Project Profile

For

REPROCEESING OF WASTE PLASTIC INCLUDING

PVC IRRESPECTIVE OF QUANTITY OF GENERATION
OF TRADE EFFLUENT

(PROCESSING CAPACITY: 1 TPD)

Prepared By
Mr. Rangaswamy
S/o Rangappa,
UthuvlliVillage
Chamarajanagar -571313
Ph: 9916283360

1
 Index

A) Introduction 3
B) Products to be manufactured 4
C) Market potential 4
D) Licenses for manufacture, storage and sale 4
E) Production capacity 4
F) Raw materials 5
G) The finished goods standards 5
H) Applications of Products 5
I) Technology and manufacturing process 6
J) Advantages of the manufacturing process 6
K) Building 6
L) Plant and machinery cost 7
M) Quality control laboratory equipments 7
N) Production cost 8
O) Project cost 9
P) Profitability analysis 10
Q) Annexure I 11
R) Annexure II 12

2
A) Introduction:
Plastic is a synthetic material made from a wide range of organic polymers such as
polyethylene terephthalate (PET), high density polyethylene (HDPE), Polyvinyl
chloride (PVC) and low-density polyethylene (LDPE) that can be moulded into a rigid
or slightly elastic form. Plastic materials produced from oil by a chemical process are
nonbiodegradable, light in weight and do not break easily. Any property of a large
number of synthetic polymers materials usually organic that have a polymeric
structure and can be moulded when soft and then set, such materials are subspecies
of a class of materials known as polymers. These are composed of large molecules
formed by joining many, often thousands of smaller molecules (monomers) together.
Other kind of polymers is fine, film, elastomers (rubber) and biopolymers.

The plastic industry, owing to its use in a wide variety of sectors, such as the
automotive, construction, electronics, healthcare, textiles, drink industry, etc., is
amongst the fastest growing markets. (RRN Bhattacharya, 2018). As the world’s
population continues to grow by leaps and bound, so does the amount of plastic
waste that people produce. On-the-go lifestyles require easily disposable products,
such as soda cans or bottles of water and soft drink, but the accumulation of these
products has led to increasing amounts of plastic pollution around the world. As
plastic is composed of major toxic pollutants, it has the potential to cause great harm
to the air, water and land.

Plastic pollution is when plastic has gathered in an area and has begun to negatively
impact the natural environment and create problems for plants, wildlife and even
human population. Often, this includes killing plant life and posing dangers to local
animals. Plastic is an incredibly useful material, but it is also made from toxic
compounds known to cause illness, and because it is meant for durability, it is not
biodegradable. (Amandeep., 2019).

For many years, various methods are tried and tested for processing of
waste plastic. The plastic materials are recycled and low value products are
prepared. Plastic materials which cannot be recycled are usually dumped into
undesirable landfill.

Worldwide almost 20% of the waste stream is plastic, most of which still
ends up in landfill or at worst it is incinerated. This is a terrible waste of a
valuable resource containing a high level of latent energy.

In recent year this practice has become less and less desirable due to
opposition from Government and environmentally conscious community
groups. The value of plastics going to landfill is showing a marginal reduction
despite extensive community awareness and education programs.

Research Centre for Fuel Generation (RCFG) has conducted successful

300 successful pilot trials and commercial trials for conversion of waste plastic
materials into high grade industrial fuel. The system uses liquefaction,
3
 pyrolysis and the catalytic breakdown of plastic materials and conversion into
industrial fuel and gases. The system can handle the majority of plastic
materials that are currently being sent to landfill or which have a low recycle
value.

In reducing toxic effects of plastic wastes on the environment and public

health, waste management plays a major role. For global reduction of plastic
litters and ocean pollution, there is need for improvement in proper plastic
waste collection, treatment and disposal (Jambeck et al, 2015). Various
methods of plastic waste management in practice are land filling, incineration,
gasification, pyrolysis, bio-plastic adoption, reuse and recycling

Catalytic conversion of waste plastic into high value product is a

superior method of reusing this valuable resource.

