pet feasibilty group

8/13/2019 Pet Feasibilty Group

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DURGAPUR INSTITUTE OF ADVANCED TECHNOLOGY &MANAGEMENT

FEASIBILITY

REPORT

ON:

PRODUCTIONOFPETBOTTLES

PROJECT SUBMITTED BY: KISHALAY ROY(CH/10/02)

RITI DAS(CH/10/11)

DEBJANI BHATTACHARJEE(CH/10/26)

PRITAM GANGULY(CH/10/28)

ALOK KUMAR ROY(CH/10/31)

ARCHANA KUMARI(CH/10/37)

RIMELI ROY CHOUDHURY (CH/10/44)

PARAMITA CHAKROBARTY(CH/10/56)


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ACKNOWLEDGEMENT:

A mammoth project of this nature calls for intellectual nourishment, professional help, and

encouragement from many quarters. I would like to express my gratitude to:

Faculties and seniors for providing the stimulus for making this thesis successful.

A number of academics and practitioners for generously sharing their insight and experience

with me.

Without them the project would not have been materialized.

We were assigned a project work on the topic FEASIBILTY ANALYSIS OF PET BOTTLE

MANUFACTURING PROCESS which is approved as a successful job by the concerned project

supervisor and all the members of the authority. Undergoing the project was really a very

knowledgeable as well as adventure.

We express our deep sincere gratitude and respect to Prof. Dipshikha Dutta our project supervisorand without whose expert and able guidance this project would not have been a successful one. He

helped us in all aspects, giving us a clear vision of the concepts needed for the project. His remarks

of the right and wrong in every step helped us to compile the work in a more precise way. His

important suggestions and guidelines helped us a lot in the report writing and set up of the project.

We are indebted to him for his valuable guidance.

We are greatly indebted to our faculties of Chemical Engineering department of our college for

modelling us both technically and morally for achieving greater success in life.

We sincerely thank all the people for their constant encouragement and support throughout

our course of learning, especially for the useful suggestions given during the period of our projectwork.

PROBLEM STATEMENT


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Make a techno economical feasibility report on 575 lakhs bottles per

year.

CHAPTER-1

Introduction


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History

Plastic bottles were first used commercially in 1947, but remained relatively expensive until

the early 1960s when high-density polyethylene was introduced. They quickly became

popular with both manufacturers and customers due to their lightweight nature and

relatively low production costs compared withglass bottles.Except for wine and beer,

thefood industryhas almost completely replaced glass with plastic bottles.

about pet

PET is polyethylene terephthalate.

It's a plastic resin and the most common type of polyester. Two monomersmodified ethylene glycol and

purified terephthalic acidare combined to form the polymer called polyethylene terephthalate.

PET was discovered and patented in England in 1941.

What is PET?

The most-common plastic bottle you see nowadays is the soda bottle. It is made frompolyethylene terephthalate, also known as PET. PET is used for 14 percent of all plasticcontainers and 43 percent of soda bottles. It was developed in 1941, but it wasn't used forsoda bottles until the 1970

PET BOTTLE

Polyethylene Terephthalate(PET, PETE orpolyester)is commonly used for carbonated

beverage, water bottles and many food products. PET provides very good alcohol and

essential oil barrier properties, generally good chemical resistance (although acetones and

ketones will attack PET) and a high degree of impact resistance and tensile strength. The

orienting process serves to improve gas and moisture barrier properties and impact

strength. This material does not provide resistance to very high temperature applications

max. temp. 200 F (93 C).

CHAPTER-2

Consumption
http://en.wikipedia.org/wiki/Glass_bottlehttp://en.wikipedia.org/wiki/Glass_bottlehttp://en.wikipedia.org/wiki/Glass_bottlehttp://en.wikipedia.org/wiki/Food_industryhttp://en.wikipedia.org/wiki/Food_industryhttp://en.wikipedia.org/wiki/Food_industryhttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Polyesterhttp://en.wikipedia.org/wiki/Polyesterhttp://en.wikipedia.org/wiki/Polyesterhttp://en.wikipedia.org/wiki/Polyesterhttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Food_industryhttp://en.wikipedia.org/wiki/Glass_bottle


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CHAPTER-3

Physical properties of pet


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PET is an unreinforced, semi-crystalline thermo-plastic polyester derived from polyethylene terephthalate. Its excellentwear resistance, low coefficient of friction, high flexural modulus, and superior dimensional stabilty make it a versatilematerial for designing mechanical and electro-mechanical parts. Because PET has no centerline porosity, the possibiltyof fluid absorption and leakage is virtually eliminated.

