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Submitted by
YEDLA SATYANARAYANA
Gondu street, Narasannapeta
Srikakulam Dist.
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CONTENTS
EXECUTIVE SUMMARY
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7 NAME & ADDRESS OF SATYANARAYANA
ENTREPRENEUR Vill,
Srikakulam.
Pin:
8 LOCATION OF THE UNIT NH 5, Near Pydithalli Temple
,
NarasannapetaMandal,
Srikakulam Dist.
9 TOTAL PROJECT COST Rs. 15,00,000
10 COST OF PRODUCTION (PER ANNUM) Rs. 2,79,480
11 SALES REVENUE (PER ANNUM) Rs. 97,395
12 NET PROFIT RATIO 25.8 %
13 RATE OF RETURN ON INVESTMENT 19.4 %
14 BREAK EVEN POINT 52.7 %
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INTRODUCTION
INTRODUCTION
Plastic containers are replacing conventional metal containers and glass containers
because of their comparatively better properties and ease of handling and
transportation. Small size plastic containers are used for packing of drugs,
pharmaceuticals, insecticides, food items etc. The plastic blow moulded containers are
made from HDPE, HMHDPE, LDPE, PP etc. Blow moulded plastic containers are finding
great demand in modern era. With latest trends in Blow Moulding technology and
advanced machinery and National and International standards moulds and dyes,
many types of packaging containers are manufactured with accurate tolerance and
fine quality. These products includes Pet bottles, Dropper bottles, Upper Handle
bottles, Open top drums, wide mouth drums, Narrow mouth drums, Barrels, Jerry
Cans & Carboys, Square Jars, Round Jars, Rib Jars, Thin walled food packaging
containers etc. They are of different types and designs that are manufactured to cater
the need of packaging.
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With high quality raw materials procurement, blow moulded articles and containers
are manufactured with superior quality associated with convenient shapes and sizes,
Strong and Sturdy construction, Compact designs, Compatibility, Safe to use etc. As
there is very good demand for plastic containers of various sizes and shapes, I am
planning to set up this unit with assurance of that this is a profit oriented trade.
Though there are lot of products can be manufactured by blow moulding technology,
Initially, I am planning to manufacture only Jerry Cans of 1 Lt, 2 Lt, 2 ½ Lt, 5 Lt, 10
Lit and 20 Liters filling capacity. I would like to maintain the following in order to
fulfill the needs of our clients and consumers and I hope I can capture good market.
Strong and Sturdy: The products are made out of special grade High
Molecular - High Density Polyethylene (HMHDPE) or High Density Polyethylene
(HDPE) with excellent strength to withstand all transit hazards in any
conditions.
Standard Designs: it includes wide range of latest & standard designs in
packaging products to provide the client or end user with latest innovative
designs and products with ease in handling to provide with complete bulK
packing solutions.
Compatibility : The material used in production i.e. High Molecular High
Density Polyethylene is of food grade (certified) and compatible with food
chemicals, petroleum products, hazardous chemicals, Resins etc.
Safety : The products goes through with multiple tests to pass all of them
and use certified virgin raw material only to give you the complete packing
solution.
Packaging Standards: The products are also confirms national and
international packaging standards and are listed with IIP (Indian Institute Of
Packaging) to provide you UN Certification and other testing requirements.
Price: Believing in right & fair price policy, in which we are ready to share
information to make the customer or end user comfortable about on their
purchasing decisions.
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BASIS & PRESUMPTIONS
The Production is considered on single shift basis and the working days in a
month are 25 and that of per annum is 300.
Though the unit is run with Blow moulding technology, many types of plastic
articles and household items can be manufactured. But, Initially, Jerry Cans
of 1, 2, 2 ½, 5, 10, 20 Liter Capacity would be manufactured in the proposed
unit.
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Out of total production, 20 % of 20 Liter, 15 % of 10 liter, 15 % of 5 Liter, 20
% of 2 ½ Liter, 20 % of 2 Liter, 10 % of 1 Liter capacity Jerry cans are
manufactured.
