Detailed Project Report on pet preforms and closures for water, beverages and edible oils packing, shrink film (collation film) & stretch film (integrated unit)

PET PREFORMS AND CLOSURES FOR WATER, BEVERAGES AND EDIBLE OILS PACKING,
SHRINK FILM (COLLATION FILM) & STRETCH FILM (INTEGRATED UNIT)
[CODE NO. 3383]  

Stretch wrap or stretch film is a highly stretchable plastic film that is wrapped around items. The elastic recovery keeps the items tightly bound. In contrast, shrink wrap is applied loosely around an item and shrinks tightly with heat.

It is frequently used to unitize pallet loads but also may be used for bundling smaller items. Types of stretch film include bundling stretch film, hand stretch film, extended core stretch film, machine stretch film and static dissipative film.

The most common stretch wrap material linear low-density polyethylene or LLDPE, which is produced by copolymerization of ethylene with alpha-olefins, the most common of which are butene, hexene and octene. The use of higher alpha-olefins (hexene or octene) gives rise to enhanced stretch film characteristics, particularly in respect of elongation at break and puncture resistance. Other types of polyethylene and PVC can also be used. Many films have about 500% stretch at break but are only stretched to about 100 – 300% in use. Once stretched, the elastic recovery is used to keep the load tight.

There are two methods of producing stretch wrap. 1) Blown: the resin is melted and extruded through an annular die, it is air-cooled. This is a slower process but provides for higher quality in all the areas listed below. The cost of production is also higher due to the quantity that can be produced per hour. 2) Cast: the film is extruded through a slot die, and then passed over cooling rollers. This makes the cooling process quick. The quality is not as good as blown but more can be produced in an hour with lower costs.


COST ESTIMATION

Plant  Capacity                                            :    PET PREFORMS AND CLOSURE FOR WATER
land & Building (7500 Sq.Mtr)                  :    Rs. 9.75 Cr
Plant & Machinery                                      :    Rs. 58.95 Cr
Working Capital for 1 Month                    :    Rs. 23.63 Cr
Total Capital Investment                          :    Rs. 97.88 Cr
Rate of Return                                           :    22%
Break Even Point                                      :    56%