Recycling Products to be manufactured:

Recycling is a good option after plastic has been reused as many times as one
can and one is ready to dispose of it. Recycling plastic takes less energy than
making plastic from raw materials. However, with a little planning, commitment and
effort, it is easy to make steps towards reducing one’s finished goods footprint. The
biggest impact is made by avoiding plastics in the first place and if that cannot be
done, reuse and recycling are the next best steps. Conscious effort should be made
to reduce the amount of plastic material being used by trying to replace plastic with
something more sustainable whenever possible. Any plastic that has already been
acquired can be reused. More also, used plastic can be recycled to keep it out of the
waste stream as this will serve to reduce demand for new plastic. Recycling will help
to reduce plastic pollution and keep our planet clean and healthy for future
generations. The drawback with this practice is waste collection problems, sorting
problem and high initial cost of machines used in recycling the plastic.

Benefits of Recycling
The benefits of waste recycling include the following:
The process of recycling plastic helps waste management by saving available space in
landfills.
 Recycling conserves the natural resources and the energy that would be
required to produce plastic from scratch.
 Plastic Recycling helps in mitigating global warming and reducing pollution
 Wealth generation - there are companies that pay cash for trash and patronizing the
recycled products saves money because they are less expensive.
. Plastic Recycling recovers the scrap or the waste plastic and reprocesses the material into
useful products.
4
 Plastic Recycling protects the environment.
 Plastic recycling promotes judicial and sustainable use of resources
 Plastic recycling creates green jobs.
 Despite the efficiencies and benefits of most recycling facilities, there can still be some
difficulties involved with the process of recycling plastic. Materials such as dyes, heavy
metals, pharmaceuticals, and sometimes pieces of biodegradable plastic can potentially
contaminate an entire batch of petroleum-based plastics and it will all need to be thrown
away. This is why it is very important for one to follow the guidelines of one’s recycling
company regarding which plastics can and cannot be accepted for recycling.

Steps Involved in Recycling Plastics

Plastic recycling refers to the process of recovering waste or scrap plastic and
reprocessing the materials into functional and useful products. This activity is known as the
plastic recycling process. The goal of recycling plastic is to reduce high rates of plastic
pollution while putting less pressure on virgin materials to produce brand new plastic
products. This approach helps to conserve resources and diverts plastics from landfills or
unintended destinations such as oceans or water courses leading to the municipal.

5
Machine Description and Operation

The waste plastic crusher has four main components; the feeding unit, the crushing
unit, the power unit and the machine frame (See figure 2, 3and 4for details on
pictorial view, orthographic projection and part drawing of the crusher). The feeding
unit is made of mild steel sheet of 6 mm thickness and the machine dimension is
1050 mm ×525 mm x 1250mm. Hopper is the section through which the waste
plastic is fed into the crushing unit. The crushing unit is where the waste plastic is
cut into smaller sizes either through shredding or impact force of a shredder or a
crusher. The crushing chamber consists of a shaft that is 539 mm length and 40 mm
in diameter. Attached to the shaft are cutters made of 12 mm mild steel flat blade
of 270 × 74 welded to 270 mm cylindrical drum to form spiral blade. The radius of
the spiral blade from the centre of the shaft is 53mm. There is a clearance 3 mm
between the spiral blade and the adjustable stationary blade. The rubbing of the
spiral blade against the stationary blade when the machine is loaded with the
materials to be processed brings about the crushing effect on the plates fed in. The
spiral blade has the same length with the stationary blade bolted to the blade holder
on the member frame in the chamber. Underneath the crushing unit is the screen of
375mm length and 392 diameters. The pore space on the screen is 8mm in
diameter. The crushed plastic passes through an outlet provided at the peripheral of
the machine. The outlet dimension is 378 mm × 151 mm x 110mm. The crushed
waste plastic discharge freely from the crushing unit through the outlet (See Figure
6
16 for details). The machine is powered by 10Hp electric motor with the aid of belt
and pulley arrangement (belt drive). The driving and the driven pulley are
respectively 100mm and 150mm. Figure 4 below shows the flow chart of processes
involved in recycling plastic. The processes are plastic waste collection, screen,
sorting, size reduction such as granulation, washing/cleaning, forming into moulds
and packaging.

PLASTIC CRUSHING MACHINE

7
 B) Market Potential:

There is great market potential for there waste products, as these can
be sold atabout 25% less prices. The potential buyers shall be as under:

1) Industries having Plastic Products and etc

2) Industries having electric automotive energy Products
3) Hotels and Resorts having electric generators and diesel stoves.
4) Construction companies.

