A. INTRODUCTION:
Indian Paper Industry which is over 100 years old, was saddled with many
constraints, not of its own making, which have prevented it from growing to
its full stature.
availability
good
of
raw
materials
modernisation
efforts
are
being
presses for wall posters and also for printing tickets, vouchers, etc..
The
The main
The major
1.
80-180
2.
60-80
3.
60-70
4.
60-70
5.
50-60
6.
60-70
7.
Blue Match
36-40
8.
Grey Poster
40-60
9.
40-60
C. MARKET POTENTIAL
INDUSTRY SEGMENTATION
Does paper have a future in the digital age? Ultimately, it is a question best
answered by the needs of the consumers, but based on the global demand
outlook, consumers still want paper well into the 21st century. World
demand for paper has doubled in the past 20 years and it is forecast to
double again by the year 2010.
Per capita consumption of paper & paper board in India at 5 Kg is very low
compared to other developing countries like China (17.2 Kg), Brazil (28 Kg)
for the year 2000. Therefore, despite the threat of paperless transaction,
scope for paper demand appears to be bright. In developed nations it is as
high as 152 Kgs per annum.
The challenge for the Indian paper industry to meet the ever-increasing
demand of paper, board and newsprint is getting crippled due to shortage of
fibres in the country. The future demand of paper is expected to grow from
5.6 MT at present TO 9.5 MT in 2010 and 13 MT in 2015. Demand for cream
wove paper and Map litho paper is expected to increase by 7-8%. Demand
for different kinds of coated paper has increased by 8% in 2002, duplex
board has recorded increase by 6.5%, kraft paper has registered a 6% rise in
demand and newsprint an impressive 10%.
It is also worthwhile to know the demand from the packaging sector which
has registered tremendous changes in the recent past.
market prospectus for paper products appears to be good and the demand
for industrial paper is expected to grow at faster rate than general paper
industries growth.
D. TECHNICAL ASPECTS:
Installed Capacity
The installed capacity per day is 20 MT per day.
Particulars
A. Waste paper pulping section:
2
3
4
5
Hydro pulper
Stock Pump
High Density Cleaner
Turbo Separator T 400
2
1
1
1
6
7
8
9
1
1
1
6
10
11
12
13
14
15
Stock Pump
Single Disc Refiner
Double Disc Refiner
C.L. Box
Fan Pump
Centricleaner (A) - 1000 LPM
7
1
1
1
1
3
16
Centricleaner (B) -
17
18
19
20
1
1
1
1
21
22
23
Framing
MG Blower, Double Line
Pope Reel
1
1
1
500 LPM
Nos.
24
25
26
Reeling Shell
Machine Drive Arrangement
Couch Pit Pump
10
4
1
27
Backwater Pump
28
Rewinder
MANUFACTURING PROCESS :
1
1
The process to be adopted for manufacturing paper from waste paper is the
conventional method of mechanical pulping. This process is a well
established one.
The major stages involved in the process are pulping, stock preparation and
paper making. It is a continuous process.
PULPING:
Waste paper is sorted manually to remove impurities and then transported
to the hydro pulper.
Further impurities like stapler pins, etc. are removed in the sand
trap.
separator after which the pulp is thickened to 4% consistency level and fed
through refiners to obtain the requisite degree of fineness. The waste paper
pulp is taken to the next section.
STOCK PREPARATION:
In this section, the pulp is treated with chemicals, necessary filling materials
and dyes are added to it. The various chemicals and dyes added to the pulp
are normally Alum, Rosin, Caustic Soda, Silicate, Acid orange, Methy Violet,
Malaite Green,Direct Black etc. to obtain various grades of paper.
The requirement of various chemicals and the quality varies with variety of
paper to be produced. The treated pulp which is ready for paper making is
kept in the stock chest with continuous stirring up with the help of
agitators.
The pulp stock is then sent to head box of paper machine after
PAPER MAKING:
Paper making process consists of two stages 1. Wet Stage
2. Dry Stage
Machineries in the wet stage are generally called wet part and similarly dry
stage machineries called as dry part.
In the wet part an endless wire mesh running on rolls will continuously
drain water from the pulp.
This is now lifted off and sent through a press for further
removal of water.
The web is now dried over steam heated MG cylinder where the dry part
starts. The paper obtained after drying is the final product with
monoglazing.
Final
product is slit and rewound paper core into reels and labelled.
Various grades of paper with different grammage are manufactured by
adjusting the valve and sluices at the Head Box.
The plant can be run continuously for a given variety of paper without
interruption. However, to change over from one variety to other, the paper
making operation has to be interrupted depending on the changes required
to be made either in pulping stage or in stock preparation.
Raw Materials
also added based on the high burst factor requirement in the final product.
Apart from paper, a few chemicals and dyers are required in small
quantities.
The steam
Nos.
Works Manager
10000
10000
Supervisors
6000
18000
Electrical engineer
6000
6000
Mechanical eng.
6000
6000
Finishing/godown/store.
4000
12000
Skilled
30
4000
120000
Semi skilled
21
3000
63000
Unskilled
24
2500
60000
Security
2500
15000
Managing Director
12000
12000
Finance Manager
10000
10000
Marketing Manager
9000
9000
Sales Representative
6000
12000
Accountant
5000
5000
Assistant
4000
12000
370000
Add : Benefits
20%
Total
74000
444000
Rs.53.28lakhs
7. IMPLEMENTATION SCHEDULE:
The project is implemented within 6 months period.
8.
ASSUMPTIONS:
11.
12.
MACHINERY SUPPLIERS
1. Scan Machinery Private Limited, Thudiyalur, Coimbtore
2. M/s.Pat Parth Engineers Ltd., 3rd Floor, Shivam Complex, Bhuyang Dev
Char Rasta, Ghatlodia, Ahmedabad 380061
3.
RAW MATERIALS
1. COST OF PROJECT
Rs.lakhs
Land 3 acres
15.00
Building
48.00
220.00
Electrical
45.00
15.00
Pre-Operative expenses
30.00
Margin for WC
29.90
Total
402.90
175.90
Term Loan
227.00
Total
402.90
Rs.lakhs]
1
6000
6000
6000
60%
70%
80%
3600
4200
4800
Rs.23,000per MT
828.00
966.00
1104.00
Raw Materials
342.00
399.00
456.00
Consumables
118.80
138.60
158.40
Power
77.35
90.24
103.13
Fuel
72.00
84.00
96.00
53.28
55.94
58.74
6.00
6.60
7.26
74.39
56.10
42.35
743.82
830.48
921.88
24.00
25.20
26.46
Selling expenses
24.84
28.98
33.12
27.24
23.84
17.03
15.37
15.37
15.37
835.27
923.87
1013.86
-7.27
42.13
90.14
0.00
14.27
30.54
-7.27
27.86
59.60
Add: Depreciation
74.39
56.10
42.35
Cash Accruals
67.12
83.96
101.95
Total
4. WORKING CAPITAL:
Months Values
Margin
Consumptions
Bank
Amount Finance
Raw Materials
2.00
57.00
25%
14.25
42.75
Finished goods
0.50
30.99
25%
7.75
23.24
Debtors
1.00
69.00
10%
6.90
62.10
Expenses
1.00
1.00
100%
1.00
0.00
29.90
128.09
157.99
59.60
Sales
Profit before Interest and Tax
Total Investment
Profit after Tax
1104.00
122.54
530.99
59.60
Promoters Capital
175.90
5%
23%
34%
[Rs.lakhs
58.74
7.26
42.35
26.46
Interest on TL
17.03
151.84
FC x 100
FC +P
90.14
=
151.84
241.98
80
100
100