Detailed Project Report on baby diapers manufacturing unit

BABY DIAPERS MANUFACTURING UNIT
 [CODE NO. 3004]

Baby diaper may be a newly developed product for India, where as for European countries it has become a general necessity for newly born child caretaking. It was developed & marketed by a Swedish firm some time in the year 1958. As a matter of fact a diaper is used for wrapping the newly born or pretty young children who have not get developed the fixed routine for making water or latrine. He or she may discharge at any time which creates a lot of trouble to his mother or caretaker. Who has no convenient place or time to attend the baby while for an outing, shopping, going to movies or friends & relatives? To avoid all trouble they just wrap their babies with the diaper & baby may discharge whenever he feels to. It can retain the wetting for about two hours or so. Till then his mother finds a suitable time & place & removes the diapers, through it away & replace now one. This way it has given a lot of relief to new mothers.
A disposable diaper consists of an absorbent pad sandwiched between two sheets of nonwoven fabric. The pad is specially designed to absorb and retain body fluids, and the nonwoven fabric gives the diaper a comfortable shape and helps prevent leakage. These diapers are made by a multi-step process in which the absorbent pad is first vacuum - formed, then attached to a permeable top sheet and impermeable bottom sheet. The components are sealed together by application of heat or ultrasonic vibrations. Elastic fibers are attached to the sheets to gather the edges of the diaper into the proper shape so it fits snugly around a baby's legs and crotch. When properly fitted, the disposable diaper will retain body fluids which pass through the permeable top sheet and are absorbed into the pad.

Disposable diapers are a relatively recent invention. In fact, until the early 1970s mothers had no real alternative to classic cloth diapers. Cotton diapers have the advantage of being soft, comfortable, and made of natural materials. Their disadvantages include their relatively poor absorbency and the fact that they have to be laundered. Disposable diapers were developed to overcome these problems. The earliest disposables used wood pulp fluff, cellulose wadding, fluff cellulose, or cotton fibers as the absorbent material. These materials did not absorb very much moisture for their weight, however. Consequently, diapers made from these materials were extremely bulky. More efficient absorbent polymers were developed to address this issue.

Since the 1970s, disposable diaper technology has continued to evolve. In fact, nearly 1,000 patents related to diaper design and construction have been issued in the last 25 years. Today's diapers are not only highly functional, they include advanced features such as special sizing and coloring for specific gender and age, color change indicators to show when the child is wet, and reattachable VelcroTM-type closures. These innovations have enabled disposables to capture a large share of the diaper market. In 1996, disposable diaper sales exceeded $4 billion in the United States alone. Proctor and Gamble and Kimberly Clark are the two largest brand name manufacturers, and their sales account for nearly 80% of the market. Private label manufacturers that produce store brands and generic diapers account for most of the remaining 20%.

A diaper (also called a nappy in South Africa, Ireland, United Kingdom, New Zealand, Australia and Zimbabwe) is a type of underwear that allows one to defecate or urinate, without the use of a toilet. When diapers become soiled, they require changing, generally by a second person such as a parent or caregiver. Failure to change a diaper on a sufficiently regular basis can result in skin problems around the area covered by the diaper.

Diapers are made of cloth or synthetic disposable materials. Cloth diapers are composed of layers of fabric such as cotton, hemp, bamboo or microfiber and can be washed and reused multiple times. Disposable diapers contain absorbent chemicals and are thrown away after use. Plastic pants can be worn over diapers to avoid leaks, but with modern cloth diapers, this is no longer necessary.


Diapers are primarily worn by infants, and by children who are not yet potty trained or who experience bedwetting. They are also used by adults with incontinence or in certain circumstances where access to a toilet is unavailable. These can include those of advanced age, individuals with certain types of physical or mental disability, and people working in extreme conditions, such as astronauts. It is not uncommon for people to wear diapers under dry suits.


COST ESTIMATION

Plant Capacity                                               48000.00 Nos./day
Land & Building (2000 Sq.Mtr)                   Rs.92.00  Lacs
Plant & Machinery                                         Rs. 2.27     Cr
W.C. for 1 Month                                            Rs. 1.53    Cr
Total Capital Investment                              Rs.  4.79    Cr
Rate of Return                                               72%
Break Even Point                                           32%


•    PRODUCT INTRODUCTION    
•    USES AND APPLICATIONS    
•    PRODUCT (DIAPER) ANALYSIS    
•    TYPES OF DISPOSABLE DIAPER    
•    PROPERTIES    
•    MARKET SURVEY    
•    PRODUCTION OF DIAPERS    
•    IMPORT AND EXPORT OF DIAPER    
•    INSTALLED CAPACITY, UTILIZATION AND PRODUCTION OF DIAPER
•    APPARENT CONSUMPTION OF DIAPERS    
•    ESTIMATED DEMAND    
•    DEMAND SUPPLY GAP    
•    OVERVIEW OF BABY DIAPER IN INDIA    
•    GLOBAL MARKET POSITION OF BABY DIAPER    
•    MANUFACTURER & EXPORTER OF DISPOSABLE BABY DIAPERS    
•    B.I.S SPECIFICATION (BABY DIAPERS)
•    RAW MATERIALS DESCRIPTION & SPECIFICATIONS    
•    PRESSURE SENSITIVE ADHESIVE    
•    SPECIFICATIONS OF THE RAW MATERIALS    
•    MANUFACTURING PROCESS OF DIAPER (ADULT AND BABY)    
•    PROCESSING DETAILS OF DIAPER MANUFACTURE    
•    SEQUENCES OF OPERATION OF BABY DIAPERS MANUFACTURE    
•    PROCESS FLOW DIAGRAM    
•    WASTE AND QUALITY CONTROL    
•    PRECIOUS BABY DIAPER    
•    DIAPER FOR MALE BABY    
•    PLANT LAYOUT    
•    CONSULTANT FOR SETTINGUP THE DISPOSABLE DIAPER PROJECTS    
•    SUPPLIERS OF PLANT AND MACHINERY    
•    SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)    
•    SUPPLIERS OF RAW MATERIALS    
•    MANUFACTURERS OF NON WOVEN FABRIC    
•    THE FOLLOWING TYPES ARE MULTI-FUNCTION LINES:
        YOU CAN SHIFT THE FUNCTION TO THE DIAPER FUNCTION    
•    CH NON – FOOD IMPORT – EXPORT CORP.    

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