Detailed Project Report on kraft paper from waste paper (40 tpd)

KRAFT PAPER FROM WASTE PAPER (40 TPD)
 [CODE NO.3360]


Paper form a commodity of prime importance to day from the parts of view of mass communication, education, and industrial and economic growth. The art of paper making was first discovered in China in and around 2nd century. B.C. pan where it travelled slowly west ward and reached the prantiens of Europe. By the end of 14th century, a member of paper mill existed in Europe, particularly in Spain, Italy, France and Germany. the invention of printing in 1956 brought a vastly in creased demand for paper, and paper-manufacturing was introduced to  England. America followed in 1690.

Agricultural residues, such as bagasse, rice husk, wheat husk jute sticks, grasses, etc are fast becoming  popular  materials for  paper making. considerable attention is being given to the utilization of  various agricultural by products  for  preparing pulp for paper manufacture landable efforts are being make in this direction.

Paper production requires a disintegration of the bulky fibrous material to individual or small agglomerate fibres.

This is called pulping. The ideal fibre for high grade paper should be long, high in cellulose content and low in ligrin content. Most ideal raw material for paper products is bamboo. Other sources are bagasse and hardwoods like jute stick must be developed and good quality paper pulp make by blending with bamboo fibre.

Over recent years, the emergencies of mini paper plants on a reality seems to hold the promise of adding new horizons to the development and growth of Indian paper industry. In may be  noted with  concern that the large sector of this industry  for  quite sometime,  has  failed to sustain any appreciable  growth  due  to various factors  eg. The plant being highly capital intensive low rats  of  return  and the raw material bottlenecks etc. mini paper plants are viewed as an effective remedy to the current  ailments of  the paper industry  as they involve much less  capital cost and are proved to be technically feasible and economically viable these  plants can be erected on the basis of fully indigenous expertise, know how and  machinery. Moreover, they after an effective means of lasing considerably the burden an conventional raw materials.

The paper industry of India is faced with numerous difficulties, some of which are given below

1.   Shortage of Fibrous Raw Material
     
     The lack forest resources requires long range planning for development of improved bamboo has vesting utilization of bagasse, jute etc.

2.   High process and Shortage of Chemicals

          Shortage of sulphur, salt cake (Na2So4) and chlorine with corresponding high prices place in the Indian paper industry to a great disadvantage in attempting to export paper product to a regement of foreign exchange position. This forces a great deal move attention an chemical recovery methods.

         Due to the above problems, it become necessary to use simple and more scientific methods for the manufacture of paper products. Due to the lack of the fibres material jute stick is now being started to be wed as the starting material. the  paper produced  from  jute  is very hard  and  has  comparatively  high tensile  strength. Move over, the chemicals used are available indigenously without any difficulty. There are move than 30 to 40 paper industries producing in public and small scale sector. The other factors which can be kept in view in selecting the  raw materials.

1.     The fibres of the raw material should be of high strength.

2.    Strength methods used for preparing the pulp shaved be easy and hot be complicated.

3.    Properties of the product shaved be of quality by seeing the above  problems and  jute  sticks are  quite  suitable  for  the production  of  paper.  A good     supply of jute sticks should be ensured by the suppliers.

         Mini paper plants are mainly dependent on supplies of waste paper and rafs. They also make pulp out of cereal straw and other agricultural residues. A further important factor in favour of the mini paper plants is that their consumption of chemicals is far less than in the large scale units, and the power requirements are also less. The quality of paper produced in mini paper plants is, however, some what inferior to that obtainable in large scale units.

COST ESTIMATION

Plant  Capacity                                               :     40.00 MT/day                    
land & Building  (16000 sq.Mtr                    :    Rs.12.00 Cr
Plant & Machinery                                           :   Rs. 15.19 Cr
Working Capital for 3 Months                      :    Rs. 9.61 Cr
Total Capital Investment                               :    Rs. 37.74 Cr
Rate of Return                                                :    32%
Break Even Point                                            :    48%

INTRODUCTION                                            
USES AND APPLICATION                                    
B. I. S. SPECIFICATION                                        
B.I.S. SPECIFICATION FOR KRAFT PAPER                            
MARKET SURVEY                                            
GLOBAL MARKET POSITION OF KRAFT PAPER                        
OVERVIEW OF PAPER MARKET IN AFRICA                        
INSTALLED CAPACITY OF PULP,PAPER AND PAPER BOARD IN AFRICA        
GLOBAL INSTALLED CAPACITY OF PULP, PAPER AND PAPER BOARD        
PRODUCTION OF KRAFT PAPER IN AFRICA                        
IMPORT AND EXPORT OF KRAFT PAPER IN 41
APPARENT  CONSUMPTION OF KRAFT IN AFRICA                    
ESTIMATED DEMAND OF KRAFT PAPER IN AFRICA                    
DEMAND SUPPLY GAP OF KRAFT PAPER IN AFRICA                    
GLOBAL PACKAGING MARKET POSITION                            
PRESENT MANUFACTURERS/SUPPLIERS                            
MANUFACTURING PROCESS OF KRAFT PAPER                        
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF KRAFT PAPER FROM WASTE PAPER                                       
FLOW SHEET OF MANUFACTURE OF PAPER                        
FORMING OF WET WEB, PRESSING THE WET SHEET
AND DRYING THE SHEET                                    
METHOD OF PREPARATION OF DIFFERENT TYPES OF PULPS            
PLANT LAYOUT                                            
POLLUTION CONTROL IN PULP AND PAPER INDUSTRIES(IN DETAIL)        
COMMON PULPING PROCESSES                                
CHEMICAL CHARACTERISTIC OF EFFLUENT FROM A LARGE SULPHATE    
(KRAFT) PULP AND PAPER MILL USING CHEMICAL RECOVERY            
POLLUTION CONTROL FOR LIQUID EFFLUENTS                    
COMPLETE MACHINERY MANUFACTURERS/ SUPPLIERS FOR PAPER PLANT    
SUPPLIERS OF RAW MATERIALS                                
PLANT AND MACHINERY SPECIFICATIONS FOR KRAFT PAPER FROM WASTE PAPER                                              
LIST OF PLANT & MACHINERY WITH COST                        
WASTE TREAD STREET                                        
LIQUOR AND CHEMICAL PREPARATION SECTION                    
STOCK PREPARATION AND APPROACH FLOW SYSTEM                


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