Detailed Project Report on tetra pak manufacturing plant
Detailed Project Report on tetra pak manufacturing plant
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TETRA PAK MANUFACTURING PLANT
[CODE NO.3895]
Tetra Pak is one of the largest producers of aseptic carton packaging. The company primarily operates within the B2B segment. However, they pay a special emphasis on CSR specifically green sourcing. This paper will focus on the issues the company faces as they try to be an environmentally friendly company in India. A SWOT analysis will be done on the company, as well as some strategies that the company can use to be sustainable in its endeavour.
Tetra Pak is a multinational food processing and liquid carton packaging company of Swedish origin, founded in 1951 by Ruben Rausing. The company’s aseptic packaging ensures perishable liquid foods to be stored and distributed even for long periods of time. Tetra Pak has grown to become the leading company within its business area and constitutes the majority of liquid carton packaging seen on the market today. The company operates in more than 150 countries and employs over 21,500 people worldwide. In 2008, a total of 70,538 million liters of liquid food products were sold in Tetra Pak packages. This was equivalent to 141,379 million packages of different sizes and designs.
Tetra Pak produces packages designed to contain liquid products e.g. milk and juice. These are low cost every-day products requiring low packaging costs while aspects such as hygiene, design and durability leads to high development and material costs. In 2009 Tetra Pak sold over 145 billion packages. Such quantities means that even the smallest reduction in production time or material usage leads to great profit. Thus the need for more accurate dimensioning of both package performance and packaging processes are increasing as the need for optimization grows.
COST ESTIMATION
Plant Capacity : 1,00,00,000 Pieces
Land & Building (5000 sq.mt.) : Rs. 4.45 Cr
Plant & Machinery : Rs. 65.09 Cr
Working Capital for 2 Month : Rs. 143.00 Cr
Total Capital Investment : Rs. 213.00 Cr
Rate of Return : 52%
Break Even Point : 28%
INTRODUCTION
SUITABLE FOR DIFFERNENT SHAPES, SUCH AS BRICK SHAPE, GABLE TO SHAPE, TRIANGLE SHAPE, AND ETC.
GENERAL TRENDS WITHIN LIQUID CARTONS
TRENDS WITHIN MILK AND OTHER DIARY PACKAGING
TRENDS IN JUICE PACKAGING
TRENDS IN FOOD- AND BEVERAGE PACKAGING MACHINERY
PLANT LOCATION
GENERAL CHARACTERISTICS OF THE DISTRICT
LOCATION & GEOGRAPHICAL AREA
TOPOGRAPHY
MAP OF GAUTAM BUDH NAGAR DISTRICT
LIST OF THE MEDIUM ENTERPRISES IN GAUTAM BUDH NAGAR & NEAR BY AREA
MAJOR EXPORTABLE ITEM BY NOIDA EXPORT PROCESSING ZONE (NEPZ)-
PRODUCTS-
TRANSPORT
METRO
NOIDA HAS EXCELLENT METRO CONNECTIVITY.
ROAD
A ROAD IN NOIDA
NOIDA-GREATER NOIDA EXPRESSWAY
RAIL/AIR
BUS
HISTORICAL BACKGROUND
LIQUID CARTON PACKAGING
BASIC STRUCTURE 26
PACKAGING MATERIAL STRUCTURE OF A LIQUID CARTON
PROTECTION AND PRESERVATION
PAPERBOARD PRINTING
LAMINATION AND CREASING
CUTTING
THE THREE MAIN PACKAGING MATERIAL CONVERTING STAGES
THE FORM/FILL/SEAL MACHINE
PAPER FEED
PUNCHING AND PATCHING
PULLTAB ATTACHMENT
LONGITUDAL STRIP APPLICATION
ASEPTIC BATH
TUBE-FORMING
ASEPTIC RING
FOLDING
EXTERNAL CAPPING
PRINCIPLE LAYOUT OF A FORM/FILL/SEAL-MACHINE
ASEPTIC AND CHILLED SEGMENT
OPENING ATTACHMENT
THERMAL SEALING
ADHESIVES BONDING
DISTRIBUTION
PACKAGING LEVELS
PRIMARY PACKAGING
SECONDARY PACKAGING
TERTIARY PACKAGE
LIQUID CARTON PACKAGING OPENINGS
OPENING CATEGORIZATION
RESEALABLE OPENING
RECLOSABLE OPENING
NON-RECLOSABLE OPENING
1-STEP AND 2-STEP OPENINGS
STEP OPENINGS
STEP OPENING
TETRA PAK OPENINGS
PERFORATION™
EASY OPENING™
STRAW HOLE/ STRAWS
PULLTAB™
FIG THE PERFORATION™, EASY OPENING™, STRAW HOLE AND PULLTAB™
OPENING SOLUTIONS (COURTESY OF TETRA PAK AB )
GRANDTAP
BAJKAL
HURON
FIG THE GRANDTAP, BAJKAL, AND HURON OPENING SOLUTIONS (COURTESY
OF TETRA PAK AB)
RECAP™
FLEXICAP™
SIMPLYPULL™
FLIPCAP
FIG THE RECAP™, FLEXICAP™, SIMPLYPULL™ AND FLIPCAP OPENING
SOLUTIONS (COURTESY OF TETRA PAK AB )
TETRA PAK – BENEFITS
IT HAS FOLLOWING BENEFITS:
PROTECTION
PRESERVATION
COMMUNICATION
CONVENIENCE
ASEPTIC PACKAGING
PROPERTIES OF ASEPTIC PACKAGING MATERIAL
ADVANTAGES OF ASEPTIC PACKAGING TECHNOLOGY
FEW ADVANTAGES IN ALL CATEGORIES
ADVANTAGES OF BULK ASEPTIC PACKAGING
ADVANTAGES IN PROTECTION
ADVANTAGES IN LOGISTICS
LOWER TRANSPORT WEIGHT
LOWER STORAGE COSTS
ADVANTAGES IN GENERAL
TYPICAL PACKAGING APPLICATIONS
SEALING TECHNIQUE AT TETRA PAK
FIGURE : MATERIAL LAYERS OF A TETRA BRIK ASEPTIC PACKAGE.
