Detailed Project Report on diaper manufacturing industry (sanitary pad & diaper)
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DIAPER MANUFACTURING INDUSTRY
(SANITARY PAD & DIAPER)
[CODE NO.3794]
Sanitary Napkins and Diaper (Kids and Adult) have got tremendous demand in India and abroad. The global market for absorbent hygiene products is over US$ 50 bn (including wipes). The evolution of hygiene products in Europe and the North America has taken 4 to 5 generations. Feminine care was introduced over 100 years ago. Baby diapers were invented 60 years ago. Adult incontinence products appeared 30 years ago.
Feminine hygiene (lady napkins) is hygiene absorbent products engineered to absorb and retain body fluid without causing any leakage. The user should always feel dry and comfortable. It consists of an absorbent pad sandwiched between two sheets of nonwoven fabric.
There are 3 major types of products, viz, (a) Thick sanitary napkins. (b) Ultra thin sanitary napkins. (c) Panty liners being used in the market. The size of each and their content vary from market to market.
The menstrual cycle starts for young women between the ages 11 - 17, frequently around 12-1 3 years. On average a woman experiences a period every 28th day, 12 - 13 times in a year. A menstrual period normally lasts 3 - 7 days. The loss of fluid in a period is on average half a cup or 65 - 80 ml. The menstrual pattern is influenced by giving birth and contraceptive methods. Menstruation lasts until menopause at the age 45 - 55. The feminine hygiene products market has evolved over more than 100 years to a more than US$ 17 bn in the following category worldwide.
Disposable baby diapers are designed to absorb and retain an infant’s urine and faeces while keeping the skin dry and healthy and to be easily and hygienically disposed of in household solid waste. Diapers are available in a wide range of sizes designed to fit all ages of children.
COST ESTIMATION
Plant Capacity Nil
Land & Building (4000 sq.mt.) Rs. 2.68 Cr
Plant & Machinery Rs. 6.24 Cr
Working Capital for 2 Month Rs. 3.11 Cr
Total Capital Investment Rs. 12.70 Cr
Rate of Return 55%
Break Even Point 38%
INTRODUCTION
THE STRUCTURE OF TYPICAL SAMPLES IS GIVEN BELOW:
PRODUCT DESIGNS, FULL SIZE PADS:
PRODUCT DESIGNS, ULTRA THIN PAD:
USES AND APPLICATIONS
ADULT AND KIDS/BABY DIAPERS
SANITARY NAPKINS FOR LADIES
PRODUCT (DIAPER) ANALYSIS
PROPERTIES
BABY DIAPERS
IMPORTANT PROPERTIES OF SANITARY NAPKINS:
POTENTIAL PROBLEMS OF SANITARY NAPKINS
HYGIENE RISK
DISPOSABILITY:
AFFORDABILITY
STRUCTURE & PERFORMANCE CHARACTERISTICS OF SANITARY NAPKINS
STRUCTURE OF SANITARY NAPKINS:
PERFORMANCE CHARACTERISTIC OF SANITARY NAPKIN:
RAW MATERIALS
MARKET DYNAMICS IN SANITARY PRODUCT MARKET
MARKET SURVEY
MARKET POTENTIAL OF SANITARY NAPKINS
GLOBAL MARKET STATUS & POTENTIAL
INDIA'S DISPOSABLE DIAPER MARKET SHOWS BIG GROWTH POTENTIAL
CONSUMPTION NORMS AND THE MARKET SIZE
PRODUCTION OF BABY DIAPERS
IMPORT AND EXPORT OF BABY DIAPER
INSTALLED CAPACITY, UTILIZATION AND PRODUCTION
OF SANITARY NAPKINS & BABY DIAPERS
GROWTH SPURT
BABY CARE MARKET - INDIA
MARKET POTENTIAL OF INDIAN HYGIENE MARKET
(SANITARY NAPKIN & ADULT/BABY DIAPER)
FEMININE HYGIENE
ADULT/BABY DIAPERS
ADULT DIAPERS
OVERVIEW OF SANITARY NAPKIN IN INDIA
LEAPING INTO GST
WANTED: MORE STARTUPS
EXPORT DATA OF SANITARY PADS
MANUFACTURER/EXPORTERS AND SUPPLIER OF SANITARY NAPKINS
DISPOSABLE BABY DIAPERS
B.I.S SPECIFICATION
PREPARATORY PROCESSES FOR SANITARY NAPKINS
OPENING
SECOND STAGE
THIRD STAND KIERING BLEACHING & WASHING
BLEACHING
STERILISATION
DRY HEAT
AUTO CALVING
EXPOSURE TO ETHYLENE OXIDE
HYDRO - EXTRACTING
DRYING
ALTERNATE MANUFACTURING PROCESS OF DIAPERS
FORMATION OF THE ABSORBENT PAD
PREPARATION OF THE NONWOVEN
ASSEMBLY OF THE COMPONENTS
BYPRODUCTS/WASTE
QUALITY CONTROL
RAW MATERIALS REQUIRED
BABY DIAPER
RAW MATERIALS FOR BABY DIAPER
OTHER COMPONENTS
RAW MATERIALS' DESCRIPTION & SPECIFICATIONS
ROLL PULP
NON-WOVEN FABRIC
POLYETHLENE FILM
TISSUE:
HOT MELT AND POLYEXTRUDED ADHESIVE:
PRESSURE SENSITIVE ADHESIVE
SILICONE RELEASE PAPER:
SPECIFICATIONS OF THE RAW MATERIALS
WOOD PULP
NON-WOVEN FABRIC:
SILICONE RELEASE PAPER
HOT MELT
LACK OF AWARENESS ABOUT WOMEN’S HEALTH IN INDIA
UNDERSTANDING MENSTRUATION CYCLE
CREATING AWARENESS ABOUT MAINTAINING HYGIENE
EDUCATING WOMEN
EMPOWERMENT AND WELL-BEING OF WOMEN
MANUFACTURING PROCESS OF BABY DIAPER
PROCESS IN DETAILS OF BABY DIAPERS
(1) PREPARATION OF COTTON LAP:
(2) WRAPPING THE COTTON LAP IN LINT TISSUE PAPER & PASTINGS.
