Detailed Project Report on Stone Paper

STONE PAPER

[EIRI/EDPR/4264] J.C.: 2445US$

INTRODUCTION

"Stone paper" is also known as rock paper, paper from waste marble, mineral paper, or rich mineral paper. Stone paper is a product resembling paper. It is strong and durable; made from calcium carbonate with a binder of high density polyethylene (HDPE).

Stone paper is a term that describes a number of formulas for papermaking which basically contain calcium carbonate which can come from waste rock, marble and tiles, not from plant fibers. The main content of rock paper is calcium carbonate which comes from stone (rock); so that stone paper is sometimes also called rock paper. Stone paper is made from stone which is crushed into powder form, mixed with a non-toxic and recyclable binder, i.e. HDPE.

Stone paper containing 80% limestone and 20% recycled polyethylene have been produced by a printing industry in Germany. The mixture of raw materials used are claimed environmentally friendly and can be used for several printed products such as posters, leaflets, up to bag products, and used by farmers for labels and coatings of pot. This paper can be used as a substitute for polypropylene because it is more water resistant, ultra violet (UV) resistant, with high tear strength, even higher than ordinary paper. In addition, stone paper can be even written when it is in wet condition.

Rock paper is claimed to be very environmentally friendly paper. It is different from conventional paper because it does not use wood pulp as its raw material. The technology for making stone paper is also claimed not to pollute air and water; no chlorine or acid compounds used, and the resulting stone paper is really non-toxic and even food safe. It is also believed that the stone paper production process improves air, soil and water quality, and reduces energy consumption.

The basic difference between stone paper and conventional paper is in terms of the raw materials used. Conventional paper uses plant fibers as raw material and a lot of water in the production process, while stone paper does not use plant fibers and water at all in its production process. In addition, stone paper production produces low carbon emissions, no acid, base nor bleaching chemicals require, and stone paper can be recycled.

Another interesting thing from the technology of stone paper making process is that the investment costs of production equipment are 40% lower than conventional paper mills for the same production capacity. This is due to no water used in the production process. In other words, the factory does not need to install a water treatment unit, so that it can reduce investment and energy costs.

Stone paper is a shortened form of environmentally friendly inorganic powder rock paper, the name in the paper industry called "synthetic paper". It's a kind of variety processing paper. As the main raw material of calcium carbonate from the earth's most abundant mineral resources combining with polymer materials and various inorganic materials for the auxiliary, stone paper is made by the world's leading advanced technologies which solve the traditional paper-making harm to the environment pollution problems, but also solve the white pollution and plenty waste of oil problems.

Inorganic Powder Environmental Protection Stone Paper (hereinafter referred to as Stone Paper) is made by huge storage and wide distribution of limestone mineral resources for main raw material (calcium carbonate content for 70 ~ 80%), combining with the high polymer material of raw materials (content is 20 to 30%), using polymer interface chemical principle and the characteristics of the polymer modification, under treatment of a special technology through the polymer extrusion and blow workmanship. Stone paper not only own the same writing and printing characters of plant fiber paper, but also has the core characters of plastic packing materials.

Using 85% 1500-2500 meshes super fine powder of calcium carbonate from limestone combining with 15% additive making into master batch convert into paper or bags through extrusion blown film equipment.

Stone paper (also known as rock paper, paper from waste marble, mineral paper, or rich mineral paper) is a paper-like product manufactured from calcium carbonate bonded with high-density polyethylene (HDPE). It is used for stationery, leaflets, posters, books, magazines, bags, packaging, wallpaper, adhesives, tags, in-mould labels, plates, trays, containers and many other uses.

 The process for creating stone paper was first developed by the Lung Meng Tech Co. of Taiwan during the late 1990s. Stone paper has been patented in over 40 countries, where it is marketed under a variety of trade names such as MIST™ Paper, Parax Paper™, Terraskin™, ViaStone™, Kampier™, EmanaGreen™ and Rockstock™, Pixz Printing™.

Stone Paper is nicknamed as Shiliao Paper (Shiliao is a Chinese term and it means the paper made from the stone). The raw material of the Stone Paper consists of 80% limestone powder and 5% adhesives. Because no wood pulp is needed in order to make this kind of paper, no tree will be doomed to die for the production of this paper. The birth of this paper poses a new challenge to the traditional paper industry and it will establish a new era of paper making. 

Because no water and no wood pulp are needed during the production of environment-friendly Stone Paper and no additions such as the bleaching powder, strong acid and alkali in the process, there are no by-products such as waste gas, waste water and waste cinders. So there is no environment pollution problem during its making process. It is a totally zero-emission technology.

 Stone Paper retains the goodness of the traditional wood pulp paper and is better in safety and physical stability. It has unique features such as water proof, moisture proof, anti-fogging, anti-oil, pest control, tear-resistant, crack-resistant, corrosion resistance, fire-resistant, solid ink absorption, and clear color printing (the resolution is up to 2880clpi).

