HDPE/PP Bags Manufacturing Plant Detailed Project Report, Profile, Business plan, Industry Trends, Market research, survey, Manufacturing Process, Machinery, Raw Materials, Feasibility study, Investment Opportunities, Cost and Revenue
Introduction Woven fabric is a textile formed by weaving. It is produced on a loom, and made of many threads woven on a warp and a weft. Wove Woven n poly polypr prop opyl ylen ene/ e/HD HDPE PE bags bags or simply woven PP/HDPE bags are considered
to
be
the
toughest
packaging bags, widely used to pack materials for grain, milling and sugar industry.
HDPE/PP
oriented
strips
are
becoming
increasingly popular in India & have caught the eye of many end users for their requirement of packing materials. They have become popular on account of their inertness towards chemical, moisture & excellent resistance towards rotting & fungus attack. They are non toxic. Lighter in weight
&
have
conventional bags.
more
advantages
than
PP/HDPE
woven
sacks
laminated
with
LDP LDPE/PP E/PP line linerr have have wide widerr appl applic icaation tions. s. HDPE HDPE woven sacks are much stronger & can withstand much higher impact loads because of HDPE strips elongation at break is about 15-25% as compared to 30% of Jute. These sacks are much cleaner & resist fungal attack. Jute prices are very unstable in the market since Jute is an agriculture product.
These sacks have many advantages over other conventional
sacks
materials
&
are
quite
competitive in price. HDPE/PP Woven bags ideally suitable for Buildi lding Material ials, Cement, fertiliz lizers, Urea, Potash, plastic, polymers, plastic pellets, etc. Food grains: Rice, Wheat, Pulses, Tea, Coffee, Beans, Peanuts, Sand, Sugar.
Chemicals:
Pigments,
Dyestuffts,
oxides,
barytes, alumina, hydrates, ores, gypsum, feldspar, mica, Lime, limestone, limestone, Woven Packaging Fabrics, Woven bags and fabrics are often used as an industrial packaging material. The packaging bags and fabrics are available mostly in HDPE (High Density Polythene) and PP (Polypropylene).
Depending on end use these are either laminated,
or
supplied
without
lamination. These materials are valuable for
applications
in
many
different
industries. Any entrepreneur venture into this field will be successful.
Few Indian Few Indian Major Major Players Players are are as as under under
Abdo Abdos s Poly Polyme mers rs Ltd. Ltd.
Ashok Polymers Ltd.
Dalmi Dalmia a Lamina Laminator tors s Ltd. Ltd.
Emmbi Emmbi Indust Industries ries Ltd. Ltd.
Ganpati pati Plast lastfa fab b Ltd Ltd.
Gujarat Raffia Inds. Ltd.
Indra Indra Indust Industrie ries s Ltd. Ltd.
Jajodia Industries Ltd. Karna Karnavat vatii Alfa Alfa Intl. Intl. Ltd. Ltd.
Karu Karurr K C P Pac Packk kkag agin ings gs Ltd. Ltd.
Magnum Polymers (India) Ltd.
Poly Polysp spin in Expo Export rts s Ltd.
Primo Pick N Pack Pvt. Ltd.
Salgut Salgutii Indust Industrie ries s Ltd. Ltd.
Shanka Shankarr Packa Packagin gings gs Ltd. Ltd.
Shiv International Ltd.
Smit Sm ita abh Inte Interc rcon on Ltd Ltd.
Stanp Stanpack acks s (India (India)) Ltd. Ltd.
Timespac India Pvt. Ltd.
Project at a Glance PROJECT AT A GLANCE
(` in lacs)
COST OF PROJECT Particulars
Existing
MEANS OF FINANCE Proposed
Land & Site Development Exp.
0.00
85.00
Buildings
0.00
186.25
Plant & Machineries
0.00
396.57
Motor Vehicles
0.00
12.00
Office Automation Equipments
0.00
Technical Knowhow Fees & Exp.
