PLASTIC BOTTLES CAPS
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- Dora Hodge
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1 PLASTIC BOTTLES CAPS INTRODUCTION Bottle caps can be manufactured both form thermosetting material (UF & PF) as well as thermoplastic material (PP, HIPS, HDPE etc.) the present scheme envisages setting up of a unit comprising of a compression moulding and injection moulding sections. However, many a time more than one conversion techniques may be employed in the same unit in order to cover a wider range of products. MARKET The plastic caps are widely used in capping the bottles where liquids are packed. The plastic market has been increasing phenomenally as can be seen for the following figures. The Indian Plastic Industry has taken great strides in its quest for success. The last few decades have seen it rise to the position of a leading force in the country with a sizable base. The industry itself is growing at a fast pace and the per capita consumption of plastics in the country has increased manifold as compared to the earlier decade. Plastic has undoubtedly gained notable importance in every sphere of activities. It has helped substitute and save scarce natural resources. It is an inseparable part of our daily life. Constant development in polymer technology, processing machinery, know how and cost effective production is fast replacing plastics in every segment from its conventional materials Polymer demand in India to touch 7.3 million tons by and 12.4 million tons by India is expected to be the 3rd largest consumer of plastics after US and china by
2 Growth rate between 12% - 15%. Consistently outperforming GDP. Major Raw Material Producers 15 Processing Units 22,000 Nos Turnover Rs. 25,000 crores Capital Asset Rs. 47,000 crores Raw Material produced approx. 4.2 million tones Raw Material consumed approx. 3.7 million tones Employment Direct / Indirect 2.5 million Export value approx. USD 1104 million Revenue to Government approx. Rs crores Demand estimates for major Polymers - INDIA (1000 Tones) LDPE 281 Linear PE / LLDPE / HDPE PP PVC PS PET Bottles PET Film Demand estimates for Engineering Thermoplastics ABS Polyamide ( 6 & 66) PET / PBT Moulding Material 2 3 Polycarbonate Other Thermoplastics
3 Thermo sets Demand estimates for Machinery Injection Moulding Nos Blow Moulding 5050 Nos Extrusion Nos * Source : Task Force on Petrochemical / Industry Estimate The per capita plastics consumption, which is currently at 3 kg, is projected to go up to 7.7 kg by the year While it is true that our consumption is below the world average of 17 kg, per capita figures should be viewed in the context of our large population; sometimes per capita figures are useful only for trend analysis and not in absolute terms. INSTALLED CAPACITY Product Installed No of Capacity Capacity per capacity per working per day annum hour hours 300 days per per day annum Plastic bottles caps 1. U/F P/F Bottle Caps 1000 pieces pieces 24 Lakhs 2. Thermoplastic caps 1000 pieces pieces 24 Lakhs PLANT AND MACHINERY No. Description Qty Price (Nos.) (Rs.) 1. Compression moulding section : 1 1,00,000 3
4 (i) Table ting machine (ii) Hydraulic thermosetting 1 1,80,000 Moulding press cap. 25 MT. stroke 12" single day light size of table 16 x 13 working pressure 2 tons/sq. inch. complete with arrangements of ejection, electrically operated, with 5 HP motors and other accessories 2. (i) Injection moulding section : Fully automatic vertical plunger type 1 4,35,000 injection moulding machine 100 gms shot capacity with all accessories & micro processor controlled. (15 HP). (ii) Set of moulds of bottle caps both 2,00,000 injection and compression mouldings 3. Small hand tools, greasing equipment etc. 85,000 Total 10,00,000 MANAFACTURING PROCESS For the manufacture of UF/PF bottle caps hydraulic type compression moulding process is employed. The thermosetting material is put in the cavities of a preheated mould and pressed between the two platens of the press. The combined effect of heat and pressure causes cross linking in the material leading to formation of micro-molecules. This causes the compound to fill the cavity of mould and harden. After a certain time the mould is opened and the mouldings are removed. For the manufacture of bottle caps from thermoplastic material the process involves the following steps : 1. Fixing of requisite dies in the die head 2. Feeding of raw materials in the hopper 3. Injecting molten material into the die 4
