hdpe blow moulding project report
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12-13-1086/1, Plot No.78, Kimty Colony, Shiridi Sai Nagar, Tarnaka, Sec’bad - 500 017.
Tel.: 27016135/40269625, , e’mail:oriolepackaging@gmail.com
Blue Packagingjay
Project Report
on
Mfg. Unit of Blow Moulded Containers
P A C K A G I N G
P A C K A G I N G
Cooling TowersChilling Plant
Air CompressorMoulds
Scrap Grinder
Main MachinerY
Contents
Summary
Introduction
Basis & Presumptions
Process of Manufacture
Blow Moulding Process
Location of Unit
Unit Name
Financial Analysis
Financial Aspects
Break Even Analysis
Repayment Schedule
Machinery Suppliers
Machine Details
Blow Moulding Machine
Scrap Grinder
High Speed Mixer
Quality Checking Tests
Moulds
P A C K A G I N G
Summary
Name of the unit Bluejay Packaging1.
Type of ProjectHDPE (High-density polyethylene)
Blow Moulded Containers2.
Constitution Proprietor ship Firm3.
Production Capacity 170 TPA (Tonnes per Annum)4.
Location of the unit Cherlapally Phase III5.
Total Project Rs. 27,00,000.006.
P A C K A G I N G
INTRODUCTIONPacking Industry is one such industry where lot of SMES are concentrated. In India the consumer
pracking is undergoing adramatic change in recent past. In many Industries the 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 ( High-density polyethylene), LDPE (Low-
density polyethylene ), PP (Polypropylene) etc. Blow moulded plastic containers are finding great
demand in modern era. In replacing the traditional Metal / Non Metal and Glass containers
throughout the world. With latest trends in Blow Moulding technology and advanced machinery
and National and International standards moulds and dies, many types of packaging containers
are manufactured with accurate tolerance and fine quality. To suit the requirement of each and
every product manufacturing. 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. 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 and quality to meet the requirment of one and all.
Though there are lot of products can be manufactured by blow moulding technology. Are hope
ful of aiihably we 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. Share with in a shortening.
P A C K A G I N G
v Strong and Sturdy: The products are made out of special grade High Density
Polyethylene (HDPE) with excellent strength to withstand all transit hazards in any
conditions.
v Standard Designs: It includes wide range of latest & standard designs in packaging
products to provide and meet the requirement of each client or end user with latest
innovative designs and products with ease in handling to provide with complete bulk
packing solutions.
v Compatibility: The material used in production i.e. High Density Polyethylene (HDPE) is of
food grade (certified ) and compatible with food chemicals, petroleum products,
hazardous chemicals, Resins etc.
v Safety: The products goes through with multiple tests to pass all of them and use certified
virgin raw material only to give out complete packing solution.
v Packaging Standards: The products are also confirms national and international
packaging standards and are listed with IIP (Indian Institute of Packaging) to provide UN
Certification and other testing requirements.
v 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.
P A C K A G I N G
The promoter Mr. G. Suresh Babu as an SSI unit. Is the main promoter of Spectrum
Designers. Who is having enough of experience since 2001 closely associated with Dr. Reddy’s
Laboratories in designing. Printing & Packaging of different consumers packs of
Pharmaceuticals manufactured by Dr. Reddy’s Laboratories Hyderabad, as inside ancillary
having successfully assuming the unit, along with other clients.
As backword integration and on also encouraged by lot existing clients who is taking our
services in designing the packing material other literature and advertising and publishing
material right from ides developing and designing stage. Encouraged by the enquires and the
confidence and the assurance offered by the exciting clients and known customers related and
associatis it is thought to promote their unit in the name of ORIOLE PACKAGING as a different
manufacturing unit.
Promoters
P A C K A G I N G
BIS SPECIFICATIONS
SCOPE
a) Formulation of Indian Standards on rigid, semi-rigid and flexible plastic containers, closures and their
methods of test.
b) To co-ordinate with the work of ISO/TC 122 (Plastic Packaging only) so far as it concerns its own scope
of work.
c) To co-ordinate with the work of ISO/TC 61 ‘ Plastics ‘ so far as it concerns its own scope of work.
SCOPE
IS No. TitleSl.No.
IS 7408 (Part 1/ Sec 0): 2000 Blow moulded polyolefin containers Part 1 Up to 5 litres capacity(Second revision)
1.