Total
Particulars
85.00 Capital
Existing
Proposed
Total
0.00
307.86
307.86
186.25 Share Premium
0.00
0.00
0.00
396.57 Other Type Share Capital
0.00
0.00
0.00
12.00 Reserves & Surplus
0.00
0.00
0.00
99.00
99.00 Cash Subsidy
0.00
0.00
0.00
0.00
25.00
25.00 Internal Cash Accruals
0.00
0.00
0.00
Franchise & Other Deposits
0.00
0.00
Long/Medium Term 0.00 Borrowings
0.00
923.58
923.58
Preliminary& Pre-operative Exp
0.00
5.00
5.00 Debentures / Bonds
0.00
0.00
0.00
Provision for Contingencies
0.00
40.00
0.00
0.00
0.00
Margin Money - Working Capital
0.00
382.62
TOTAL
0.00
1231.44
0.00
1231.44
1231.44
40.00 Unsecured Loans/Deposits
382.62 1231.44 TOTAL
Project at a Glance Year
Annualised
Book Value
Debt
Dividend
Retained Earnings
Payo Payout ut
Prob Probab able le Market Price
P/E Ratio
Yield Price/ Book Value
No.of Times Per Share
Per S h ar e
EPS
CEPS
Per Share
`
`
`
`
`
%
`
%
`
1-2
5.76
8.93
15.76
24.00
0.00
100.00
5.76
0.00
5.76
1.00
0.00
2-3
8.69
11.45
24.45
18.00
0.00
100.00
8.69
0.00
8.69
1.00
0.00
3-4
11.62
14.02
36.07
12.00
0.00
100.00
11.62
0.00
11.62
1.00
0.00
4-5
14.46
16.55
50.53
6.00
0.00
100.00
14.46
0.00
14.46
1.00
0.00
5-6
17.20
19.02
67.73
0.00
0.00
100.00
17.20
0.00
17.20
1.00
0.00
%
Project at a Glance Year
D. S. C. R.
Debt / Equity Total Return asNet on Net Depos Equity Worth Worth its Debt
Individ Individual ual Cumula Cumulative tive Over all
(Number of times)
Initial
(Number of times)
3.00
3.00
%
%
Profitability Ratio
GPM
PBT
PAT
%
%
%
Assets Curren Turnove t Ratio r Ratio
Ne t P/V Contrib Ratio ution
%
1-2
1.31
1.31
1.52
1.52
4.04
9.60%
4.39%
3.05%
2010.19
34.63%
2.40
1.21
2-3
1.63
1.47
0.74
0.74
2.61
10.61%
6.02%
3.95%
1608.53
23.75%
2.51
1.29
3-4
2.02
1.63
0.33
0.33
1.78
11.31%
7.20%
4.62%
1820.78
23.52%
2.52
1.39
4-5
2.47
1.82
0.12
0.12
1.28
11.78%
8.05%
5.11%
2033.03
23.35%
2.46
1.51
5-6
3.02
2.01
0.00
0.00
0.96
12.10%
8.65%
5.47%
2245.28
23.21%
2.37
1.80
2.01
Project at a Glance BEP
BEP - Maximum Utilisation Year
5
Cash BEP (% of Installed Capacity)
54.76%
Total BEP (% of Installed Capacity)
57.26%
IRR, PAYBACK and FACR
Internal Rate of Return .. ( In %age )
Payback Period of the Project is ( In Years )
Fixed Assets Coverage Ratio ( No. of times )
29.76%
2 Years 3 Months
19.895
Table of Contents of the Project Report
1. District Profile & Geotechnical Site Characterization 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1. 6. 1.7.
General Phys ysiical Char Chara acteristics Map Culture & Languages Climate & Rainfall Tran Tr ansp spor orta tati tion on an and d Co Comm mmun unic icat atio ions ns Economy & Industry
2.
Introduction
2.1. Advantages 2.2. Polypropylene Bags
2.3. HDPE Bags
3.
Properties
3.1. 3.2. 3. 2. 3.3. 3. 3. 3.4. 3. 4. 3.5. 3.6. 3. 6.
Polypropylene Phys Ph ysic ical al Pr Prop oper erti ties es of Pol olyp ypro ropy pyle lene ne Chem Ch emic ical al Re Resi sist stan ance ce of Po Poly lypr prop opyl ylen ene e Sali Sa lien entt Fe Feat atur ures es of PP Wo Wove ven n Sa Sack cks: s: High De Density Po Polyethyl yle ene Sali Sa lien entt Fea Featu ture res s of of HDP HDPE E Wov Woven en Sa Sack cks: s:
4.
Uses & Applications
4.1. 4. 1. App ppli lica cati tion ons s of of HD HDPE Wov Woven en Sa Sac cks ks::
5.
Importance of Packaging
5.1. Pl 5.1. Plas asti tics cs-M -Mos ostt pr pref efer erre red d Pa Pack ckag agin ing g Material: 5.2. 5. 2. Bu Bulk lk Co Com mmod odit itie ies s Pac acka kagi gin ng: 5.3. 5. 3. PP PP/H /HD DPE Wov Woven en sa sac cks ro role le in Bulk Packaging:
6.
