PAPER BAG MAKING
• PROCESS OF MANUFACTURE
• ROTARY MACHINE FOR MANUFACTURING PAPER CARRY BAGS
• FEED:
• FLEXOGRAPHIC PRINTING UNITS:
• SCORING SECTION:
• SIDE FLAP GUMMING SECTION:
• SIDE FLAP FOLDING SECTION:
• BOTTOM BLOCK GUMMING AND FOLDING SECTION:
• STAGGERING SECTION:
• DRYING SECTION:
• SEGMENT SEPARATING SECTION AND ALIQNER SECTION:
• EYELETTING SECTION:
• TAG FITTING:
• DRIVE:
• COMPARATIVE STUDY OF PAPER BAGS AND PLASTIC BAGS
• PAPER BAGS VS. PLASTIC BAGS
• ENERGY AND NATURAL RESOURCES
• POLLUTION
• POLLUTANTS PAPER VS. PLASTIC
• RECYCLING
• DEGRADABILITY
• EFFECTS:
• SEQUENCES IN MULTI WALL PAPER BAGS
• STEP 1: PRINTING
• STEP 2: TUBING
• STEP 3: BOTTOMING
• STEP 4: PALLETIZING/DRYING
• PLANT LAYOUT
• PRINCIPLES OF PLANT LAYOUT
• 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:
• 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. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• DETAILS OF THE MACHINERY
• SUPPLIERS OF PLANT AND MACHINERY [IMPORTED]
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF RAW MATERIALS
• COMPLETE PLANT AND MACHINERY SUPPLIERS (IMPORTED)

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)