Typical Property Values

Physical Properties ASTM TestMethod Units PET

Density D792 lbs/cu in. 0.0499Water absorption, 24hours D570 % .10Mechanical Properties ASTM Test

Method Units PETSpecific Gravity D792 g/cu cm.3 1.38Tensile Strength at break, 73F D638 psi 11,500Tensile Modulus, 73F D638 psi 4 X 10 Elongation at break, 73 F D638 % 70Flexural Strength,73 F D790 psi 15,000Flexural Modulus, 73F D790 psi 4 X 105Izod Impact Strength,Notched, 73F D256 ft-lbs/in. 0.7Rockwell Hardness D785 ---- R117Coefficient of Friction @40psi, 50 fpm ---- Static/Dynamic 0.19/0.25Thermal Properties ASTM Test

Method Units PETHeat Deflection, 264 psi D648 F 175Melting Point ---- F 490Coefficient of Linear ThermalExpansion D696 in./in./-F 3.9 X 10-5

Applicable Temp. Range forThermal Expansion ---- F 50 - 250Max. Serving Temperature for LongTerm ---- F 230Flammability UL94 ---- HBElectrical Properties ASTM Test

Method Units PETVolume Resistivity, 73F D257 ohm-cm 1016Dielectric Constant @ 60 Hz,(73F, 50% RH) D150 ---- 3.4Dissipation Factor, @ 60 Hz,73F

D150 ---- 0.002Dielectric Strength D149 V/mil 400


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CHAPTER-4

PROCESS DESCRIPTION

Traditionally PET bottle moulding machines could be divided into two categories-those usingthe One-Step hot perform method and those using the Two-Step cold perform


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method.The One-Step method -- from PET granule to finished bottle -- all processes are

completed on one integrated machine. This means the injection-moulded preform is

withdrawn from the injection cavity while still hot enough to be stretch blown to form the

bottle. No extra heating is required, and since preforms are not stockpiled to be blown at a

later date, but are freshly moulded every time, there is no risk of surface damage from

preforms knocking together during storage or transportation. One-Step method is highly

suited to small and medium scale production lines. The Two-Step method uses two separate

machines. The preform is injection moulded on the first, then reheated and blown on the

second. The Two-Step system uses two separate machines: an injection moulding machine

for making the preforms, and a reheat blow moulding machine to reheat the preforms from

cold and blow the bottles. The requirement for a preform heating system means the Two-

Step process has a lower thermal efficiency. This method is most suited to medium to large-

scale production. Usually 2-stage method is adopted to produce PET bottle.

Drying of PET

PET absorbs moisture from the atmosphere. This must be removed by a

dehumidifying drying before processing.

Plasticizing the PET

Dried PET pellets are compressed and melted by a rotating

screw.

Injection Molding the PET Preform

Molten PET is injected into the injection cavity and cooled

rapidly to form a perform(The test-tube-like form from which bottles are

blown is known as a preform).

Heating the PET Preform

The temperature of the preform is adjusted to the correct profile for

blowing.

Stretch Blow Molding the PET Container

The hot preform is simultaneously stretched and blown (thereby orienting

the crystals of and strengthening the PET*) into a shaped blow mould to

form a tough, lightweight container. PET that is heated to a temperature

where its chain-like molecules are sufficiently mobile to uncoil instead of

breaking when extended, can be oriented by stretching. Stretching applied from two

directions at right angles, as in stretch blow moulding, gives biaxial orientation.

Oriented PET contains closely packed chains aligned in the directions of stretch. The

material is stronger because the molecules act together instead of individually. The

tensile strength of oriented PET is several times that of the unstretched material and

the impact strength, barrier and chemical resistance are also significantly improved,

so bottles can be lighter without sacrificing performance.

PET Container Ejector

The finished container is ejected.

Pictorial representation of pet

manufacturing process
http://www.kenplas.com/project/pet/petblow.aspxhttp://www.kenplas.com/project/pet/petinj.aspxhttp://www.kenplas.com/project/pet/petblow.aspxhttp://www.kenplas.com/project/pet/petinj.aspxhttp://www.kenplas.com/project/pet/petblow.aspxhttp://www.kenplas.com/project/pet/petinj.aspxhttp://www.kenplas.com/project/pet/petblow.aspxhttp://www.kenplas.com/project/pet/petinj.aspx


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FLOWSHHET of process

SPECIFICATIONS OF DIFFERENT EQUIPMENTS

USED


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Preform Injection Moulding Machine:

Power consumption=11 KW

Heater power=7.5 KW

Pump pressure=16 MPa

Shot weight=170gm/sec

Screw dia.=38mm

Max mold thickness=380mm

Min. mold thickness=150mm

Machine dimension=4.5*1.3*1.9 (m)

Machine weight=3.6 ton

8-CAVITY PREFORM MOULD :

INJECTON MOULDING MACHINE:


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Blow molding machine:

Machine name & model no.: 1200-9000 pcs/hr PET bottle making machine.

