Detailed Project Report (DPR) on pet bottle recycled into polyester

PET BOTTLE RECYCLED INTO POLYESTER [CODE NO 3652]  

 The polyster filament yarn unique in regard to its high resistance to its high resistance to stretching, high elastic recovery and high tensile strength. This combinaton of properties permits the manufacture of sheer extremly light weight fabrics.

This filament can be made which has a tensile strength lighter than silk and linen. The high tensile strength and resistance to stretching possessed by filament yarn caused it to be an interesting possibility for sewing thread in wearing apparel, in certain v-belt which cannot be adjusted readily, and as a smaller bulk of host is desired.

Excellant resistance to abrasion in the wet condition and to bleaching solutions, are properties utilised in laundary nets. The high resistance to heat is of interest in pressing fabrics sail fabrics utilise the favourable properties-high tensile strength, resistance to stretching mildew and directional capability in the dry and wet states.


COST ESTIMATION


Plant Capacity            2000 Kg/Day       
Land & Building (3000 sq.mt.)      Rs. 3.75 Cr         
Plant & Machinery                      Rs. 1.30 Cr     
Working Capital for 2 Months     Rs. 55 Lac
Total Capital Investment              Rs. 5.77 Cr
Rate of Return            26%                   
Break Even Point             53%                
         
        
INTRODUCTION    
TYPES    
STAPLE    
TOWS    
USES & APPLICATION OF RECYCLED PET    
RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:    
USES AND APPLICATION OF POLYESTER YARN    
B.I.S. SPECIFICATION    
MARKET POTENTIAL OF PET RECYCLING    
FIGURE: BOTTLE-TO-FIBER RECYCLING    
FIGURE: GLOBAL ANNUAL R-PET MARKET VOLUME BY END-USE IN 2016    
COMPANIES USING RECYCLED PET    
RECYCLING PET BOTTLES INTO POLYESTER    
THE STEPS INVOLVED IN THE PRODUCTION PROCESS ARE AS FOLLOWS     
PROCESS OF RECYCLED POLYESTER    
SORTING    
BALES OF CRUSHED PET BOTTLES.    
FURTHER TREATMENT    
MELT FILTRATION    
TECHNOLOGY    
MANUFACTURING PROCESS OF PET BOTTLE RECYCLING INTO POLYESTER    
SORTING    
PET COLLECTION SORTING AND RECYCLING    
PET COLLECTION AND SORTING    
PET RECYCLING PROCESS    
PROCESS FLOW DIAGRAM FOR PET BOTTLE RECYCLED INTO POLYESTER    
DETAILS OF PET BOTTLE RECYCLING    
STEP 1:  REACHING THE WASTE STREAM, GETTING COLLECTED    
STEP 2. SORTING    
STEP 3: REMOVING NON-PET COMPONENTS, SORTING, BALING AT
   THE TRADERS    
STEP 4: AT THE PET RECYCLERS—SORTING (ONCE AGAIN),
   CLEANING, FLAKING    
STEP 5: AT THE MANUFACTURERS – TURNED INTO POLYESTER FIBERS    
MANUFACTURING PROCESS OF POLYESTER YARN FROM WASTE
   (ACCORDING TO STEVENSON)    
OTHER METHODS OF MAKING POLYESTER YARN FROM WASTE    
(ACCORDING TO MAC DOVELL)    
POLYESTER YARN FROM WASTE    
(ACCORDING TO GRUSCHKE ET.AL)    
FABRICATION OF POLYESTER FIBRES    
WET SPINNING    
OTHER PROCESS OF SPINNING    
MELT SPINNING    
SOLUTION SPINNING    
DRY SPINNING    
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE    
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE    
FLOW DIAGRAM OF MANUFACTURE OF POLYESTER YARN FROM WASTE    
PRINCIPLES OF PLANT LAYOUT    
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. TERM LOANS:    
8. TOTAL LOAD:    
9.   LAND AREA/MAN POWER RATIO:    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
PLANT LAYOUT    
SUPPLIERS OF PET WASTE    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF GRINDER/SHREDDER    
SUPPLIERS OF HOT AIR FLAKER DRYER    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)    
SUPPLIERS OF D.G. SETS    
SUPPLIERS OF LABORATORY EQUIPMENTS

    
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)