B.I.S. Specifications
6.1. 1. IS: 16187 – 2014 Textiles – Textiles – High density polyethylene (HDPE//polypropylene (PP) leno woven sacks for packaging and storage of fruits and vegetables.
6.2. 2. IS: 11653 – 1986 1986 – – For polypropylene (PP) woven sacks for packing cement (withdrawn) superseded by IS 11652.
7. Differ Different ent Typ Types es of Pla Plastic stics s and and The Their ir Classifications 8.
Various Type of HDPE/PP Bags
8.1. Th 8.1. The e var vario ious us ty type pe of PP ba bags gs co comm mmon only ly in practice. 8.2. Courier Bags 8.3. Mail Bag
8.4. PP Woven Bags/ Fabric 8.5. Silt Fence/Box Bags 8.6. Pp Big Bags
9.
Market Survey
9.1. Dem 9.1. eman and d fr from om Cem emen entt In Indu dust stry ry 9.2. Polymers 9.3. Market Structure
10. Fin 10. inan anci cial als s & Co Comp mpar aris ison on of Maj ajor or Indian Players/Companies 10.1. Abou Aboutt Financia Financiall Statemen Statements ts of CMIE Database
10.2. Pro 10.2. Profit fits s & Approp Appropria riatio tions ns 10.3. 10. 3. Tot Total al Lia Liabil biliti ities es 10.4 10 .4.. To Tota tall As Asse sets ts 10.5. Net Cash Flow from Oper Operating ating Activities 10.6 10 .6.. Se Sect ctio ion n – I 10.6.1. Name of Company with Contact Details 10.6.2. Name of Director(S) 10.6.3. Plant Capacity 10.6.4. Location of Plant 10.6.5. Name of Raw Material(S) Consumed With Quantity & Cost
10.7 10 .7.. Se Sect ctio ion n – II 10.7.1. Assets 10.7.2. Cash Flow 10.7.3. 10. 7.3. Cos Costt as % Ge of Sal Sales es 10.7.4. Forex Transaction 10.7.5. Growth in Assets & Liabilities 10.7.6. Growth in Income & Expenditure 10.7.7. Income & Expenditure 10.7.8. Liabilities 10.7.9. Liquidity Ratios 10.7.10. Profitability Ratio 10.7.11. Profits 10.7.12. Return Ratios 10.7.13. Structure of Assets & Liabilities (%) 10.7.14. Working Capital & Turnover Ratios
11. Export & Impor ortt St Stati tis stics Da Data of India 11.1. Expor Exportt Statistic Statistics s Data Data for PP PP Woven Woven Sack 11.2. 11. 2. Exp Export ort Stati Statisti stics cs Data Data for Hdpe Hdpe Woven Sack 11.3. Impor Importt Statisti Statistics cs Data Data for PP Woven Woven Sack 12.Present Manufacturers
13. Manufacturing Pr Process
14. Stage Wise Process Diagram 15. Process Flow Diagram 16. En 16. Envi viro ron nme men nta tall As Aspe pec cts Reg egar ard din ing g Plastic 16.1. Usage Rule Rules s (Comman (Command d and and Control): Control):
17. Suppliers of Raw Material 18.. Sup 18 uppl plie iers rs of Pl Plan antt an and d Ma Mac chi hin ner ery y 18.1. Compl Complete ete Mach Machinery inery Suppl Suppliers iers
19. Product, Ma Machinery & Raw Material Photographs 19.1. Pro 19.1. Produc ductt Phot Photogr ograph aphs s 19.2. 19. 2. Mac Machin hinery ery Phot Photogr ograph aphs s 19.3. 19. 3. Raw Mate Materia riall Photog Photograp raphs hs
20. Plant Layout 21. Quota tattio ion n of of Pl Plant, Ma Machinery and Equ Equipm ipment ents s from Sup Suppli plier er
Project Financials • Project at a Glance Annexure • Assumptions for Profitabilit Profitability y workings ………………………..1 • Plant Economics………………… Economics…………………………………………………..2 ………………………………..2 • Production Schedule Schedule………………………………………………3 ………………………………………………3 • Land & Building……………………………………………….…… Building……………………………………………….……4 4 Factory Land & Building Site Development Expenses
• Plant & Machinery……………………………………………..…….. Machinery……………………………………………..……..5 5 Indigenous Machineries Other Machineries (Miscellaneous, Laboratory etc.)