C) Licenses for manufacture, storage and sale:

Pollution control Board, Permission and license is required for Processing of of Waste
conversion into other Products
.

D) Production Capacity:

Daily 1000 kg. waste plastic shall be processed per day in 3 shifts. On
and average, 700 kgs finished goods is obtained from 1000 kg. municipal
plastic waste.

Conclusions and Recommendations

The plastic crusher is widely used in industries for plastic waste management. By using
this plastic crushing machine, the overall costing of recycling process is reduced and labour
work becomes less. To recycle waste plastic into other forms of plastics, the following machines
are involved: Plastic crusher/shredder, extruder, granulating machine, washing machine, bale
breaker, plastic melting and moulding machine etc. This technical brief focused on plastic crusher.
The following are the conclusions from the evaluation work carried out on the machine:
 The plastic crusher is not a suitable machine for PET bottle recycling.
 The screen size used for the crusher design is small since materials above 8mm cannot flow easily
through it. This in turn affects the feeding rate of plastic into the machine.
 When the machine is in operation, all parts are set in motion due to vibration of major parts like the
transmission shaft. The vibration of parts brings about spill of materials under process out of the
machine through hopper. Lid can be provided for the hopper to prevent material flow out of the
machine.
 The plastic crusher can only be used for small scale recycling of plastic.
 The efficiencies of various type of polymers processed are 90% for HDPE, 68%for LDPE, 45% for
PVC and 10% for PET bottles. Direct implication from this analysis is that the machine is not
suitable for crushing PET bottles. Shredding machine should rather be used for materials of that
nature by processors in the industry.
8
 E) Raw Materials:

The raw materials include following:

1) Polyethylene: Buckets, drums, Chapels, sandal, bottles, plastic

parts, carry bags etc.

2) Polypropylene: Pipe fitting, filter cloths etc.

3) Polyamide: Nylon ropes

4) Polyvinyl Chloride (PVC): PVC pipes and fittings

5) Polystyrene: Cloths and fiber

6) Rubber: Tires, automobile parts

7) Electronic Goods: Telephone sets, computers, keyboards, monitors

laptops, electronic devices etc.

I) Technology and manufacturing process:

Research Centre for Fuel Generation (RCFG) has developed innovative

technology for cracking of plastics by inventing a new catalyst which cracks
the plastic more efficiently in short duration and the conversion of 1000 kg. of
mixed plastic gives about 700 industrial waste. In addition we get about 15%
hydrofinished goods gas and about 80 kg. finished goods black. 80 kg.
finished goodsblack can be converted to 50 kg. activated finished goods.

The technology developed is tested over the period of one year and is
economically viable.

J) Advantages of the manufacturing process:

1) Problem of disposal of waste plastic is solved.

2) Waste plastic is converted into high value fuels.

3) Environmental pollution is controlled.

4) Industrial and automobile fuel requirement shall be fulfilled to some

extent at lower price.
9
 5) No pollutants are created during cracking of plastics.

6) Any type of plastic or rubber can be proceed and converted into fuel.

K) Building(Shed) Rented :
246 Sq.Mtrs.

L) Plant and Machinery Cost:

Qty Description and Specifications

2 Conveyor for shredded plastic / rubber materials for feeding melting machine
2 Horizontal reactor screw type, processing capacity 110 kg. rubber or plastic
processing per hour with stirrer, condenser and receiver
1 Cooling tower: 100TR
1 Sparkler Filter: 8”dia X 8 plates 1 HP

1 Gas collection tank with floating hood, M.S. 1,000 L

1 set Machinery for manufacture of activated finished goods from finished goods black

1 set Pipe fittings, process pumps and electrical fittings with control panel

1 Electricity generation set 20 KVA

1 set Laboratory glassware and equipments

Cost of machinery = Rs. 5,00,000/-

+ Installation and commissioning Charges = Rs. 38,000/-
= Rs. 5,38,000/-

M) R. & D. AND Quality Control Laboratory Equipments:

1. Specific gravity apparatus

2. Hot Air blower
3. Analytical balance
4. Hot plate
5. Glass distillation Unit
6. Water bath
7. Laboratory stirrer

10
N) Production cost:

Production cost:

Raw material: 1000 kg.

