Project Report On Biodegradable Carry Bags
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EIRI Board of Consultants and PublishersProject Report On Biodegradable Carry Bags
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EIRI Board of Consultants and PublishersBIODEGRADABLE CARRY BAGS
[EIRI/EDPR/3925] J.C.: 2047
INTRODUCTION
Bio-plastics can be defined as plastics where part or all of the material is derived
from renewable biomass resources. For the purposes of clarity we will refer to bio-
based plastics as those made from plant-based molecular sources. The term ‘bio-
based’ must not be confused with the term ‘biodegradable’ which refers to the
natural breakdown of a material at the end of life disposal phase. Not all bio-based
polymers are biodegradable and not all biodegradable polymers are bio-based;
some biodegradable polymers only biodegrade under specific circumstances.
With the introduction of plant-based bio-PE as a ‘drop-in’ alternative to fossil-
derived PE (offering a direct replacement to its fossil based equivalent), coupled
with an increase in the production capacity of these bio-polymers, it is becoming
increasingly difficult to ignore the potential that bioplastics offer to improving the
sustainability of plastic products. They are making an impact on the wider
plastics market, in part because:
As a result of increased demand and finite supply there is a long term
upward trend in the cost of fossil based resources. As a result demand for
bio-plastics is rising strongly year on year at a rate of 20-100%.
The resources used to make bio-polymers are predominantly annual crops
(such as corn and sugar beet) or perennial cultures (such as cassava and
sugarcane) and as such are considered renewable.
Bio-based plastics present a unique opportunity to reduce greenhouse gas
(GHG) emissions or even become carbon neutral.
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The production costs of sugarcane bio-ethylene across the globe are summarised
in Table. Overall the current production cost of bio-ethylene is between 1.1-2.3
times higher than the global average petrochemical ethylene, but ligno-cellulosic
bio-ethylene is expected to reduce the gap in the near future to the point where
bio-ethylene could be less expensive than fossil-based ethylene.
Table Average production cost of bio-ethylene
With regards to the cost of feedstock’s used to produce polymers the market
conditions are quite variable. Currently according to the Market Price Information
and Comparison of Price Indexes and IMF Commodity Price Forecasts for crude
oil, sugar, and cereals, the trend in the price of oil is stable to falling, based on a
growing supply of shale oil in the USA. The price of cereals is also not trending up
and the price of sugar is projected to strengthen slightly. On this basis, the trend
in the short term cost of oil-based ethylene is likely to be stable to falling, and the
trend for bio-based ethylene from sugarcane ethanol is likely to be stable to rising.
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However, large scale production of ligno-cellulosic ethanol will enable a significant
fall in the cost of bio-ethylene, but as it will take at least five years to develop and
construct such a plant, it must be considered that few will start up before 2020.
The longer term trend (10 – 20 years) is expected to see renewable sources of bio-
ethylene remain more stable and exhaustible sources of oil-ethylene follow a rising
trend as supplies dwindle. However, there is no guarantee on the predicted costs
into the future as has been shown with the impact of shale gas in recent years.
Total world petroleum-based ethylene production capacity (including oil-based
naphtha and ethane, propane and butane (natural gas liquids (NGLs)) reached
138 million tons per year (Mtpa) in 2011. The global demand for ethylene is
expected to increase at a higher rate than the gross domestic product (GDP) rate
of 3.9% through to 2020.
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Another bio-based polymer, Poly Lactic Acid (PLA) initially led bio-based plastic
production globally, but Braskem became the world’s leading bio-based plastic
producer when its 200,000 tons per year bio-PE plant, based in Brazil, started up
in 2011. One of the key attributes of bio-PE is that it’s a ‘drop-in’ replacement for
oil-based PE and as such there is no obvious technical obstacle to growth of
demand in the market. Bio-PE has quickly attracted the attention of leading
brands such as Procter and Gamble who were early adopters, announcing their
bio-HDPE bottle for Pantene shampoo in April 2011. It is understood that
Braskem’s production is currently sold out to these premium end users, and there
is no other bio-PE producer available in the market at present. This is a potential
constraint on the introduction of bio-PE for SUPCBs in the short term.
Although SUPCBs are a much lower value product than those which currently use
bio-PE they also have very low material content so the additional cost of
converting them from oil-based PE to bioPE is likely to be very small when
compared to the expected 5p charge for SUPCBs in England.
The current world production capacity of bio-ethylene monomer is about 375
kilotons per annum (ktpa), of which 200 ktpa are used for producing bio-PE
polymer. The capacity and status of known plants and projects, based on
information from multiple sources, are shown in Table.
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Table Capacity and status of known plants and projects (bio-PE and bio-E)
Biodegradable (PE) plastic bags own almost the same qualities as ordinary plastic
bags. Biodegradable plastic bags differ mainly through its composability (biological
reduction).The underlying technology is based on special additives which, if
incorporated into standard PE resins, are purported to accelerate the degradation
of the film products. Degradable PE films can help lessen the problem of plastic
wastes. By using degradable plastics, farmers can protect their horticultural crops
from harsh elements like too much sun, wind, rain, and diseases, without
significant negative effect on yield, quality, and heavy metal content of these crops
as well as on soil properties.