5 4. Cooling and opening of the moulds 5. Ejection of moulding piece and 6. Finishing RAW MATERIALS Pieces Qty-MTs Rate/MT Value Rs. Lakhs Thermosetting-PF UF moulding pwd Thermostatic-HDPE/PP Matster batches & colour TOTAL Packing materials LOCATION LAND AND BUILDING Built up area-sq.ft 1000 Rent p.m.-rs per.5 per sq.ft 5000 Advance-10 months.rs UTILITIES Three phase- KW Power charges Rs.lakhs p.a 8.21 For process-litres per day 0 For human consumption-litres/day 200 MANPOWER Monthly wages Total Supervisor
6 Skilled Unskilled Accounts Assistant Sales Executive Security sub total Add benefits 20% 8600 Total per month TOTAL PER ANNUM-Rs. lakhs 6.19 SCHEDULE OF IMPLEMENTATION If the financing arrangements are finalised the project can be implemented in three months time. COST OF PRODUCTION AND PROFITABILTY Assumptions Installed capacity Quality 1 UF/PF bottle caps 48 lakh pcs per annum and thermoplastic bottle caps Capacity utilisation Year-1-60% Year -2-70% Year-3 onwards- 80% Selling price Rs.1.00 per piece Raw materials As per the details given above Packing materials As per details given above Power Rs lakhs per annum at 100% Wages and salaries Rs.6.19 lakhs with increase 5% every year. Repairs and Maintenance Rs lakh per annum with 10% annual increase Depreciation Written down value method -15 % on machinery Selling general and Rs per month with 5% annual increase 6
7 administrative expenses Interest on Term loan Interest on working capital Income tax 11% per annum 11 % per annum % on profits LIST OF MACHINERY SUPPLIERS 1. Textair Plastics & Hydraulics, 18-Ambal Nagar Main Road, Ekkattuthangal J.B. Industries, 7 / 36 PH-2 TNHB, Muthamil Nagar Klokner Windor India Ltd, 2-J Mound Road, Teynampet , 4. Polymechplast Machines LTd, Gold Coin House, 775, G.I.D.C Makarpura Vadodara D. G.P. Windsor India Ltd, 2 J, Century Plaza, Teynampet, Chennai Europack Machines India Pvt Lts, 52, Bindal Industrial Estate, Sakinaka, Andhari East, Mumbai. 7. Ambica Engineering & Wire Products, L 45, GIDC Estate, Odher, Ahmedabad , 8. Hind Hydraulics & Engineers, Faridabad, Plot No. 13, Sector 74, Faridabad Prasad Groups & Companies, Plot No GIDC Industrial Estate, Phase 1 Valva, Ahmedabad HMT International Ltd, 59 HMT Bhavan, Bellary Road, Bangalore LIST OF RAW MATERIAL SUPPLIERS 1. Lucky Plastics, 421-c, Sngr Road Gpathy CBE Maruthi Plastic, Old 3 Thirupali ST Sowcarpet Reliance Industries, 501 JVL Plaza Anna Salai, Teynampet Shri Swastic PlastICS, 57/2, Thirupalli Street Abs Plastics Ltd, 51 Gidc Industrial Estate, Nadesari Polychem Ltd, 74 Jamshedji Tata Road, Mumbai Sankar Mercantile Agencies, 43 Vysarpadi Industrial Estate, Chennai Indian Petrochemical Corporation. 89 Santhome High Road, Chenai PP Industries, 91 Stranhas Road, Ooteri,Chennai
8 10. Haldie Petrochemicals, 41 UN Road, T.nagar, Chennai V.B. Sree GanpathyColourCompany, 63, Devaraja Mudali Street, 2 nd Floor, Chennai Prayag Polytech Pvt. LTd. 2468, Prayag House,?Nalwa Street, Pahar Ganj, New Delhi FINANCIAL ASPECTS 1. COST OF PROJECT [Rs. lakhs] Land & Building (Advance) 0.50 Plant & Machinery Other Misc. assets 0.50 Pre-Operative expenses 2.00 Margin for WC MEANS OF FINANCE Capital 6.29 Term Loan Term Loan amount is assumed at 75% value of the Machinery. 3. COST OF PRODUCTION & PROFITABILITY STATEMENT [Rs. lakhs] Years Installed Capacity No of pieces Utilisation 60% 70% 80% 80% 80% Production/Sales Selling Price per Piece 1.00 Sales Value (Rs. lakhs) Raw Materials Packing Materials Power Wages & Salaries Repairs & Maintenance Depreciation Cost of Production Selling, Admin, & General exp Interest on Term Loan Interest on Working Capital Total
9 Profit Before Tax Provision for tax Profit After Tax Add: Depreciation Cash Accruals Repayment of Term loan WORKING CAPITAL: Months Values % Margin Bank Consumpti Amount Finance ons Raw Materials % Consumables % Finished goods % Debtors % Expenses % PROFITABILITY RATIOS BASED ON 80% UTILISATION Profit after Tax = 4.19 Sales Profit before Interest and Tax = 7.07 Total Investment Profit after Tax = 4.19 Promoters Capital BREAK EVEN LEVEL Fixed Cost (FC): [Rs. lakhs] Wages & Salaries 6.83 Repairs & Maintenance 0.73 Depreciation 1.08 Admin. & General expenses 2.65 Interest on TL Profit Before Tax (P) 6.32 BEL = FC x 100 = x 80 FC +P % 44% 67% x % of installed capacity Or Production volume lacs pieces or Sales value Rs lacs 9
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