POLYMER 2) PAPER 3) POLYMER 4) ALUMINUM 5) POLYMER 6) POLYMER
FIGURE : PRINCIPLE SKETCH OF THE MANUFACTURING OF THE LONGITUDINAL SEALING (LS) AND THE TRANSVERSAL SEALING (TS).
FIGURE : PRINCIPLE SKETCH OF THE TS PROCESS, SHOWING THE DIFFERENT PARTS.
PRODUCT MIX OF TETRA PAK
PRODUCT MIX
TETRA PAK PRODUCT MIX
TETRA BRIK
TETRA REX
TETRA TOP
TETRA BRIK ASEPTIC
TETRA CLASSIC ASEPTIC
TETRA GEMINA ASEPTIC
TETRA PRISMA ASEPTIC
TETRA WEDGE ASEPTIC
TETRA FINO ASEPTIC
TETRA EVERO ASEPTIC
TETRA RECART
LEVELS OF TETRA PAK PRODUCTS
CORE LEVEL
ACTUAL LEVEL
AUGMENTED LEVEL
MARKET SURVEY
TETRA PACK CONTAINER MARKET – MARKET SEGMENTATION:
BASED ON MATERIALS, TETRA PACK CARTONS, THE MARKET IS SEGMENTED INTO,
ON THE BASIS OF PACKAGED PORTFOLIO, THE MARKET IS SEGMENTED INTO,
TETRA PACK CONTAINER MARKET - MARKET SEGMENTATION:
BASED ON MATERIALS, TETRA PACK CARTONS, THE MARKET IS SEGMENTED INTO,
ON THE BASIS OF PACKAGED PORTFOLIO, THE MARKET IS SEGMENTED INTO,
BASED ON END USER INDUSTRY, THE TETRA PACK CARTONS MARKET IS
SEGMENTED INTO
BASED ON THE APPLICATIONS, THE TETRA PACK CARTONS MARKET IS
SEGMENTED INTO
TETRA PACK CARTON MARKET - MARKET DYNAMICS:
TETRA PACK CARTON MARKET - REGIONAL OUTLOOK:
FIT FOR THE FUTURE
TETRA PACK LIQUOR MARKET
PLASTIC FILM AND SHEET MANUFACTURING METHODS
EXTRUSION
PRINCIPLE LAYOUT OF A SHEET EXTRUSION PROCESS
CALENDERING
PRINCIPLE LAYOUT OF A SHEET CALENDERING PROCESS
MULTILAYERED PLASTIC FILM AND SHEET MANUFACTURING METHODS
CO-EXTRUSION
PRINCIPLE LAYOUT OF A CO-EXTRUSION PROCESS
MULTILAYER CALENDERING
PRINCIPLE LAYOUT OF A CO-CALENDERING PROCESS
KNIFE SPREAD COATING
PRINCIPLE LAYOUT OF A KNIFE SPREAD COATING PROCESS
CURTAIN COATING
PRINCIPLE LAYOUT OF A CURTAIN COATING PROCESS
SUGGESTED PLASTIC FILM AND SHEET SHAPING METHODS
THERMOFORMING
PRINCIPLE LAYOUT OF A VACUUM FORMING PROCESS
FOLDING
FOLDING EXAMPLE WITH PREDEFINED FOLDING PATTERN
PROCESS OF MANUFACTURING
THEN, WITH THE HELP OF A LASER AND TEMPERATURE CONDITIONS, SUCH A PATTERN IS OBTAINED.
THE FINISHED TEMPLATE IS WOUND ON SHAFTS
THESE BLANKS ARE INSTALLED IN THE PRINTING EQUIPMENT AND
THE PRINTING PROCESS TAKES PLACE ON A HUGE MACHINE.
EACH INK IS APPLIED SEPARATELY; IT REMINDED ME OF THE WORK
OF AN INKJET PRINTER.
THE CORRECT COLOR IS AUTOMATICALLY CONTROLLED.
AFTER PRINTING, THE LAMINATION PROCESS BEGINS - THE MOST DIFFICULT
AND SECRET SITE.
AFTER LAMINATION - CUTTING. THE FINAL STAGE OF WORK - SHRINK PACKAGING.
PROCESS FLOW DIAGRAM
STERILE SYSTEM TBA/8,, TBA/19
GENERAL ENVIRONMENT
CULTURAL AND SOCIAL ENVIRONMENT
ECONOMIC AND TECHNOLOGICAL ENVIRONMENTS
POLITICAL AND LEGAL ENVIRONMENT
FEDERAL, STATE, AND LOCAL REGULATION. LIMIT CHOICES AVAILABLE TO ORGANIZATION.
COMPETITIVE ENVIRONMENT
POLITICAL CONDITIONS
DEMOGRAPHIC ENVIRONMENT
GLOBAL ENVIRONMENT
ECOLOGICAL ENVIRONMENT
THE “GREENING” OF MANAGEMENT
HANDLING OF WASTE
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
ALUMINUM FOIL
PAPER BOARD
MACHINERY PHOTOGRAPHS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
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
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