IS 7408 (Part 2/ Sec 0): 2000
IS 7408 (Part 3/ Sec 0): 2000
Blow moulded polyolefin containers Part 2 Up to 5 litres up to andincluding 60 litres capacity (first revision).
Blow moulded polyolefin containers Part 3 Closed head containersover 60 litres, upto and including 250 litres capacity ( first revision)
2.
3.
IS 8747:1977 Methods of tests for environmental stress-crack resistance of Blow moulded polyethylene containers
4.
IS 1080 : 1994
IS 15473 (Part 0/Sec 0) : 2004
Blow moulded HDPE containers for packing of vanaspati ( secondrevision)
Blow moulded HDPE containers for packaging of edible oilspecification.
5.
6.
TECHNOLOGY
P A C K A G I N G
Blow molding is a manufacturing process that is used to create hollow plastic parts by
inflating a heated plastic tube until it fills a mold and forms the desired shape. The raw
material in this process is a thermoplastic in the form of small pellets or granules, which is
first melted and formed into a hollow tube, called the parison. There are various ways of
forming the parison, as explained below. The parison is then clamped between two mold
halves and inflated by pressurized air until it conforms to the inner shape of the mold cavity.
Typical pressures are 25 to 150 psi, far less than for injection molding. Lastly, after the part
has cooled, the mold halves are separated and the part is ejected.
Parts made from blow molding are plastic, hollow, and thin-walled, such as bottles and
containers that are available in a variety of shapes and sizes. Small products may include
bottles for water, liquid soap, shampoo, motor oil, and milk, while larger containers
include plastic drums, tubs, and storage tanks. Blow molded parts can be formed from a
variety of thermoplastic materials, including the following:
Low Density Polyethylene (LDPE)
High Density Polyethylene (HDPE)
Polyethylene Terephtalate (PET)
Polypropylene (PP)
Polyvinyl Chloride (PVC)
As mentioned above, there are different methods used to form the parison which
distinguish the following three forms of blow molding:
Extrusion blow molding
An extruder uses a rotating screw to force the molten plastic through a die head that forms
the parison around a blow pin. The parison is extruded vertically between the two open
mold halves, so they can close on the parison and blow pin. Pressurized air flows through
P A C K A G I N G
the blow pin to inflate the parison. This is the most common type of blow molding and is used
to manufacture large quantities of relatively simple parts.Injection blow molding
The molten plastic is injection molded around a core inside a parison mold to form the hollow
parison. When the parison mold opens, both the parison and core are transferred to the blow
mold and securely clamped. The core then opens and allows pressurized air to inflate the
parison. This is the least commonly used method because of the lower production rate, but is
capable of forming more complicated parts with higher accuracy. Injection blow molding is
often preferred for small, complex bottles, such as those in medical applications.
Stretch blow molding
The parison is formed in the same way as injection blow molding. However, once transferred to
the blow mold, it is heated and stretched downward by the core before being inflated. This
stretching provides greater strength to the plastic. Stretch blow molding is typically used to
create parts that must withstand some internal pressure or be very durable, such as soda
bottles.
P A C K A G I N G
A Balloonof Material is
Injected BetweenMold Halves
1 2 3Mold ClosesAir Forced In
Pushes MaterialInto Mold Cavities
Mold OpensHollow PartIs Removed
And Trimmed
P A C K A G I N G
P A C K A G I N G
STEPS INVOLVING IN BLOW MOULDING PROCESS
PLASTIC GRANULES DROPPING ON TO SCREW THREAD
HDPE GRANULES
HEATMOULD
FLUID PLASTIC MOVED BY ROTATING SCREW THREAD
HDPE GRANULES
HEATMOULD
HEATMOTOR
P A C K A G I N G
FLUID PLASTIC FORCED INTO MOULD
HDPE GRANULES
MOULD
MOTOR
HEAT
HEAT
AIR BLOWN INTO MOULD FORCING PLASTIC AGAINST THE SIDES
HDPE GRANULES
HEAT
HEAT MOTOR
COMPRESSED AIR
P A C K A G I N G
BIN REMOVED FROM MOULD
HDPE GRANULES
HEAT
HEAT
MOULD
HDPE BINMOTOR
HDPE GRANULES
HEAT
HEAT
COMPRESSED AIR IN
MOTOR
P A C K A G I N G
LOCATION UNIT
We are going to start the unit at Cherlapally Phase III , besides Indian Oil Corporation, we
have taken newly construction building for lease.