Supplier: zhangjiagang eceng machinery co. ltd.


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TYPE ITEM MODEL YCQ-1L-6

CONTAINER No. of cavity 6

Theoretical output 7000-8000pcs/hr

Max. container volume 1L

Max. neck dia. 28-30 mmMax. container dia. 60 mm

Max. container height 260mm

No. of lamp 56pcs

ELECTRICAL SYSTEM Max. heating power 34 KW

Installation power 44 KW

Actual power consumption 24 KW

AIR SYSTEM Operating pressure 7-8 kg/cm2

Low pressure consuming 1600 lit/min

Blowing pressure 25-35 kg/cm2

High pr. consuming 2000-2200 lit/min

CHILLER WATER Operating pressure 5-6 kg/cm2

Temperature 10c

Consuming 8000 kcal/hr

Flow rate 88 lit/min

MACHINE Machine dimension 5.2*2.0*2.0 (m)

Machine weight 5.0 ton

AIR COMPRESSOR:

MODEL KCA 0.63-30

CAPACITY(m3/min) 0.63

MAX. PRESSURE(BAR) 30TEMPERATURE


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COOLING METHOD AIR

FULL LOAD POWER 7.5 KW

RUNNING POWER 2 KW

DIMENSION 149*60*116(cm)

WEIGHT 380 Kg

VOLUME OF AIR TANK 220(L)

WATER CHILLER:

MODEL KCW03

COMPRESSOR POWER 3.05

NOMINAL CHILLING CAPACITY 10700kcal/hr

CHILLER WATER PUMP POWER 0.75KW

FLOW 3(T/hr)

PIPE I Dia. 1

MACHINE WEIGHT 120 kg

MACHINE DIMENSION 88*66*96(cm)

Material & energy balance:


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Material balance:

Perform machine:

Weight of bottle=22 gm

Per second stroke= 170gm

Cavity= 6

Material waste= 170-(6*22)=38gm/sec

Total material required per hour= (170*3600)/1000 kg/hr = 612kg/hr

Weight of perform manufactured= 22*6*3600/1000 kg/hr= 475.2kg/hr

Total waste=(38*3600/1000 )kg/hr =136.8kg/hr

Material in= material out (kg/hr)

612=475.2+136.8

Blow moulding machine:

Material in= material out (kg/hr)

475.2=475.2

Energy balance:

Inlet temperature of water=10c =283k

Heat consumed= 8000kcal/hr

Mass of water entering= 5280kg/hr

Heat equation:

Q=m*cp*dt

8000=5280*1*(T2-283)

T2=284k

CHAPTER-10


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PROJECT ECONOMICS:

DESCRIPTION OF LAND AREA REQUIREMENT

DESCRIPTION LENGTH BREADTH AREA(m^2)

Main plant 100 30 3000

Q.C. lab 10 10 100

Security office 10 6 60

Assembly point 20 10 200

General stores 30 10 300

Weigh bridge 10 5 50

Workshop 10 5 150

Power substation 25 10 250

Fire-fighting 5 4 20

Garden 10 10 100Administrative building 20 20 400

Guard room 5 4 20

Pond 10 10 100

Worker change room 5 4 20

Garage 8 5 40

Cycle stand 10 6 60

Canteen 15 15 225

Toilet block 10 8 80

Internal road(6m wide) 1500

Gate 10 5 50

Weighing office 10 10 100Land for future

expansion

2000

TOTAL 11814 (2.92 acres)


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ESTIMATION OF COST FOR BUILDING

Sl. No. Description Area(m^2) Rate(Rs./m^2) Total cost(Rs. In

lakhs)

1. Main factory building 1500 8000 48

2. Building for auxiliary services

a. Pump house

b. Air compressor

c. Laboratory

d. Power substation

10

5

30

250

3500

3500

5000

3500

0.35

0.175

1.5

8.75

3. Non-factory buildings

a.

Medical room

b. Guard room

c. Time office

d. Workers change

room

e. Cycle stand

f. Canteen

g. Toilet block

20

10

10

15

10

30

10

4000

3000

3000

3000

3000

3500

3500

0.8

0.3

0.3

0.45

0.3

1.05

0.35

4. Administrative building 300 4000 12

5. Stores/godown/warehouse

etc.

a. Raw materials storage

b. Preform storage

c. Bottle storage

400

600

600

2000

2000

2000

8

12

12

6. Miscellaneous building/civil

works

a. Pond(2m deep)

b. Garden

200

30

160

2000

0.64

0.6

7. Water reservoir(2m deep) 200 4000 24

Total : 107.536 lakhs


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Sl. No. Description Quantity Cost(Rs.