• Other Fixed Assets………………………………………..........…....... Assets………………………………………..........…....... 6 Furniture & Fixtures Pre-operative Pre-operativ e and Preliminary Expenses Technical Knowhow Provision of Contingencies • Working Capital Requirement Per Month…………………….…7 Month …………………….…7 Raw Material Packing Material Lab & ETP Chemical Cost Consumable Store
• Overheads Required Per Month and Per Annum…………. Per Annum…………..… .…8 8 Utilities & Overheads (Power, Water and Fuel Expenses etc.) Royalty and Other Charges Selling and Distributi Distribution on Expenses • Salary and Wages …………………………………………....…………..9 • Turnover Per Annum …………………………………………….....… …………………………………………….....…10 10 • Share Capital………………………………… Capital………………………………………………………..... …………………….....11 11 Equity Capital Preference Share Capital
•
•
Anne An nexu xure re 1 :: Co Cost st of Pr Proj ojec ectt an and d Me Mean anss of Fi Fina nanc ncee Annexur Ann exuree 2 :: Pr Profit ofitab abilit ility y and Net Cas Cash h Acc Accrual rualss
Revenue/Income/Realisation Expenses/Cost Expenses/C ost of Products/ Products/Services/It Services/Items ems Gross Profit Financial Charges Tota otall Cost Cost of Sal Sales es Net Profit After Taxes Net Cash Accruals
Annexure 3 :: Asses Annexure Assessment sment of Working Capital requirements •
•
Current Assets Gross Working Working Capital Cap ital Current Liabilities Net Working Working Capital Working Note for Calculation Calculation of Work-in process proce ss Annexuree 4 :: Sources and Disposi Annexur Disposition tion of Funds
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•
•
Annexure 5 ::
Projected Balance Sheets
ROI (Av (Average of Fixed Assets) RONW (Av (Average of Share Capital) ROI (Av (Average of Total Assets) Annexure 6
::
Profitability Ratios
D.S.C.R Earnings Per Share (EPS) Debt Equity Ratio
•
Annexure 7
::
Break-Even Break-Ev en Analysis
Variable Cost & Expenses
Semi-Variable/Semi-Fixed Expenses
Profit Volume Ratio (PVR)
Fixed Expenses / Cost
B.E.P
•
Annexure 8 to 11 :: Sensitivity Analysis-Price/V Analysis-Price/Volume olume
Resultant N.P.B.T
Resultant D.S.C.R
Resultant PV Ratio
Resultant DER
Resultant ROI
Resultant BEP
•
Annexure 12 :: Shareholding Pa Pattern ttern and Stake Stake Status
Equity Capital
Preference Share Capital
•
Annexure 13 :: Quantitativ Qu antitativee Details-Output/Sales/Stocks
Determined Capacity P.A P.A of Products/Services
Achievab Achiev able le Efficiency/Yield Efficiency/Yield % of Products/Services/Items
Net Usable Usable Load/Capacity of Pro Products/ ducts/Services Services/Items /Items
Expected Sales/ Rev Revenue/ enue/ Income of Products/ Services/ Items
•
Annexure 14
::
Product wise Domestic Sales
Realisation •
Annexure 15
::
Total Raw Material Cost
•
Annexure 16
::
Raw Material Cost per unit
•
Annexure 17
::
Total Lab & ETP Chemical Cost
•
Annexure 18
::
Consumables, Store etc.
•
Annexure 19
::
Packing Material Cost
•
Annexure 20
::
Packing Material Cost Per Unit
•
Annexure 21
::
Employees Employ ees Expenses
•
Annexure 22
::
Fuel Expenses
•
Annexure 23
::
Power/Electricity Po wer/Electricity Expenses
•
Annexure 24
::
Royalty Roy alty & Other Charges
•
Annexure 25
::
Repairs & Maintenance Expenses
•
Annexure 26
::
Other Manufacturing Expenses
•
Annexure 27
::
Administration Expenses
•
Annexure 28
::
Selling Expenses
Annexure 29 :: Depreciation Charges (Total) •
Annexure 30 :: Depreciation Charges & M) •
–
as per Books
–
as per Books (P
Annexure 31 :: Depr Annexure Deprecia eciation tion Charg Charges es - as per IT Act WDV (Total) •
Annexure 32 :: Depr Annexure Deprecia eciation tion Charg Charges es - as per IT Act WDV (P & M) •
•
Annexuree 33 :: Inter Annexur Interest est and Re Repa payment yment - Term Loans
•
Annexure 34 :: Tax on Profits
•
Anne An nexu xurre 35 35 :: Pr Proj ojec ecte ted d Pa Payy-Ba Bacck Per Perio iod d and and IR IRR R
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