(3) CUTTING THE LINT TISSUE PAPERED COTTON LAP TO REQUIRED
SIZE SAY 12"
(4) CUTTING THE PIECES OF POLYSTYRENE SHEET:
(5) ENCANNELMENT OF ELASTIC STRIL ON THE LENGTH SIDES OF SHEET:
(6) BONDING: THE ELASTIC ENCANNELED POLYSTYRENE PIECES &
SHEET WITH THE LINT
(7) FINISHING:
(8) PACKING:
PROCESS FLOW SHEET FOR BABY DIAPERS MANUFACTURE
MANUFACTURING PROCESS OF DIAPER (ADULT AND BABY)
THERE ARE THREE BASIC PROCESSES IN THE MANUFACTURING OF DIAPER
PROCESSING DETAILS OF DIAPER MANUFACTURE
THERE ARE FIVE MAIN COMPONENTS THAT MAKEUP DIAPERS.
PREPARATION OF THE NONWOVEN
ASSEMBLY OF THE COMPONENTS
BASIC PRODUCTION PROCESS FOR SANITARY NAPKIN
STEP 1: PULVERISATION:
STEP 2: CORE FORMATION:
STEP 3: COVERING LAYER:
STEP 4: ACCESSORIES FORMATION
STEP 5: STERILIZING
STEP 6: PACKAGING:
QUALITY CONTROL
BABY DIAPER MAKING MACHINE AND ITS PROCESS
BABY DIAPERS MAKING MACHINES FOR BIG ELASTIC EAR DIAPER
DISPOSABLE BABY DIAPERS ARE PRODUCED IN CONTINUOUS PROCESS
PRODUCTION METHOD OF SANITARY NAPKIN
(A) PREPARATION OF COTTON LINT SLIVER:
(1) COTTON OPENING:
(2) SCUTCHING OR LAPPING:
(3) CARDING:
(4) DRAW FRAME:
(5) TISSUE PAPER WRAPPING:
B) MANUFACTURE OF SANITARY NAPKINS:
1) CONE WINDING:
2) KNITTING & INSERTION OF TISSUE PAPER WRAPPED SLIVER:
3) CUTTING & LOOPING OF BOTH ENDS OF SANITARY NAPKINS:
4) PACKING:
PROCESS DESCRIPTION FOR SANITARY NAPKIN WITH AUTOMATION
FLOW SHEET
RAW MATERIAL CALCULATION
RAW MATERIAL FOR APPROXIMATE 8 GM REGULAR SANITARY NAPKIN
PLANT LAYOUT
PERFORMANCE TEST OF SANITARY NAPKIN
TESTS TO EVALUATE PERFORMANCE:
ABSORBENCY TEST:
FLUID RETENTION CAPACITY:
LIQUID STRIKE THROUGH TEST:
WICKING EXPERIMENTS:
CONSULTANT FOR SETTINGUP THE SANITARY NAPKINS
AND DISPOSABLE ADULT & KIDS DIAPER PROJECTS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
SUPPLIERS OF RAW MATERIALS
ADHESIVE (CHEMISTICK)
LINT TISSUE PAPER:
POLYTHENE FILM
TISSUE PAPER
RELEASE PAPER
MANUFACTURERS OF NON WOVEN FABRIC
MORE INFORMATION ON MACHINERY
INSTALLATION, TRAINING, TECHNOLOGY TRANSFER
MANAGING
PRODUCTION LINE OPERATOR:
PACKING WORKER:
THE SPECIFICATIONS AND MAIN PARAMETERS:
PRODUCTION COST AND PROFIT ANALYSIS OF WINGSHIELD
SANITARY NAPKIN
MACHINERY STRUCTURE
POWER CONSUMING
MACHINERY SIZE:
GRINDER SET:
FORMING AND WRAPPING SYSTEM SET:
EMBOSSER, ADH. APPLYING, FINISHED PRODUCTS SET:
CONVEYOR SET:
EXPORT PACKING SIZE
THE SIZE OF THE SANITARY PAD (NAPKIN):
NAME AND SPECIFICATION OF THE RAW MATERIAL
OF THE SANITARY PAD (NAPKIN):
PRODUCTION PROCESS
THE PROPERTY OF THE RAW MATERIALS
THE FOLLOWING TYPES ARE MULTI-FUNCTION LINES:
YOU CAN SHIFT THE FUNCTION TO THE DIAPER FUNCTION.
RELEASE PAPER: GOOD RELEASE, WIDTH 19-50MM(STANDARD)
MAIN PARAMETERS:
OPTIONS:
MAIN FEATURES:
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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