Stone Paper can be used in wide areas. It can be used as office paper, commercial paper, cultural paper, and printing paper. It can also be used in industrial packaging. Besides, it can be used as special purpose paper such as fieldwork paper, underwater operations paper, underground mining operations paper, or other military special-used paper. It can be used wherever wood pulp paper is used. With the newly developed SPC stone granule technology which can replace many plastic products, the application area of stone paper is further expanded. The newly developed SPC stone granule technology has great energy-efficiency significance considering the increasingly strained oil resource in the world.

Stone Paper is truly one-of-a-kind, environmentally friendly paper; beginning with sourcing raw materials to production, end-use and finally degradation or recycling. It functions as paper, performing and often surpassing all requirements for a multitude of conversions and print jobs.

Stone Paper is not a synthetic paper, it is simply a very durable paper made from stone. No other paper can compare to Stone Paper; this ecological paper is an intelligent choice for all applications demanding durable, superior and environmentally-friendly paper. Stone Paper is an excellent alternative for all types of eco-friendly packaging and purely ecological printing needs.

The following is an illustrated calculation of a Stone Paper user’s contribution to preserve our natural resources by replacing 1 ton of virgin coated paper with 1 ton of Stone Paper.

 Stone Paper is photo-degradable, it reverts back to calcium carbonate when left out in sunshine and natural conditions without any harmful effects. As it photo-degrades (around 12 months for RP in direct UV light, and 18months+ for RB) it will look and feel like broken egg shells which continually crack until they again become stone powder (CaCO3).

The global stone paper market is expected to grow at a CAGR of 2.6% during 2021-2026.

It is intended to prepare a Feasibility Report to install a Stone Paper production facility with an installed capacity of 5000 Tons / Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                    17 Ton/Day

Land & Building (8755 sq.mt.)  US$ 11.66 Lac

Plant & Machinery                              US$ 31.88 Lac

Working Capital for 3 Months    US$ 9.96 Lac

Total Capital Investment                   US$ 55.48 Lac

Rate of Return                                     19%

Break Even Point                                 69%

CONTENTS

INTRODUCTION

USES/APPLICATION/ADVANTAGES/FEATURES 

USES AND APPLICATION OF STONE PAPER

IN ADDITION, THE BELOW PRODUCTS CAN BE MADE FROM STONE PAPER:

ADVANTAGES AND FEATURES

MARKET OVERVIEW

MARKET POSITION OF STONE PAPER

U.S. STONE PAPER MARKET REVENUE, BY APPLICATION, 2013 - 2024 (USD MILLION)

MARKET FORECAST OF STONE PAPER

GLOBAL STONE PAPER MARKET COMPETITIVE LANDSCAPE

STONE PAPER - ORIGIN & TECHNOLOGY

PROPERTIES & SPECIFICATIONS 

PROPERTIES

SPECIFICATION (TYPICAL)

TECHNICAL BENEFITS OF STONE PAPER

ENVIRONMENTAL COMPARISON OF STONE PAPER

SAVE TRESS, USE STONE PAPER

WATER CONSUMPTION

PRODUCTION WASTE

LARGE TRASH BAGS!

GREENHOUSE GAS EMISSION

RAW MATERIALS

FORMULATION 

THE RAW MATERIAL DETAILS ARE TABLED BELOW:

MANUFACTURING PROCESS STEPS & PROCESS FLOW SCHEMATIC

GRIND POWDER PROCESS

PELLETIZING PROCESS

EXTRUSION PROCESS

BLOWN FILM 

COATING PROCESS

CUTTING & FINISHING

PROCESS OPERATING CONDITION

PROCESS FLOW SCHEMATIC

MATERIAL BALANCE

UTILITIES (ESTIMATED - MONTH)

BROAD PLANT MACHINERY/EQUIPMENT DETAILS 

STONE PAPER PRODUCTION MACHINE - FEATURES/EQUIPMENTS

EXTRUSION

BLOWN FILM

CASTING

CORONA SYSTEM, EDGE CUTTING, AND WINDER

COATING

BROADLY, THE MACHINERY USED IN PRODUCTION LINE

GRANULATION MACHINE

EXTRUDER MACHINE

BLOWING MACHINE

CASTING MACHINE

ROLLING MACHINE

COATING MACHINE

ENVIRONMENTAL ASPECT OF STONE PAPER

PLANT & MACHINERY SUPPLIER

RAW MATERIAL SUPPLIER

CALCIUM CARBONATE (LIME STONE)

POLYETHYLENE RESIN

SUPPLIERS OF STONE PAPER {GLOBAL}

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WASTE WATER 

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

SAFETY DATA SHEETS

CALCIUM CARBONATE

POLYETHYLENE (PE) RESIN

TESTING OF STONE PAPER

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)