Detailed Project Report on mineral paper manufacturing (stone paper)

MINERAL PAPER MANUFACTURING (STONE PAPER)
[CODE NO.3095]  

Stone paper is a shortened form of environmentally friendly inorganic powder rock paper, the name in the paper industry called "synthetic paper". It's a kind of variety processing paper. As the main raw material of calcium carbonate from the earth's most abundant mineral resources combining with polymer materials and various inorganic materials for the auxiliary, stone paper is made by the world's leading advanced technologies which solve the traditional paper-making harm to the environment pollution problems, but also solve the white pollution and plenty waste of oil problems.

Inorganic Powder Environmental Protection Stone Paper (hereinafter referred to as Stone Paper) is made by huge storage and wide distribution of limestone mineral resources for main raw material (calcium carbonate content for 70 ~ 80%), combining with the high polymer material of raw materials (content is 20 to 30%), using polymer interface chemical principle and the characteristics of the polymer modification, under treatment of a special technology through the polymer extrusion and blow workmanship. Stone paper not only own the same writing and printing characters of plant fiber paper, but also has the core characters of plastic packing materials.

Using 85% 1500-2500 meshes super fine powder of calcium carbonate from limestone combining with 15% additive making into master batch convert into paper or bags through extrusion blown film equipment.

Stone paper (also known as rock paper, paper from waste marble, mineral paper, or rich mineral paper) is a paper-like product manufactured from calcium carbonate bonded with high-density polyethylene (HDPE). It is used for stationery, leaflets, posters, books, magazines, bags, packaging, wallpaper, adhesives, tags, in-mould labels, plates, trays, containers and many other uses.
 
The process for creating stone paper was first developed by the Lung Meng Tech Co. of Taiwan during the late 1990s. Stone paper has been patented in over 40 countries, where it is marketed under a variety of trade names such as MIST™ Paper, Parax Paper™, Terraskin™, ViaStone™, Kampier™, EmanaGreen™ and Rockstock™, Pixz Printing™.

Stone Paper is nicknamed as Shiliao Paper (Shiliao is a Chinese term and it means the paper made from the stone). The raw material of the Stone Paper consists of 80% limestone powder and 5% adhesives. Because no wood pulp is needed in order to make this kind of paper, no tree will be doomed to die for the production of this paper. The birth of this paper poses a new challenge to the traditional paper industry and it will establish a new era of paper making.
 
Because no water and no wood pulp are needed during the production of environment-friendly Stone Paper and no additions such as the bleaching powder, strong acid and alkali in the process, there are no by-products such as waste gas, waste water and waste cinders. So there is no environment pollution problem during its making process. It is a totally zero-emission technology.
 
Stone Paper retains the goodness of the traditional wood pulp paper and is better in safety and physical stability. It has unique features such as water proof, moisture proof, anti-fogging, anti-oil, pest control, tear-resistant, crack-resistant, corrosion resistance, fire-resistant, solid ink absorption, and clear color printing (the resolution is up to 2880clpi).

Stone Paper can be used in wide areas. It can be used as office paper, commercial paper, cultural paper, and printing paper. It can also be used in industrial packaging. Besides, it can be used as special purpose paper such as fieldwork paper, underwater operations paper, underground mining operations paper, or other military special-used paper. It can be used wherever wood pulp paper is used. With the newly developed SPC stone granule technology which can replace many plastic products, the application area of stone paper is further expanded. The newly developed SPC stone granule technology has great energy-efficiency significance considering the increasingly strained oil resource in the world.


COST ESTIMATION

Plant  Capacity                               :       16.00 Ton./day                   
Land & Building (3000 Sq.MT)    :    Rs. 3.62 Cr
Plant & Machinery                          :    Rs.22.00 Cr
Working Capital for 1 Month        :    Rs. 1.11 Cr
Total Capital Investment              :    Rs.27.00 Cr
Rate of Return                                :    17%
Break Even Point                           :    65%

INTRODUCTION    
PROPERTIES OF STONE PAPER    
USES AND APPLICATION OF STONE PAPER    
TECHNICAL BENEFITS OF STONE PAPER    
ORIGIN AND TECHNOLOGY    
MARKET SURVEY    
PULP & PAPER INDUSTRY OF INDIA    
GLOBAL MARKET POSITION OF STONE PAPER    
PRESENT MANUFACTURERS/SUPPLIERS OF STONE PAPER    
ADVANTAGE AND FEATURES OF STONE PAPER (SYNTHETIC PAPER)    
MATERIAL SAFETY DATA SHEET (MSDS) OF RAW MATERIALS    
OVERVIEW OF STONE PAPER MANUFACTURE    
RAW MATERIALS    
ENVIRONMENTAL COMPARISON OF STONE PAPER    
MANUFACTURING PROCESS OF STONE PAPER    
PROCESSING DETAILS OF STONE MADE GREEN ENERGY PAPER    
FORMULATION OF STONE PAPER    
PROCESS FLOW DIAGRAM    
STANDARDIZED STONE PAPER MANUFACTURING    
STONE PAPER PRODUCTION AND MATERIAL COMPOSITION    
TECHNICALITIES AND SPECIFICATION OF STONE PAPER PROCESSING LINE    
THE PAPER EXTRUSION FLOWING CHART    
MANUFACTURERS OF STONE PAPER    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT & 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