PROPOSED NAME OF UNIT & BRAND NAME
We would like the name the production unit as
blue PACKAGINGjay
bluejay
BRAND NAME
P A C K A G I N G
FINANCIAL ANALYSIS
P A C K A G I N G
FINANCIAL ASPECTS
A. Fixed Capital
1. Building (2,300 sft work are a is leased with deposit) : 2,00,000
2. Machinery & Implements
DESCRIPTIONSl.No.
Blow moulding Machine 3 Ltr.1.
Nos RATE ( ` ) AMOUNT IN ( ) `
1 6,44,500.00 6,44,500.00
Blow moulding Machine 500 ml2. 1 5,17,000.00 5,17,000.00
Scrap Grinder3. 1 1,19,600.00 1,19,600.00
Air Compressor4. 1 1,45,128.00 1,45,128.00
Cooler Tower5. 1 51,660.00 51,660.00
Chiller6. 1 2,37,145.00 2,37,145.00
Platform Type Weighing Machine7. 1 15,000.00 15,000.00
Leak Detectors8. 1 1,97,000.00 1,97,000.00
Sub Total 24,31,473.00
Set Moulds9. 15 21,000.00 3,15,000.00
Packing & Forwarding charges @ 5 % 1,2,3,4,5,6,8,10,11 1,05,823.65
Commissioning @ erection charges @ 5% except item no. 1,2,3,4,5,6,8,10,11 1,05,823.65
Sub Total 26,43,120.03
Total Fixed Capital Investment
Sub Total: 26,43,120.00
Furniture & Office Equipment 50,000.00
Total 26,93,120.03 Say `.27,00,000.00
Hopper Loader 10. 1 41,600.00 41,600.00
Vertical Colour Mixer11. 1 47,840.00 47,840.00
Other Machineries 12. 1,00,000.00 1,00,000.00
3. Furniture & Office Equipment 50,000.00 `
P A C K A G I N G
A. Working Capital per month
1. Raw materials & Consumables
MATERIALNo.
HDPE (HIGH DENSITY POLYETHYLENE) Granules1.
QUANTITY UNIT RATE AMOUNT ( ` )
7 Tones 80,000 per Tone 5,60,000.00
Basis & Presumptionsv The production is considered on single shift basis and the working days in a month are 25 and that of
per annum is 300.
v The Installed Capacity of the unit is 480 kg per shift. HDPE Granules is processed to manufacture Jerry
Cans of different shapes and sizes. The time period for achieving fully / envisaged capacity utilization is
three years.
v Though the unit is run with Blow moulding technology, many types of plastic articles and households
items can be manufactured. Initially, Jerry Cans of 250 ml, 500 ml, 1 , 2 Liter capacity would be
manufactured in the proposed unit.
v The weight 250 ml capacity Jerry Can is 40 grams, 500 ml capacity Jerry can is 50 grams, 1 liter capacity
Jerry can is 92 grams, 2 Liter capacity Jerry can is 100 grams.
v Wastage in the Raw Materials and process losses has been considered at a rate 2 %.
v The salaries and wages for staff and labour have been taken into consideration as per the Minimum
Wages Act.
v 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,
manufactures, market and other various reasons.
ParticularsSl.No.
Machine operator (Skilled)1.
Nos. Salary ( ` ) AMOUNT ( ` )
1 15,000.00 15,000.00
2. Salary & Wages
Semi Skilled Worker2. 1 8,000.00 8,000.00
Helpers3. 3 5,000.00 15,000.00
Watchman4. 1 5,000.00 5,000.00
Total 6 43,000.00
P A C K A G I N G
DescriptionSl.No.
Electricity1.
Units Rate / Unit AMOUNT ( ` )
13,440 4.13 55,507.20
2.Utilities
MachineSl.No.
Blow Moulding Machine 2 Ltr1.
Power Load
30 HP
Annexure
Blow Moulding Machine 500 ml2. 22 HP
Scrap Grinder3. 5 HP
Air Compressor4. 1 HP
Chiller5. 2 HP
As the machines run intermittent, the connect load of all the machinery and the other lighting, fans etc is 10 HP
Marketing Expenses
ParticularsSl.No.
Own employees 1.
Nos. Salary ( ` ) AMOUNT ( ` )
2 10,000.00 20,000.00
Commission Agent 5% on there billing 2.
Advertising & Publication 3. 15,000.00 15,000.00
Total 6 35,000.00
2
4. Other Expenses
Description Sl.No.
Rent for Building (2300 sft)1.
