Detailed Project Report (DPR) on pet bottles recycling plant

PET BOTTLES RECYCLING PLANT
 [CODE NO. 2066]

Nowadays, PET bottles are the global number one in beverage packaging. More than 400 billion plastic bottles come on the market every year and PET is becoming increasingly valuable as a recyclable raw material used in the production of beverage bottles. Thus, it is important that all of the production steps applied for the manufacture of your PET bottles are made sustainable for the future.

The gentle treatment of resources and economical use of materials are a must when it comes to sustainable production. Valuable raw materials such as PET must be processed as efficiently as possible while still tapping into every way of saving costs. The PET manufacturing and production process allows for the application of a sustainable approach which can optimally combine environmental awareness and cost effectiveness: the bottle-to-bottle recycling concept.
Bottle-to-bottle recycling plant efficiently recycles used PET bottles - and the recyclate is then reused in the food and beverage industry as recycled PET (rPET). The complete process comprises the cleaning of the used PET bottles and the treatment of the recyclate so that the end product - which could come in the form of flakes, pellets or preforms - can meet the highest quality requirements after the recycling process. European and American certificates (e.g. FDA), and a number of different corporate approvals, all confirm the high quality of the recyclate for direct use in containers which come into direct contact with foodstuffs.
•    Food-grade PET flakes and pellets

Recycling plant produces food-grade PET. With it, returned PET bottles can be reused to make new PET bottles. The use of recyclate has clear economic and ecological benefits.
•    Flakes, pellets or preforms
The  procedure gives you the freedom to decide which end product you wish to create. The decontamination step required for the material's later contact with foodstuffs is only ever performed with flakes. Afterwards, the flakes are either used directly or are made into pellets. Another extremely energy-efficient use for the decontaminated flakes is the direct feeding of the material into an extrusion process -
 
Worldwide, PET-bottles more and more replace glass bottles in the beverage and
food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages.

On the one hand, the production of PET is less expensive and energy consuming
than the production of glass. Secondly, the light weight of the PET-bottle makes it
easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers
more or less the same material properties as glass regarding hygiene, taste and gas impermeability.

The negative impacts of PET-bottles in recent years result from their use as nonreturnable beverage containers leading to a dramatic increase of beverage container waste. But even here, changes are on the move, particularly in industrialized countries, where PET-bottles enter more and more the existing returning and refilling schemes. Apart from returning and refilling, recycling of used PET-bottles is also possible, and will be an interesting option especially for developing countries, where refilling schemes are not in place or economically unfavourable.


COST ESTIMATION

Plant Capacity                                                3.00 Ton./day                       
Land & Building (4000 Sq.Mtr)                    Rs. 2.44      Cr
Plant & Machinery                                          Rs.  2.40     Cr
W.C. for 2 Months                                           Rs. 70.54 Lacs
Total Capital Investment                               Rs. 5.75     Cr
Rate of Return                                                19%
Break Even Point                                            62%

INTRODUCTION                                            
HISTORY OF PET                                            
PROPERTIES & CHARACTERISTICS                                
USES AND APPLICATION OF PET                                
RECYCLING OF PET BOTTLES                                
MARKET SURVEY                                            
US RECYCLED PLASTIC DEMAND, 2006-16                        
INDIA’S PET RECYCLING MARKET TO OUTGROW BY 2019                
OVERVIEW OF PLASTIC RECYCLING                            
MANUFACTURERS/SUPPLIERS OF PET GRANULES                    
ADVANCEMENT AND PRACTICES IN PET RECYCLING                    
POST CONSUMER PET WASTE SORTING PROCESSING FOR SALE        
FURTHER TREATMENT                                        
PROCESS OF PET RECYCLING UNIT                            
SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT        
MANUFACTURING PROCESS IN DETAILS                            
PROCESS FLOW DIAGRAM                                    
LOWERING THE COST OF PET RECYCLING THROUGH BETTER LABEL TECHNOLOGY                                           
PLANT LAYOUT                                            
PRINCIPLES OF PLANT LAYOUT                                
PLANT LOCATION FACTORS                                    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT                
ADDRESSES OF CONSULTANT                                
SUPPLIERS OF PLANT AND MACINERIES                            
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)                    
SUPPLIERS OF RAW MATERIAL                                

APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET