Detailed Project Report on 100% biodegradable bioplastic

100% BIODEGRADABLE BIOPLASTIC
[CODE NO.3745]  

The theory behind bioplastics is simple: if we could make plastics from kinder chemicals to start with, they'd break down more quickly and easily when we got rid of them. The most familiar bioplastics are made from natural materials such as corn starch and sold under such names as EverCorn™ and NatureWorks—with a distinct emphasis on environmental credentials. Some bioplastics look virtually indistinguishable from traditional petrochemical plastics. Polylactide acid (PLA) looks and behaves like polyethylene and polypropylene and is now widely used for food containers. According to NatureWorks, making PLA saves two thirds the energy you need to make traditional plastics. Unlike traditional plastics and biodegradable plastics, bioplastics generally do not produce a net increase in carbon dioxide gas when they break down (because the plants that were used to make them absorbed the same amount of carbon dioxide to begin with). PLA, for example, produces almost 70 percent less greenhouse gases when it degrades in landfills.

Another good thing about bioplastics is that they're generally compostable: they decay into natural materials that blend harmlessly with soil. Some bioplastics can break down in a matter of weeks. The cornstarch molecules they contain slowly absorb water and swell up, causing them to break apart into small fragments that bacteria can digest more readily. Unfortunately, not all bioplastics compost easily or completely and some leave toxic residues or plastic fragments behind. Some will break down only at high temperatures in industrial-scale, municipal composters or digesters, or in biologically active landfills (also called bioreactor landfills), not on ordinary home compost heaps or in conventional landfills. There are various eco-labeling standards around the world that spell out the difference between home and industrial composting and the amount of time in which a plastic must degrade in order to qualify.


COST ESTIMATION

Plant Capacity            5 Ton                      
Land & Building (4000 Sq.Mtr)     Rs. 3.78 Cr  
Plant & Machinery                    Rs. 10.35 Cr
Working Capital for 2 Months    Rs. 4.98 Cr
Total Capital Investment          Rs. 19.66 Cr
Rate of Return                         51%
Break Even Point                     39%


INTRODUCTION    
A RECIPE FOR PLA BIOPLASTICS    
BIODEGRADABLE PLASTICS    
BIOPLASTIC    
PROPERTIES OF BIODEGRADABLE PLASTICS    
PROPERTIES OF POLYLACTIC ACID    
BASIC PROPERTIES INCLUDE:    
PHYSICAL PROPERTIES OF POLY LACTIC ACID:    
MECHANICAL PROPERTIES OF POLY LACTIC ACID:    
USES AND APPLICATION OF BIODEGRADABLE PLASTICS    
USES AND APPLICATION OF POLYLACTIC ACID    
POLY (LACTIC) ACID PLASTIC APPLICATIONS    
POLY (LACTIC) ACID FIBER APPLICATIONS    
END-SEGMENT APPLICATIONS    
PLA FOOD PACKAGING & NANOTECHNOLOGY    
PLA NANOCOMPOSITES    
BIODEGRADABILITY AND COMPOSTABILITY    
RENEWABILITY AND SUSTAINABLE DEVELOPMENT    
CHEMISTRY OF BIODEGRADABLE POLYMERS    
(A) NATURAL POLYMERS    
(B) SYNTHESIZED BIODEGRADABLE POLYMERS    
(C) ADDITIVES    
ADVANTAGES AND DISADVANTAGES    
OF BIODEGRADABLE PLASTICS    
ADVANTAGES OF BIODEGRADABLE PLASTICS    
1. REDUCTION IN CARBON EMISSION    
2. LESSER ENERGY CONSUMPTION    
3. ECO-FRIENDLY DISPOSABLE SOLUTION    
4. RECYCLABLE MATERIAL    
DISADVANTAGES OF BIODEGRADABLE PLASTICS    
POLYLACTIC ACID (PLA)    
GLOBAL MARKET POSITION OF BIOPLASTIC    
LEADING MANUFACTURERS OF POLYLACTIC ACID    
GLOBAL TRADE BALANCE OF PLA    
TOP 10 COUNTRIES EXPORTING PLA    
TOP 10 COUNTRIES IMPORTING PLA    
WORLD POLYLACTIC ACID MARKET FORECAST    
OPPORTUNITIES & RISING DEMAND IN VARIOUS INDUSTRIES    
LEADING MANUFACTURE OF POLYLACTIC ACID    
EXPORT OF POLYLACTIC ACID    
IMPORT OF POLYLACTIC ACID    
BIO PLASTIC MARKET SHARE    
TECHNOLOGY DESCRIPTION FOR POLY LACTIC ACID MANUFACTURE    
OLIGOMERIZATION AND LACTIDE FORMATION    
LACTIDE POLYMERIZATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF 100% BIODEGRADABLE BIO PLASTIC    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF POLYLACTIC ACID FROM CORN    
CONVERSION OF CORN TO DEXTROSE    
CONVERSION OF DEXTROSE TO L-LACTIC ACID    
MANUFACTURING PROCESS OF POLYLACTIC ACID USING RENEWABLE
    AGRICULTURAL FEED STOCKS    
PROCESS FLOW DIAGRAM OF POLYLACTIC ACID FROM RENEWABLE
    FEED STOCK    
DETAILS OF PLA (POLYLACTIC ACID) PROCESSING    
EXTRUSION    
INJECTION MOLDING    
TABLE    
INJECTION STRETCH BLOW MOLDING    
CAST FILM AND SHEET    
THERMOFORMING    
PROCESS FLOW DIAGRAM OF PHA (POLY HYDROXYAL KANOATES)    
TESTING METHOD OF BIODEGRADABLE POLYMER    
APPARATUS:-    
ANALYTICAL EQUIPMENTS:    
REAGENTS AND MATERIALS:-    
CALCULATION:    
COMPLETE BIODEGRADATION (USING ASTM D5338 TEST METHOD):    
DISINTEGRATION:    
SAFETY    
PRINCIPLES OF PLANT LAYOUT    
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:    
6.   TRANSPORTATION:    
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. TERM LOANS:    
8. TOTAL LOAD:    
9. LAND AREA/MAN POWER RATIO:    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF MOLASSES/BIO MASS    
SUPPLIERS OF HDPE WOVEN SACK    
SUPPLIERS OF LABORATORY CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF CENTRIFUGE    87
SUPPLIERS OF PACKED DISTILLATION COLUMN    
SUPPLIERS OF EVAPORATORS    
SUPPLIERS OF CRYSTALLIZER    
SUPPLIERS OF ROTARY VACUUM FILTER    
SUPPLIERS OF LABORATORY EQUIPMENTS    
SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF PACKAGING MACHINE    
SUPPLIERS OF BOILERS    


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)