Detailed Project Report (DPR) on Packaging Paper (Kraft Paper) from Agricultural Residue (Bagasse/Wheat Husk)

PACKAGING PAPER (KRAFT PAPER) FROM AGRICULTURAL RESIDUE (BAGASSE/WHEAT HUSK)

[EIRI/EDPR/4383] J.C.: 2576ETB, 2577INR

INTRODUCTION

Paper form a commodity of prime importance to day from the parts of view of mass communication, education, and industrial and economic growth. Agricultural residues, such as bagasse, rice husk, wheat husk jute sticks, grasses, etc are fast becoming popular materials for paper making considerable attention is being given to the utilization of  various agricultural by products  for  preparing pulp for paper manufacturing efforts are being made in this direction.

Bagasse is used for each of the four main paper categories, namely packaging and boxes, printing, writing and photocopier paper, tissues, and newsprint. Both chemical and mechanical pulping processes are used, and these processes are described. This chapter focuses on the considerations for bagasse-based pulp and paper manufacture with only a broad overview of the general wood-based process. Depithing is used to improve pulp drainage in the pulp washers and at the paper machine, reduce cooking chemical usage, reduce foaming, reduce costs for handling and storage, reduce dirt count in the paper, improve tensile properties and improve black liquor quality.

Wheat straw pulp plays an indispensable role in the paper and pulp industry. There are some restrictive factors that limit the development of wheat straw pulp. Firstly, the collection and transportation of raw materials; secondly, the straw pulp mill usually has a small scale, poor technology, and paper pulper machines, which result in low-quality pulp and market competition. Last but not least, serious environmental pollution caused by wheat straw pulp production. With the development of straw pulping technology, the straw pulp will have a bright future in the industry.

Paper production requires a disintegration of the bulky fibrous material to individual or small agglomerate fibres. This is called pulping. The ideal fibre for high grade paper should be long, high in cellulose content.

The evolution of the packaging industry across the globe acts as one of the major factors driving the growth of kraft paper market. The increase in demand for sustainable and recyclable material from packaging and various other end-use industries, and advancements in packaging and wrapping applications accelerate the market growth. The rise in demand for more environment friendly and effective packaging materials and solutions from end-use industries such as foods & beverage, building and construction, automotive, pharmaceuticals, cosmetics & personal care, aerospace, and electronics, and rise in consciousness regarding environment among population further influence the market. Additionally, change in consumer preference, increase in incidences of pollution, rapid urbanization, growth in awareness, breakthrough in new technologies and high disposable income positively affect the kraft paper market. Furthermore, rise in e-commerce and retail sectors, and product premiumization extend profitable opportunities to the market players in the forecast period of 2021 to 2028.

The kraft paper market is expected to witness market growth at a rate of approximately 3.25% in the forecast period of 2021 to 2028.

COST ESTIMATION

Plant Capacity            40 MT/Day

Land & Building (14,130 sq.mt.)    Rs. 14.89 Cr

Plant & Machinery                    Rs. 42.35 Cr

Working Capital for 1 Month    Rs. 4.61 Cr

Total Capital Investment          Rs. 63.22 Cr

Rate of Return                          31%

Break Even Point                      60%

CONTENTS

INTRODUCTION

MARKET OVERVIEW

GLOBAL

KEY MARKET PLAYERS OPERATING IN THE KRAFT PAPER MARKET ARE

ETHIOPIA

USES/APPLICATIONS

OVERALL, THE USES OF PAPER ARE MANIFOLD

SPECIFICATIONS

TABLE 1 REQUIREMENTS OF KRAFT PAPER

TABLE 2 OPTIONAL REQUIREMENTS OF KRAFT PAPER

EACH PACKAGE AND ROLL SHALL BE MARKED WITH THE FOLLOWING INFORMATION:

PACKAGE

ROLL

MANUFACTURING PROCESS STEPS

PULPING

SCREENING OF PULP

PULP BEATING

REFINING

PAPER MAKING AND FINISHING

FORMING OF WET WEB

PRESSING WET SHEET

DRYING SHEET:

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

PLANT & MACHINERY SPECIFICATIONS (TYPICAL) FOR KRAFT PAPER FROM AGRICULTURE RESIDUE

POLLUTION CONTROL IN PULP/PAPER INDUSTRIES

PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS

CHEMICAL CHARACTERISTIC OF EFFLUENT FROM (KRAFT) PULP AND PAPER MILL

POLLUTION CONTROL - LIQUID EFFLUENTS

IN-PLANT MEASURES

PROCESS CHANGES

COMPLETE MACHINERY MANUFACTURERS/PLANT SUPPLIERS

SUPPLIERS OF RAW MATERIALS

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

GENERATION & MANAGEMENT OF WASTES/GREEN BELT

WASTE WATER (ESTIMATED)

WASTE (ESTIMATED)

THE ABOVE DATA IS TO BE VALIDATED DURING EIA/EMP STUDY

ETP FACILITY IS TO BE INSTALLED BASED ON THE STUDY

SEWAGE AND WASTE TREATMENT FACILITY

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

CONCLUSIONS

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