(mixed plastic waste) @ Rs. 5 per kg. 5,000
Chemicals /catalyst cost 1,000
Processing cost (electrical) NIL
Fuel cost NIL
Total Production cost
6,000
Administrative cost + salaries 3,040

(Rs. 76000/25 days)

Total production cost 9,040
Production cost
i(Rs. 9040/700 KGS) Interest on 12.91
capital investment / KGS
(Rs. 493050/210000 KGS) 02.34
Depreciation on fixed assets / liter
(Rs. 282500/210000 liters) 01.34
Production cost 16.59

Production cost per kg.:

Raw material: 80 kg.

(finished goods black as by- NIL
product)
Chemicals cost 80
Processing cost (electrical) NIL
Fuel cost NIL
Total Production cost for 50 kg. activated
finished goods 80
Production cost per kg. of Activated
01.60

11
O) Project Cost
Basis:
Products to be manufactured
1) Finished Goods 17,500 kgs per month
2) Activated finished goods 1,250 kg. per month or 15,000 kg. per year

Sr.
No. PARTICULARS Rs. Rs. Rs.
A FIXED ASSETS
Machinery + Pipe fittings +
Installation etc.
1 (As per list enclosed in K above)
2 Land (140 sq.ft.)
3 Factory shed AND SITE (246
sq. Meters
Lab. Equipments, Furniture &
4 Fixtures

Total Fixed assets: 5,38,000 5,38,000

12
B. One month’s production expenses
1 Raw Materials 1,55,000
A Waste plastic 25,000 kg. 1,25,000

B Water and chemicals 30,000

2 Electrical expenses NIL NIL
3 Packing cost NIL NIL
4 Salaries 61,000 61,000
a) Manager 1x Rs.10,000 p.m. 10,000
Production Supervisor 3 x Rs. 5,000
b) pm 15,000
c) Helpers 9 x Rs.4,000/- p.m. 36,000
5 Administrative Cost: Office expenses,
transportation telephone etc. 15,000
Total one month’s recurring
expenses 2,31,000
Two month’s working capital 4,62,000
Fixed assets 5,38,000
Total Capital Investment 10,00,000
Total Project Cost
(In lacs) (round 10,00,000
up)

6 Cost of production per annum

a) production cost
(Rs. 16.59 X 210000 kgs) 34,83,900
b) Activated finished goods
production cost(Rs. 01.60 X 15000 24,000
kg.) 35,07,900
Total production cost
7 Yearly receipts:
a) Finished (210000 KGS
X Rs. 20) 42,00,000
b) Activated finished
goods sale(15000 4,50,000
kg. X Rs. 30) 46,50,000
Total receipts
8 Gross Profit per annum 11,42,100

13
P) Profitability analysis:

1) Rate of return = (Profit per annum / Total capital investment) x 100

= (1142100/1000000) X 100
= 87.55 %

2) Break Even Point = [Fixed cost/(Fixed cost + Profit per annum)] x 100
= [1466700/ (1466700 + 1142100)] X 100
= [1466700/ 2608800] X 100
= 56.22 %

Fixed cost =
Depreciation on fixed assets
@ 15% pa (Rs.538000) = Rs. 80700

+ Recurring cost for 6 months = Rs. 1386000

Rs. 1466700

14
 ProcessFlowChart
Conversionof WastePlasticintoIndustrial raw materials
Process Machine Material Balance
(5%Variabledepending on
Collectionof wasteplastic qualityof Rawmaterial andcatalyst)

Transportationof plastic 1000kgof plastic wasteas

wastetofactory input

Cutting Cutter 1000kgof cut plastic waste

Shreddingof plastic PlasticShredder 1000kgof shreddedplastic

Plastic Meltingmachine
Plastic melting 1000Lof moltenPlastic
screwtype

Plasticevaporation Reactor PlasticVapours

Catalyticcrackingof plastic Catalyst chamber attached Raw materials

vapours toreactors

Condenser attachedto
Condensation
Catalyst chamber

I
In-linestorage HDPEstoragetank

Sparkler Filter
Filtration

Storage Gascollectiontank HydrocarbonGases

15