AMOUNT ( ` )
27,600.00
Repair & Maintenance2. 5,000.00
Stores Consumables3. 4,000.00
Telephone4. 2,500.00
Miscellaneous expenses5. 4,000.00
45,600.00Total
Insurance6. 2,500.00
P A C K A G I N G
Total Capital Investment
Description Sl.No.
Total Fixed Capital1.
AMOUNT ( ` )
27,00,000.00
Total Operational cost2. 7,04,107.00
34,04,107.00Total
Means of Finance
My Contribution (@ 25% on Capital Investment)1. 8,51,026.00
Loan From Bank2. 25,53,081.00
34,04,107.00Total
Packaging & Transportation
Description Sl.No.
Packaging 1.
AMOUNT ( ` )
Transportation 2.
Total
Total Working Capital
Description Sl.No.
Raw Material & Consumables1.
AMOUNT ( ` )
5,60,000.00
Salary & Wages 2. 43,000.00
Utility Charges3. 55,507.00
Other Expenses4. 45,600.00
7,04,107.00Total
Cost of production ( per annum)
Description Sl.No.
Total working capital1.
AMOUNT ( ` )
84,49,284.00
Depreciation @ 10% on Machinery & Equipment2. 2,43,147.30
Depreciation @ 15% on Furniture & office equipment3. 7,500.00
Interest on Total Investment @15%4. 5,10,616.00
92,10,547.00Total
P A C K A G I N G
Sales Realisation ( per Annum)
Description Sl.No.
2400 bottle of 100 ml @ 20 gm wt. @ Rs. 2.50 1.
AMOUNT ( ` )
6,000 x 12
2400 bottle of 250 ml @ 40 gm wt. @ Rs. 4.80 2. 11,520 x 12
2400 bottle of 500 ml @ 40 gm wt. @ Rs. 6.00 3. 14,400 x 12
72,000 bottle of 100 ml @ 40 gm wt. @ Rs. 11.00 4. 7,92,000 x 12
Total
2,47,176.00
96,39,864.00
AMOUNT ( ` )
72,000.00
1,38,240.00
1,72,800.00
95,04,000.00
98,87,040.00
Less Marketing Expenses @ 2.5 %
Net Turnover
PROFITABILITY ESTIMATES
A. Sales revenue per Annum : Rs. 96,39,864.00
B. Cost of production per Annum : Rs. 92,10,547.00
C. Net Profit before Tax (A-B) : Rs. 4,29,317.00
PROFIT RATIO
Net Profit Ratio =Net Profit per year
Annual Sales Revenuex 100
4,29,317
96,39,864x 100=
= 4.5%
P A C K A G I N G
RATE OF RETURN ON INVESTMENT
Rate of Return on investment =Net Profit per year
Total Capital Investmentx 100
4,29,317x 100=
= 12.6%
34,04,107.00
BREAK EVEN ANALYSIS
Description Sl.No.
Rent on Building1.
AMOUNT ( ` )
27,600.00
Depreciation @ 10% on Machinery & Equipment2. 2,43,147.30
Depreciation @ 15% on Furniture & office equipment3. 7,500.00
Interest on investment @ 15%4. 5,10,616.00
14,80,576.00Total
40% Salary & Wages 5. 2,06,400.00
40% Utility Charges6. 2,66,433.00
40% Other Expenses except rent7. 2,18,880.00
Fixed Cost
B.E.P.Fixed Cost
Fixed Cost + Profitx 100=
B.E.P.14,80,576
14,80,576 + 4,29,317x 100=
77.5%=
P A C K A G I N G
Machinery Suppliers
1) M/s AARNA MACHINES PVT. LTD
A-4, Gundecha Building, 3 X H.K. Road, Kandivali (W),
Mumbai - 400067, Maharashtra, India
Phone:91-22-28051466
2) M/s ELGI EQUIPMENT LIMITED
Singanallur, Coimbatore - 641 005, India.
Tel: 422- 2589555
3) M/s GEM Equipments Limited,
S.F. No.103, Avanashi Road, Arasur,
Coimbatore, TN 641 407, INDIA
Phone: 422- 2360013
4) M/s SARO ENTERPRISES
OFFICE & FACTORY: 28,
First Reddy Street, Ekkattuthangal,
Chennai – 600 032
M: 9884068651
5) M/s Progressive Engineers
Mumbai, INDIA.
T: +91-22-25796760 /
32944289 /32953422
P A C K A G I N G
Other Blow Moulded Containers
P A C K A G I N G
P A C K A G I N G
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