Detailed Project Report (DPR) on 20 Litres PET Bottle Blowing Unit with PET Preforms for PET Bottles

PET is a semi-crystalline thermoplastic, which softens at approx. 76°C (what is called “Glass Transition”). Above this temperature, the material becomes elastic, and can be formed, a property utilized effectively in the Stretch Blow Molding process.


Due to its glass transition at approx. 76°C, PET is initially unsuitable as a bottle material for a hot-filling process above this temperature, since deformations may occur: Firstly, the bottles shrink, since they “remember” their previous shape (namely the preform), and secondly they collapse under internal pressure, a typical phenomenon during the cool-down period after hot filling.

For this reason, the hot-fill PET bottles feature, what are called "Vacuum Panels", which compensate for the negative pressure (vacuum) produced during the cool down period without the bottle collapsing. In a way, these Vacuum Panels are used for "Designed Collapse", so that the bottle does not deform at undesired portion, in undesired manner.

During the "Stretching" part of the production process for PET bottles, the material crystallises. We talk here of Stretch-Induced Crystallisation. In the standard process (often known as "Cold Set Process"), the material is frozen in this state at the mould wall, which is chilled. Inner stresses are then retained, and lead to reshrinking, particularly at heat-up. If, however, the material is heated still further after being stretched, it undergoes After crystallisation (known as thermally induced crystallisation). The stresses in the material are also decreased, thus reducing the tendency towards reshrinking. The increased crystallinity gives the material significantly enhanced thermal stability. The glass transition temperature and the rigidity increase. This process is referred to as “Heat-Setting”.

    Plastics are new materials in packaging industry compared with glass, metals,   paper boards, wood etc. Different plastic materials are available for use in packaging industry in various ways.

     PET is one type of polyester used, mainly in the production of textile fibre & indl. Yarns, very  recently  PET has penetrated into food & beverages container market.  

     Process of manufacturing bottle is a three step process. 1. Transesterification esterification 2. Poly condensation & )  Post polymerization   of prepolymer.   A  prepolymer  is  formed   by Transesterification  of dimethyl terephthalate or esterification  of  pure terephthalic acid with  ethylene  glycol followed by polycondensation.  The molten mass of the  prepolymer is  extruded, quenched D& pelletized to small  particles.   These pellets  are further poly condensed to make the polymer  suitable for bottle application.

Each ‘EIRI’ MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT tentatively covers

•            Introduction
•            Properties
•            BIS (Bureau of Indian Standard) Specifications & Requirements
•            Uses & Applications
•            Present Indian Market Position
•            Expected Future Demand
•            Export & Import Statistics Data
•            Names and Addresses of Existing Units (Present Manufactures)
•            List of Plant & Machineries
•            Miscellaneous Items and Accessories
•            Instruments, Laboratory Equipments and Accessories
•            Electrification, Electric Load and Water
•            Maintenance, Suppliers/Manufacturers of Plant and Machineries
•            Process of Manufacture with formulae if applicable
•            Flow Sheet Diagram
•            List of Raw Materials
•            Availability of Raw Materials
•            Requirement of Staff & Labour
•            Personnel Management
•            Skilled & Unskilled Labour
•            Requirement of Land Area
•            Built up Area
•            Plant Layout.
 
Along with financial details as under:
 
Summary of Capital Cost of Project
Land & Side Development Exp.
Buildings
Plant & Machineries
Misc. Fixed Assets
Technical Know how Fees & Exp.
Preliminary Expenses
Pre-operative Expenses
Provision for Contingencies

below mentioned financial statements (Annexure) will be  for 5 to 10 Years
  Annexure  ::         Cost of Project and Means of Finance
  Annexure  ::         Output, Profitability and Cash Flow Chart
  Annexure  ::         Assessment of Working Capital requirements
  Annexure  ::         Sources of Finance
  Annexure  ::         Balance Sheets
  Annexure  ::         Break-Even Analysis and profitability analysis.
  Annexure  ::         Quantitative Details-Output/Sales/Stocks
  Annexure  ::         Sales Realisation        
  Annexure  ::         Raw Material Cost       
  Annexure  ::         Other Raw Material Cost             
  Annexure  ::         Packing Material Cost         
  Annexure  ::         Consumables, Store etc.,                    
  Annexure  ::         Employees Expenses            
  Annexure  ::         Fuel Expenses                 
  Annexure  ::         Power/Electricity Expenses    
  Annexure  ::         Repairs & Maintenance Exp.    
  Annexure  ::         Other Mfg. Expenses           
  Annexure  ::         Administration Expenses       
  Annexure  ::         Selling Expenses              
  Annexure  ::         Depreciation Charges - Profitability
  Annexure  ::         Depreciation Charges
  Annexure  ::         Interest and Repayment - Term Loans
  Annexure  ::         Tax on Profit
  Annexure  ::         Assumptions for Profitability workings
  Annexure  ::         Assessment of Working Capital