Detailed Project Report on hdpe drums manufacturing plant

HDPE DRUMS MANUFACTURING PLANT
[CODE NO.3306]

HDPE  Drums & Barrels are the important  Packaging  Material for packaging of Chemicals, solvents Pharmaceuticals Pesticide, etc.

The use of barrels as storage containers is not a new concept. Originally, barrels were created from wooden planks and metal bands. These containers were excellent because they didn’t leak when filled with liquid and required no glue or nails to build. The iconic wooden barrel is still used to this day in wine and whiskey making.

In the early 1900s, wooden barrels gave way to a new more durable and easily machined material: Steel. Steel barrels were stronger, safer for use in transport and able to be manufactured on an assembly line with much less labor than wooden barrels. The steel drum is still widely used for liquid storage and transportation to this day.

More advanced technology and manufacturing practices in the late 1960s allowed for another iteration of the barrel to come about: the plastic barrel. Plastic barrels are made from high density, high molecular weight polyethylene (HDPE).

Polyethylene is an excellent material because it is inert and resistant to high or low pH contents. As foodies know, the acidity of food products can be high or low. Some materials, including food products, are caustic and can even break down steel. Have you ever left tinfoil over tomato sauce for an extended period of time? The undesirable result is a case in point: the sauce eats right through metal.

The use of high density polyethylene (HDPE) as opposed to low density (LDPE) allowed for barrels to be created completely from polyethylene, as opposed to using a plastic liner in a steel drum.

Plastic drums are manufactured through a process called blow molding. This process allows for various shapes to be created with no seams on the inside. Barrels are still molded in a cylindrical shape to allow for rolling and handling using the same tools as a steel drum. The round shape lacks weak corners (corners are vulnerable to cracking with impact and exposure). The added benefit of a seamless design is that it prevents buildup of bacteria in crevices.

Polyethylene barrels are made in various colors. Some barrels are created in a natural semi-transparent color to allow for a filler to see the levels of material in the barrels. However these are not UV resistant and are not suitable for outdoor storage. Black drums can be problematic as black pigment is often created from mixing various colors in a recycling process and there is no certainty as to what the previous plastic material was used for. Black barrels are generally not considered food-grade.

Most polyethylene drums are created using a blue pigment, and this has become the industry standard for food storage. The blue pigment in polyethylene drums has a higher UV light resistance than natural and does not show dirt or residue as readily. Blue is the standard food-grade drum.

One of the often forgotten and perhaps most important aspects of polyethylene is how easy it is to recycle and reuse the containers. The inertness and impermeability make them a perfect candidate for reuse or “up cycling.”


COST ESTIMATION

Plant  Capacity                                                  :       20.00 MT/day
land & Building (4000 Sq.Mtrs)                      :       Rs. 2.21  Cr
Plant & Machinery                                             :        Rs. 5.38  Cr
Working Capital for 1 Month                            :       Rs. 4.24  Cr
Total Capital Investment                                  :        Rs. 11.94 Cr
Rate of Return                                                   :         27%
Break Even Point                                               :        50%

INTRODUCTION                                            
USES & APPLICATIONS                                        
B.I.S SPECIFICATIONS                                        
OVERVIEW OF HIGH DENSITY POLYETHYLENE                        
MARKET SURVEY                                            
EXPORT DATA OF HDPE DRUMS                                
MANUFACTURERS/SUPPLIERS OF HDPE DRUMS                    
FEATURES OF HDPE DRUMS                                    
MANUFACTURING PROCESS OF HDPE DRUM                        
MOULDING PROCESS                                        
DETAILS OF BLOW MOULDING & PROCESS                        
BLOW MOULDING MACHINE                                    
PARISON HEAD ASSEMBLY                                    
TWO PARISON HEAD                                        
PARISON CONTROL                                        
TECHNICAL DETAILS OF BLOW MOULDING MACHINE                
BASIC SPECIFICATION                                        
TROUBLE SHOOTING GUIDE FOR BLOW MOULDING                    
EXTRUSION BLOW MOULDING                                
SPIN TRIMMING                                            
PROCESS FLOW DIGRAM FOR DRUMS & BARRELS                    
SIZES AND SPECIFICATION OF HDPE DRUMS                        
HDPE DRUM (35 LITERS)                                    
HDPE DRUM (45 LITERS)                                    
OPEN TOP DRUMS (80 LITER)                                    
HDPE DRUM (60 LITERS)                                    
STORAGE BARRELS                                        
PLANT LAYOUT                                            
PRINCIPLES OF PLANT LAYOUT                                
PLANT LOCATION FACTORS                                    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT                
PROJECT IMPLEMENTATION SCHEDULES                        
SUPPLIERS OF RAW MATERIALS                                
SUPPLIERS OF PLANT AND MACHINERIES                        
       
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