The weight of 20 Liter Jerry Can is 1000 Grams and that of 10 liter Jerry Can is
500 Grams, 5 Liter Jerry Can is 200 Grams, 2 ½ Liter Jerry Can is 110 Grams,
2 Liter Jerry Can is 90 Grams and 1 Liter capacity Jerry can is 50 Grams.
Wastage in the Raw materials and process losses has been considered at a
rate of 2 %.
The final products are marketed with a brand name i.e TOUGH PLAST. For
this, multicolour stickers are pasted on the can. These stickers are from third
party. The cost of each sticker is sack is 50 paisa with roto gravure printing.
The salaries and wages for staff and labour have been taken into consideration
as per the Minimum Wages Act.
Economics have been worked out with out the subsidy (35% on Total Capital
Investment under PMEGP Scheme) component. With the subsidy its viability
will be much better.
The cost of plant and machinery, Raw materials, selling price of finished
products etc. are the prices collected at the time preparation of project report
and may vary depending upon location, manufacturers, market and other
various reasons.
Interest on term loan has been taken at the rate of 12% on an average. This
rate may vary depending upon the policy of the financial institutions/agencies
from time to time.
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BIS SPECIFICATIONS
SCOPE
STANDARDS
Sl No. IS No. Title
IS 7408(Part 1/Sec Blow moulded polyolefin containers Part 1 Up to 5
1
0):2000 litres capacity (second revision)
Blow moulded polyolefin containers Part 2 Over 5
IS 7408(Part 2/Sec
2 litres up to and including 60 litres capacity (first
0):2000
revision)
3 IS 7408(Part 3/Sec Blow moulded polyolefin containers Part 3 Closed
0):2000 head containers over 60 litres, up to and including 250
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Sl No. IS No. Title
litres capacity (first revision)
Methods of tests for environmental stress-crack
4 IS 8747:1977
resistance of Blow moulded polyethylene containers
Blow moulded HDPE containers for packing of
5 IS 10840:1994
vanaspati (second revision)
IS 15473(Part 0/Sec Blow moulded HDPE containers for packaging of
6
0):2004 edible oil - Specification
PROCESS OF MANUFACTURE
Blow moulding follows the same stages of manufacture as injection moulding. HDPE
(high density polyethylene) is ideal for this type of manufacturing technology. The
steps in the formation of any container (the die is changed for each product and
specific design) are…
1. The plastic is fed in granular form into a 'hopper' that stores it.
heated section.
3. In this heated section the granules melt and become a liquid and the
4. Air is forced into the mould which forces the plastic to the sides, giving
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STEPS INVOLVING IN BLOW MOULDING PROCESS
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LOCATION OF UNIT
BRAND NAME
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FINANCIAL ANALYSIS
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FINANCIAL ASPECTS
A. FIXED CAPITAL
VAT @ 4 % 39,800
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B. WORKING CAPITAL PER MONTH
3. UTILITIES
ANNEXURE
SL.NO. MACHINE POWER LOAD
i Blow moulding Machine 4 ½ ‘’ 15 HP
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ii Blow moulding Machine 2 ½ ‘’ 7.5 HP
iii Scrap Grinder 5 HP
iv Dry Colour Mixer 5 HP
v Air Compressor 1 HP
vi Pumpset Motor 1 HP
TOTAL 34.5 HP
As the machines run intermittent, the connect load of all
4. OTHER EXPENSES
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SL. PARTICULARS AMOUNT IN RS.
NO
1 Total Working Capital Cost 48,00,000
3 Depreciation @ 10% on Machinery & Equipment 99,500
3 Depreciation @ 15% on Furniture & office equipment 3,000
4 Interest on Total Investment @ 12 % 1,80,000
TOTAL 50,82,500
SALE OF…
6,996 Dozens of 1 Liter Jerry Can @ Rs. 80 Per Dozen Rs. 5,59,680
7,776 Dozens of 2 Liter Jerry Can @ Rs. 144 Per Dozen Rs. 11,19,744
6,348 Dozens of 2 ½ Liter Jerry Can @ Rs. 176 Per Dozen Rs. 11,17,248
2,628 Dozens of 5 Liter Jerry Can @ Rs. 319 Per Dozen Rs. 8,38,332
12,600 Nos of 10 Liter Jerry Can @ Rs. 67 Per each piece Rs. 8,44,200
8,400 Nos of 20 Liter Jerry Can @ Rs. 133 Per each piece Rs. 11,17,200
PROFITABILITY ESTIMATES
PROFIT RATIO
Net Profit per year
Net Profit Ratio = -------------------------- X 100
Annual Sales Revenue
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4,01,976
= --------------- X 100
54,84,476
= 7.3 %
4,01,976
= -------------- X 100
15,00,000
= 26.7 %
FIXED COST
(In Rs.)
