Detailed Project Report on Texturised Yarn from Waste PET Bottles

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TEXTURISED YARN FROM WASTE PET BOTTLES

[EIRI/EDPR/4327] J.C.: 2510XL

INTRODUCTION

Poly-Ethylene Terephthalate (PET) is one of the most widely used plastics today. PET bottles are ubiquitous in our day-to-day lives–one has to just look around to spot a PET bottle containing mineral water or soft drink or used for other applications. PET bottles, post use, still carry a lot of value, and recycled PET (r-PET) can be used in a wide variety of applications. This makes post-consumer PET bottles a very sought after item by waste collectors. Discarded PET bottles fetch waste collectors Rs. 20-25/kg. These bottles are bought by kabadiwallahs or waste traders, who employ people to segregate, sort and further sell it to large vendors or recyclers. The caps, neck rings, labels (non-PET components) are removed, and the bottles are shredded, washed, and sold as what is called ‘washed flakes’. These washed flakes are then used to make (predominantly) polyester fiber, which is used as filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. These end products sell at anywhere between Rs. 50-60/kg; the market for r-PET products is quite large. There are 40+ large manufacturers across India who uses r-PET as raw material. The PET recycling business can be estimated (roughly) to be around Rs. 5,000- 10,000 crore in a given year in India.

PET Recycling

Discarded PET bottles are collected, sorted, cleaned, shredded, and made into ‘washed flakes,’ which are then used to produce a variety of products, starting from polyester fiber, which is used for a variety of applications like filling material for cushions, pillows, and converted to fabrics for use in clothing, upholstery, etc. Recycled PET (a small percentage) is also used for the manufacture of PET straps, monoYarn, sheets etc.

Value Chain of PET Recycling

There are a large number of people involved in the PET recycling business, starting from the waste collectors and kabadiwallahs to the small and medium traders, recyclers, and manufacturers who use recycled PET for various products. The chart above provides a simplistic illustration of the participants in the PET recycling business in India.

COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (4935 sq.mt.) Rs. 5.70 Cr

Plant & Machinery Rs. 9.80 Cr

Working Capital for 1 Month Rs. 3.70 Cr

Total Capital Investment Rs. 20.09 Cr

Rate of Return 27%

Break Even Point 66%

CONTENTS

INTRODUCTION

PET RECYCLING

VALUE CHAIN OF PET RECYCLING

CHARACTERISTICS/APPLICATIONS

THE MAJOR CHARACTERISTICS OF POLYESTER YARNS INCLUDE

SPECIFICATIONS OF PRODUCTS

MARKET OVERVIEW

REGIONAL SEGMENTATION ANALYSIS:

SALIENT TRENDS OF THE POLYESTER YARN MARKET

KEY PLAYERS IN THE POLYESTER YARN MARKET ARE

MARKET-O-NOMICS

FORMULATION

THE POLYESTER TEXTURIZED YARN IS MANUFACTURED WITH THE FOLLOWING COMPOSITION

PRODUCT YIELD IS AS FOLLOWS:

RAW MATERIALS DETAILS

POST-CONSUMER PET BOTTLES

CLEANING AGENT

FINISH OIL

ANTISTATIC OIL

CHEMICAL USED FOR PURIFICATION

MANUFACTURING PROCESS STEPS/PROCESS FLOW

STEP - A

PRODUCT: PET GRADUALS

STEP - B

PRODUCT: POLYESTER YARN (PY)

EFFLUENT TREATMENT FACILITY

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE EFFLUENT/FLUE GAS EMISSION (ESTIMATED)

GREEN BELT

WATER

EMISSION

WASTE MANAGEMENT (ESTIMATED)

BIS SPECIFICATION

POTENTIAL TURNKEY PLANT/EQUIPMENT SUPPLIERS/CONSULTANT

BOILERS

SUPPLIERS OF EFFLUENT TREATMENT PLANT

D.G. SETS

SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS

LABORATORY TESTING EQUIPMENT

ENGINEERING CONSULTANTS/CONTRACTOR

STORAGE TANKS

LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT

GOVT. LICENSE DETAILS

PLANT & MACHINERY (MAJOR)

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:

PROJECT MANAGEMENT

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

POTENTIAL RISKS

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

SAFETY DATA SHEETS

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)

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