Detailed Project Report on PET Recycling to Manufacture Polyester Staple Fiber

PET RECYCLING TO MANUFACTURE POLYESTER STAPLE FIBER

[EIRI/EDPR/4269] J.C.: 2450XL 

INTRODUCTION

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 is 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.

COST ESTIMATION

Plant Capacity  50 MT/Day

Land & Building (16,000 sq.mt.) Rs. 8.39 Cr

Plant & Machinery                         Rs. 14.00 Cr

Working Capital for 2 Months    Rs. 8.91 Cr

Total Capital Investment            Rs. 31.67 Cr

Rate of Return                              24%

Break Even Point                         54%

CONTENTS

INTRODUCTION

PRINCIPLE OF POLYCONDENSATION

HISTORY OF PET

POLYESTER FIBRES

PET BOTTLES

PROPERTIES & CHARACTERISTICS OF PET

DIFFERENT TYPES OF POLYMER STRUCTURE

PET, AMORPHOUS

PET, PARTLY CRYSTALLINE

PET IS A SUITABLE MATERIAL FOR THE PRODUCTION OF BEVERAGECONTAINERS BECAUSE IT IS:

CHARACTERISTICS OF POLYESTER FIBERS

USES AND APPLICATION OF POLYESTER STAPLE FIBER

USES AND APPLICATION OF PET

RECYCLING OF PET BOTTLES

RECYCLING OF PET-BOTTLES

DEPENDING ON THE TYPE OF RAW MATERIAL THREE TYPES OF RECYCLING IS POSSIBLE:

TABLE DESCRIBES THE PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES

PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES OF PET-BOTTLE WASTE

CLEAR PET FLAKE – BOTTLE SPECIFICATION

MARKET OVERVIEW OF RECYCLED POLYESTER STAPLE FIBER

SOLID FIBER

HOLLOW FIBER

APPAREL

HOME FURNISHING

AUTOMOTIVE

PERSONAL CARE & HYGIENE

NORTH AMERICA

LATIN AMERICA

GROWTH FACTORS OF THE RECYCLED POLYESTER STAPLE FIBER MARKET

FUTURE PROSPECT FOR PET RECYCLING

INDIA’S RECYCLING INDUSTRY

USD 80 BILLION WORLDWIDE AND IS GROWING BY 5% TO 6% EACH YEAR

MARKET POSITION OF PRODUCTS MADE FROM RECYCLED PET

CONSUMPTION OF POLYSTER STAPLE FIBRE IN INDIA

EXPORT DATA OF PET FLAKES

FINISHED PRODUCTS THAT CAN BE MADE FROM PET RECYCLED GRANULES OR FLAKES

ADDRESSES OF PET RECYCLING UNIT

MANUFACTURERS/SUPPLIERS OF PET GRANULES

RECYCLED POLYESTER STAPLE FIBER

MANUFACTURING PROCESS OF RECYCLED POLYESTER STAPLE FIBER

PROCESS FLOW DIAGRAM

POST CONSUMER PET WASTE

SORTING

PROCESSING FOR SALE

FURTHER TREATMENT

PROCESSING DETAILS OF PET RECYCLING UNIT

SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT

OPERATION IN PET RECYCLING

METHOD OF OPERATION

PRE-SORTING

DRY LABEL SEPARATION

SIZE REDUCTION

THE WASHING MODULE

WATER CASCADE

PARCIVAL FILTRATION SYSTEM

THE DECONTAMINATION MODULE CLOSE

AUTOMATIC PROCESSES AND QUALITY SURVEILLANCE CLOSE

QUALITY "TRAFFIC LIGHT"

PET BOTTLE CONVERT TO RECYCLED POLYESTER GARMENT

PROCESS OF RECYCLED POLYESTER

POLYESTER STAPLE FIBER LINE

WASH AND DRY

EXTRUDER AND QUENCHING

WINDER

CAN UNIT

CREEL STAND

STRETCHER

STACKER AND CRIMPER

RELAX AND HEATING SETTER

BALER / PACKAGING

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

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:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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

ADDRESSES OF CONSULTANT

SUPPLIERS OF PLANT AND MACHINERIES

SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)

SUPPLIERS OF RAW MATERIAL

SUPPLIERS OF PET BOTTLES WASTE

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)