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TOTAL 7,02,452
Fixed Cost
B.E.P. = --------------------------- × 100
Fixed Cost + Profit
7,02,452
B.E.P. = -------------------------- × 100
7,02,452 + 4,01,976
= 63.6 %
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O.B : Opening Balance
C.B : Closing Balance
MACHINERY SUPPLIERS
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3rd Mamletdar Wadi, Malad (W),
Mumbai-400 064.
Tel : 28822243/28821708/28821632
MACHINE DETAILES
BLOW MOULDING MACHINE
FEATURES
• Fully standarised machine of very compact design.
• Heavy duty extrusion unit fitted with nitrided screw and barrel
• Vertical head, accumulator type, robust construction with streamlined flow
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channels.
• Direct hydraulic screw drive is available optional, extra. This results in low
installed power and power consumption.
• Accurate parison programming unit is provided to obtain parison of
adjustable profile.
• Rapid, direct hydraulic clamping unit is provided with cushioned mould
closing and opening features, to avoid damage to machine and mould.
• Adequate system and operational safety is provided. Automatically
operating safety gate is fitted.
• Available with conventional contractor-timer panel or microprocessor panel
at option.
• Very low power consumption even on full load results in lower operating
costs.
• Standard machine available upto 100 litres size, 200 litres machine is
available on request for J ring and L ring drums.
• Most widely used machine for moulding plastic drums, carbuoys, jerry
cans, water pots, tanks, baby-cycle seats, wheels, large toys like horse,
elephant, hippo, etc.
SCRAP GRINDER
FEATURES
Rugged construction. Chamber is machined from thick M.S blocks to withstand
•
heavy grinding loads.
Balanced rotor ensures smooth operation and long bearing life. Blades are
•
hardened and toughened.
Rotor is specially designed for large intake and efficient cutting of scrap feed.
• Blades on the rotor are easily changeable and the blade-nip can be varied by its
adjustment device.
Heavy duty gauge sheet metal hopper and outlet chute, retains form even after
•
long use.
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SPECIFICATIONS:-
MODEL GR-8 GR-10 GR-12 GR-15
Blade Size mm 200 260 300 380
No.of blades Rotating x 2X4 2X4 4X4 4X4
stationary
Out-put kgs/hr 35 75 90 100
Electric motor HP 2 5 7.5 10
Approx. floor space mm 550 X 525 600 X 600 750 X 700 1500 X 900
Approx. height of machine mm 1000 1200 1350 1500
Approx.nett weight of machine kgs. 150 200 300 500
Approx. packing size mm 650 X 650 X 700 X 700 X 850 X 850 X 1550 X 900
1050 1260 1400 X 1550
Approx packed weight kgs. 275 375 600 700
HIGH SPEED MIXER
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QUALITY CHECKING TESTS
1. DROP TEST
For testing purpose, each drum was filled with their capacity of water and closed by
Plastic Plug (Insert) and further with P.P. (auto seal) Plastic Cap.
Full Open Top Drum filled with their capacity of sand and closed with plastic lid
provided with rubber gasket and lid was reinforced by metallic lever type ring closer.
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OTHER BLOW MOULDED CONTAINERS
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WIDE MOUTH JAR
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JERRY CANS
SQUARE CONTAINERS
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ROUND CONTAINERS
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WIDE MOUTH CONTAINER
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CHEMICAL CONTAINERS
SPECIAL PRODUCTS
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ACCESSORIES
MOULDS
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10 LITERS FLEET JERRY CAN MOULD
Size: 272 x 345 x 435 (H x W x L)
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SL. PROBLEM CAUSE SUGGESTED REMEDY
NO.