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CONTENTS
INTRODUCTION
TABLE AVERAGE PRODUCTION COST OF BIO-ETHYLENE
TABLE CAPACITY AND STATUS OF KNOWN PLANTS AND PROJECTS
(BIO-PE AND BIO-E)
BIODEGRADABLE BAGS
BIOPLASTICS AND BIODEGRADABLE PLASTICS
BIOPLASTICS
BIOPOLYMER
INGREDIENTS:
BIODEGRADABLE POLYETHYLENE BAGS
INGREDIENTS:
TYPES OF BIO PLASTIC
1) STARCH BASED OR BIOBASED (HYDRODEGRADABLE)
EXAMPLES OF POLYMERS WITH WHICH STARCH IS COMMONLY USED:
2) ADDITIVE BASED (OXODEGRADABLE/PHOTODEGRADABLE):
A) PROS & CONS OF STARCH BASED TO ADDITIVE BASED FILM/BAG
COMPARISON OF PHYSICAL PROPERTIES COMPARE TO OTHER POLYMERS:
THE BREAK DOWN CAUSED BY MICROORGANISM CAN BE OF THREE
DIFFERENT TYPES:
STARCH BASED PLASTICS
BACTERIA BASED PLASTICS
SOY BASED PLASTICS
CELLULOSE BASED PLASTICS
LIGNIN BASED PLASTIC
USES AND APPLICATION OF BIODEGRADABLE FILM/BAGS
COMMON MATERIALS USED FOR BIODEGRADABLE/DEGRADABLE FILM:
AVAILABLE THICKNESS
TOLERANCES:
BIODEGRADABLE/DEGRADABLE BAGS CAN BE USED FOR ANY
APPLICATION HOWEVER IT IS POPULAR FOR FOLLOWING USE:
CURRENTLY USED:
COMPOSTABLE BIODEGRADABLE BAGS
TYPES OF BAGS
POSITIVES OF USING BIODEGRADABLE BAGS AND IT’S IMPACT ON
ENVIRONMENT
REASON FOR USING BIODEGRADABLE BAGS IN INDIA AND FUTURE
IN INDIAN MARKET
MARKET OVERVIEW OF BIODEGRADABLE PLASTIC BAGS IN INDIA
OVERVIEW OF BIODEGRADABLE PLASTIC & PACKAGING
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TWO MARKET SEGMENTS ARE DRIVING THE SURGE:
MARKET OVERVIEW OF BIODEGRADABLE BAGS
FUTURE OF BIODEGRADABLE PLASTICS
BIODEGRADABLE PLASTICS WOLDWIDE
BIODEGRADABLE PLASTICS IN EGYT
BIODEGRADABLE PLASTICS APPLICATIONS WORLDWIDE
BIODEGRADABLE PLASTIC APPLICATIONS IN EGYPT
BIODEGRADABLE PLASTIC BAGS GLOBALLY
BIODEGRADABLE PLASTIC BAGS IN EGYPT
MANUFACTURERS/SUPPLIERS OF BIODEGRADABLE CARRY
BAGS/GARBAGE BAGS
OUTLINE OF MANUFACTURING PROCESS
MANUFACTURING PROCESS OF BLOWN FILM EXTRUSION PROCESS
AND BAG MAKING
PROCESS FLOW DIAGRAM
RECIPE OF PLA BIOPLASTICS
PROCESSING STEPS TO MANUFACTURE FILM & BAGS
EXTRUSION PROCESS
ELEMENTS OF BLOWN FILM
BLOW-UP RATIO (BUR)
COEXTRUSION OF BLOWN FILM
BIOPLASTICS AND BIODEGRADABLE PLASTICS
BIOPLASTICS
A RECIPE FOR PLA BIOPLASTICS
BIODEGRADABLE PLASTICS
SWOT ANALYSIS
RAW MATERIALS
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIALS
BIODEGRADABLE GRANULES
SUPPLIERS OF PRINTING INKS
SUPPLIERS OF PACKAGING MATERIALS
SUPPLIERS OF LUBRICANTS
SUPPLIERS OF RAW MATERIALS (IMPORTED)
SUPPLIERS OF PLANT AND MACHINERY
DIE CUTTING PUNCHING MACHINE
FLEXOGRAPHIC PRINTING MACHINE
BOTTON SEALING & SIDE SEALING MACHINE
SLITTING MACHINE
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LOOP HANDLE MAKING MACHINE
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF D.G. SETS
SUPPLIERS OF DIES
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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COST ESTIMATION
Plant Capacity 800 Kg./Day
Land & Building (19,600 sq.ft.) Rs. 1.15 Cr
Plant & Machinery Rs. 49 Lac
Working Capital for 1 Month Rs. 64 Lac
Total Capital Investment Rs. 2.50 Cr
Rate of Return 39%
Break Even Point 52%
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