in lakhs)

1. Packaging unit 1 5

2. PET storage tank 1 5

3. Pre-form molding machine 2 14.7

4. Blow molding machine 1 9.8

5. Water chiller(with pump) 1 0.08

6. Air compressor 2 0.069

7. Feed water storage tank 1 4

8. Bottle storage tank 1 5

9. Conveyors

a. Bucket elevator

b. Belt Conveyor

1

2

0.74

0.37

10. Filter 2 0.08

11. Valves

a. Gate valve

b. Ball valve

c. Globe valve

1

4

4

0.328

0.005

0.0343

12. Pipes 2 ft. 10,000

Total: 60.5632


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REQUIREMENT OF RAW MATERIALS AND UTILITIES

Sl. No. Name of raw materials,

chemicals, utilities etc.

(specific)

Consumption

per pieces of

product

Annual

requirement(per

annum in tons)

Delivered

price(Rs.)

Total(Rs. In

lakhs)

1. Raw materials- PET 25 gm 1350 8575 115.8

2. Utilities

a. Water

b. Power

1.46 l

0.1 kW-H

6000(m^3)

17* 10(^5) kW-H

9/( m^3)

5/ kW-H

5.4

85


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SALARY AND WAGES OF MANPOWER

Department Designation No. Salary(Rs./month) Annual expenses(Rs.

In lakhs)

Administration General manager

Personal manager

P.A. of G.M.

Typist/ P.C. operator

Peon

Security officer

Production manager

1

1

1

2

4

3

1

50,000

30,000

12,000

6,000

4,000

9,000

30,000

6

3.6

1.44

1.44

1.92

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3.6

21.24Production Work manager

Shift engineer

Skilled operator

Unskilled operator

Security staff

Fireman

Fire-assistant

Maintenance engineer

Electrician

Helper

Mechanic

1

3

5

15

12

2

3

3

5

2

3

25,000

18,000

10,000

6,000

4,000

3,500

3,000

18,000

5,000

2,000

5,000

3

2.16

6

10.8

5.76

0.84

1.08

6.48

3

0.48

1.8

41.4

Sales Sales officer

Sales assistant

2

4

15,000

6,000

3.6

2.88

Accounts Chief accountant

Accountant

Cashier

1

2

2

15,000

10,000

6,000

1.8

2.4

1.44

5.64

Laboratory and others Chief chemist

Chemist

Lab-assistant

Sweeper

1

3

4

2

20,000

15,000

6,000

2,000

2.4

5.4

2.88

0.48


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Gardener

Driver

2

2

5,000

3,500

1.2

0.84

13.2

Material handling Material storage

Store keeper

Store clerk

2

4

4

20,000

7,000

4,000

4.8

3.36

1.92

10.08

Total cost: 91.56 lakhs


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CHAPTER-11

PROFITABLITY ANALYSIS AND BREAK-EVEN

POINT :

Machine efficiency =94%

For the first year

Machine depreciation for first year =.5%

Particulars Rs in lakhs

PET cost 108.44

Electricity cost 85Packing cost 10

Transportation cost 20

Wages and salary 68

Total running cost 291.45

Bottles manufactured per year 564.3

Rs earn from sales @70 paise /bottle 395.01

Margins profit (395.01-291.45)

=103.56

Sales [email protected]% 12.945

Net profit 90.615

For the 2nd

year

Depreciation =1.5%


PET cost 106.81

Electricity cost 85

Packing cost 10


Wages and salary 70.72




Margins profit 81.69


Net profit 71.47

For the 3rdyear


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Depreciation =3%


PET cost 103.60

Electricity cost 85

Packing cost 10Transportation cost 20







Net profit 60.9

For the 4th

year

Depreciation =5%


PET cost 98.41

Electricity cost 85

Packing cost 10








Net profit 44.68


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For the 5 th year

Depreciation=7%


PET cost 91.52

Electricity cost 85

Packing cost 10






Margins profit 25.8


Net profit 22.57

Total fixed cost =259.93 lakhs

Total profit of the 4 year is =(90.165+71.47+60.09+48.68)

=270.40lakhs

Total investment can be recovered in 3 years 9 month 12 days =3 years 10 month

Therefore the break even point is also 3 year s 10 month

Net profit after that time is (22.57+10.47)=33.04lakhs


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CHAPTER-12

References :

www.mclube.com

www.petwikipedia.com

www.bisleri.com

www.kinley.com
http://www.mclube.com/http://www.mclube.com/http://www.petwikipedia/http://www.petwikipedia/http://www.bisleri.com/http://www.bisleri.com/http://www.kinley/http://www.kinley/http://www.kinley/http://www.bisleri.com/http://www.petwikipedia/http://www.mclube.com/

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