1 Streaking a) Contamination in die a) Clean die head
head b) Clean tooling
b) Degraded material on c) Raise temperature & check
tooling heating bands
c) Cold spot in tooling
or die head
2 Rough surface a) Insufficient venting a) Add venting by either
finish b)Material temperature sandblasting the mould
too low surface adding channels on
c) Air pressure too low the mould faces or venting
or rate of air flow too the interior of the mould
slow b) Check fuses, heating bands
d) Air leakage around and thermocouples. Raise heat
blow pin inputs
c) Check air pressure and air
lines for foreign material
d)Increase blow pin diameter
3 Parison not a) Blow timer defective a) Replace blow timer
being blown b) Clogged blow lines b) Clean blow lines
c) Pinch-offs too sharp c) Stone pinch-offs to create
d) Clamp not cushioning more pinch area
e) Cut parison d) Reset cushion
e) Clean tooling
4 Air bubbles in a) Insufficient back a) Clean back pressure valve
parts pressure and reset
b) Air leaking into head b) Check fit of mandrel in
c) Nozzle valve not forming pin
seated properly c) Check seat of spool to
prevent air from being
drawn in by movement of
spool
5 Varying parison a) Parison not dropping a) Adjust centre bushing
wall thickness straight b) Tighten mandrel on mandrel
b) Loose mandrel stud; and check fit of mandrel
c) Parison not centred in forming pin
with mould c) Check alignment of mould
d) Loose forming pin with parison
d) Tighten forming pin and
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check O.D
6 Poor colour a) Insufficient number a) Remove screw and clean
dispersion of straining rings on straining
screw b) Check ratio of coloured
b) Poor blending of resin to natural resin
material c) Raise back pressure to
c) Back pressure too improve mixing by screw
low d) Change screens
d) Clogged screen pack
7 Inadequate a) Stripper stroke not a) Adjust knockout stroke for
stripping of long enough longer movement
moulded parts b) Insufficient air b) Check air pressure and lines
pressure c) Lengthen exhaust time,
c) Parts sticking in check for large undercut
mould
8 Parison curling a) Mandrel and bushing a) Remachine tooling
not flush b) Raise bushing temperature
b) Bushing too cold
9 Flashing a) Melt too hot a) Reduce melt temperature
b) Blowing air pressure b) Reduce air pressure
too high c) Reset clamp or increase
c) Clamping mechanism clamp pressure
out of d) Increase recess at pinch-off
adjustment areas to accommodate
d) Excessive material more material
being forced into mould
10 Warped or a) Slow parison a) Check extruder rate
deformed parts extrusion b) Increase melt temperature
b) Melt temperature too c) Increase cooling cycle
low d) Review and alter mould
c) Parts ejected too hot design if necessary
d) Design of ribs,
undercuts, threads, etc.
inappropriate
11 Excessive a) Mould temperature a) Reduce mould temperature
shrinkage too high b) Decrease melt temperature
b) Melt temperature too c) Increase blowing air cycle
high and / or blowing air
c) Blowing air conditions pressure
inadequate
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12 Parts blow-out a) Blow-up ratio too a) Use large die
large b) Increase clamp pressure
b) Mould separation or decrease blow pressure
c) Pinch-off too sharp c) Provide wider land in
d) Pinch-off too hot; no pinchoff
weld d) Cool Mould pinch off
e) Parts blow too fast e) Use low-pressure blow
followed by high-pressure
blow
13 Parison tail a) Parison too long a) Shorten parison length or
sticking to parts increase pinch-off land area to
cool compressed tail.
ANNEXURE
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Basic VDA for 276
Sl.No. Name of the Category Total wage
Wage points
1 2 3 4 5 6
1 Highly Skilled 4479.00 9.00 2484.00 6963.00
2 Skilled 2854.00 5.75 1587.00 4441.00
3 Semi-skilled 2404.00 4.75 1311.00 3715.00
4 Unskilled 2024.00 4.00 1104.00 3128.00
5 Office Staff
I) Manager 4237.00 8.50 2346.00 6583.00
ii) Steno/Accountant 2854.00 5.75 1587.00 4441.00
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