INTRODUCTION    
BOTTLE GRADE PET    
USES AND APPLICATION OR PET PREFORM    
SPECIFICATIONS    
PET AS PACKAGING MATERIALS    
PET AS PACKAGING MATERIAL FOR FOODSTUFFS    
PROPERTIES OF PET    
PET RESIN    
HOMOPOLYMERS AND COPOLYMERS ARE BOTH USED IN PET RESINS.    
CSD -- CARBONATED SOFT DRINKS    
WATER -- THE CLEAR STORY    
JUICE -- HOT FILL QUALITIES    
BEER -- A NEW MARKET WITH NEW REQUIREMENTS    
TYPES OF POLYETHYLENE    
ADVANTAGE OF PET    
CRYSTAL CLEAR    
PURE    
SAFE    
GOOD BARRIER    
LIGHTWEIGHT    
NO LEAKAGE    
DESIGN FLEXIBILITY    
RECYCLABLE    
GOOD RESISTANCE    
LONG SHELF-LIFE    
USES AND APPLICATION OF SHRINK FILM    
CATEGORIES AND SUB-CATEGORIES OF STRETCH WRAPPERS    
MANUAL (OR HAND) WRAPPERS:    
SEMI-AUTOMATIC WRAPPERS:    
TYPICAL FULLY AUTOMATIC TURNTABLE STRETCH WRAPPER    
TYPE OF SHRINK WRAP FILM    
BOTTLES PACKAGING FILM    
LDPE SHRINK FILM    
PALLET SHRINK FILM    
FOOD STORAGE SHRINK FILM    
SHRINK SLEEVES    
POLYETHYLENE SHRINK FILM FOR PACKAGING    
FURTHER ADVANTAGES ARE:    
HEAVY-DUTY SHRINK FILM    
AS TOUGH AS IT GETS    
TWO MAIN SYSTEMS FOR PALLET SHRINK-WRAPPING HAVE BEEN DEVELOPED:    
MONO-AXIAL PALLET HOOD (FLAT HOOD)    
BI-AXIAL PALLET HOOD (SIDE-FOLDED HOOD)    
AUTOMATION IN PALLET SHRINKING    
1. MONO-AXIAL SYSTEM    
2. BI-AXIAL SYSTEM    
LIGHT SHRINK FILM    
THE ATTRACTIVE ALTERNATIVE    
THE MAIN TYPES OF FILM ARE:    
TRANSPORT FILM:    
PROTECTIVE SHRINK FILM:    
HIGH OPTICS SHRINK FILM:    
SHRINK PERCENTAGES    
GLOBAL OVERVIEW FOR FLEXIBLE PACKAGING    
GLOBAL DEMAND OF PLASTIC    
GLOBAL MARKET POSITION OF PET BOTTLES    
FUTURE FORECASTING DEMAND TILL 2020    
PET-WORLD SCENARIO    
MINERAL WATER    
HOT FILL    
MARKET SURVEY OF STRETCH & SHRINK FILM (GLOBAL)    
US DEMAND TO RISE 3.3% ANNUALLY THROUGH 2015    
LDPE STRETCH/SHRINK FILM RESINS TO REMAIN DOMINANT    
SHRINK FILM TO OUTPACE DOMINANT STRETCH FILM    
STORAGE AND DISTRIBUTION MARKET TO GROW THE FASTEST    
MATERIALS TRENDS    
MANUFACTURERS/SUPPLIERS    
PET PREFORMS    
SHRINK FILMS    
STRETCH FILMS    
DETAILS OF PET PREFORM    
PRODUCT FEATURES    
MARUFACTURING PROCESES OF PET PREFORM    
PROCESS IN DETAILS    
TWO WAYS OF MANUFACTURING PERFORMS ARE POPULAR:    
DRYING PROCESS    
PET PREFORM INJECTION MOLDING PROCESS    
PET PREFRMS MOLDING PROCESS    
PROCESS FLOW SHEET    
THE INJECTION MOULDING OF PET PREFORMS CONSISTS OF FIVE PROCESS STEPS.    
PET PREFORM AND BOTTLE BLOWING    
PET CONTAINER APPLICATIONS:    
POPULAR APPLICATIONS ARE:    
PURE: PRODUCTS TASTE GOOD    
MANUFACTURING PROCESSES:    
QUALITY REQUIREMENTS:    
SINGLE STAGE PROCESS    
ON-STEP AND TWO STEP SYSTEMS COMPARED    
TOW STAGE PROCESS:    
TWO STAGE SYSTEM    
INJECTION MOULDING MACHINE.    
MACHINES TO GIVE    
MOULDS    
DEHUMIDIFICATION    
HENCE DEHUMIDIFIER IS A MUST.    
CHILLERS    
HIGH PRESSURE COMPRESSOR:    
MANUFACTURING PROCESS OF STRETCH FILM    
THERE ARE TWO METHOD OF PRODUCING STRETCH FILM.    
CAS FILM:    
PROCESS FLOW DIAGRAM (BLOWN FILM)    
PROCESS FLOW DIAGRAM (CAST FILM)    
FEATURES OF STRETCH FILM    
APPLICATION AND PERFORMANCE OF STRETCH FILM    
HAND WRAP STRETCH FILM    
MACHINE WRAP STRETCH FILM    
STRETCH FILM PERFORMANCE VARIABLES    
STRETCH WRAP MACHINE PERFORMANCE    
PALLET LOAD CONFIGURATION    
STRETCH WRAPPING LOCATION    
ADVANTAGE AND DISADVANTAGE OF STRETCH WRAP FILM    
SPECIFICATION OF STRETCH FILM    102
PROPERTIES & CHARACTERIESTICS OF SHRINK FILM    
USES AND DRAWBACKS OF SHRINK FILM    
SHRINKAGE PHENOMENON OF FILMS MADE WITH LDPE RESIN    
EXTRUSION DETAILS OF STRETCH FILM    
METHODS OF STRETCH FILM MANUFACTURE    
BLOWN FILM    
CAST FILM    
MANUFACTURE OF SHRINK FILM    
SUPPLIERS OF RAW MATERIALS (IMPORTED)    
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)    
COMPLETE PLANT AND MACHINERY SUPPLIERS (IMPORTED) FOR PET PREFORM    
SUPPLIERS OF PLANT & MACHINERIES    
MOULDS SUPPLIERS FOR PET PREFORM    
COMPRESSOR    
REFRIGERATION UNIT    
SUPPLIERS OF RAW MATERIALS    
PET RESIN    
PP RESIN    
PLASTICIZER    
COLOURS    
STABILIZER    


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