BUSINESS PLAN

ON
PLASTIC RECYCLING & MANUFACTURING

A Business Plan submitted in the part fulfillment of the requirements

for the award of

Master of Business Administration

Year 2018-2020

PROJECT GUIDE – SUBMITTED BY –

Dr. Ritu Narang Ayush Bisht

Associate Professor Roll No.- 180012135

Department of Business Administration

University of Lucknow
 ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and deep regards to my

Project internal guide “Dr. Ritu Narang (Associate Professor)” , for his
exemplary guidance, monitoring and constant encouragement throughout the
course of this thesis. The blessing, help and guidance given by him time to time
shall carry me a long way in the journey of life on which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to my Head of

Department (HOD) “Mr. Sanjay Medhavi” , for his cordial support, and
guidance, which helped me in completing this task.

Last but not the least I place a deep sense of gratitude to my family members
and my friends who have been constant source of inspiration during the
preparation of this project work.

AYUSH BISHT
Roll No. - 180012135
 INDEX-
CONTENTS
ACKNOWLEDGEMENT

1.1
 OVERVIEW

Ayushman Plastics provide a wide range of plastic solutions for households and
raw material for packaging to the various companies. Lucknow is the place
where the facility will be established and other operation will commence.

We will collect the plastic garbage like consumer beverage bottles, plastic bags
from various garbage stores and then our recycle unit will process it which
eventually be used for the production of finished goods.

The plastic garbage we are getting as raw material has two components one is
PVC (Polyvinyl chloride) and other is PET (Polyethylene terephthylene ).
Firstly the whole garbage is melted and then PVC and PET are separated from
each other by froth flotation technique.

We will create a plant (actual facilities to be shared with the recycling unit) to
manufacture extruded plastic flakes (purified plastic). The extruded plastic is
thenmolded in the various products.

We will produce two types of replay plastics

· PVC( Polyvinyl chloride)
· PET( Polyethylene terephthylene )
 EXECUTIVE SUMMARY

Plastic is the basic need of our day to day life. During recent years the plastic
industry has grown with a substantial growth rate. This growth is driven by
three sectors viz packaging, infrastructure and agriculture. There are the various
varities of plastics out of which PVC (Polyvinyl chloride) and PET
(Polyethylene terephthylene) plastics have their considerable contribution. PET
plastics are generally used in the manufacturing of beverage bottles for the
packaging and PVC plastic is used in the production of household plastic
materials. The growing utilization of plastics in industrial and consumer
applications and surrounding solid waste recycling, has led to an increased
demand for recycled plastic resins and products.

We the Ayushman Plastics provide a wide range of plastic solutions for

household and raw material for packaging to various companies. As a part of
our ongoing efforts to exploit this opportunity we will recycle the plastics and
then produce kitchen ware items and other related plastic material. We will also
sell the recycled plastics to the companies in the plastic business. We will have
a recycling plant along with the production unit. The raw material will be
procured from the waste collectors. The raw material will be post consumed
beverage bottles and other soft plastic materials.

Our main focus is our industrial customer whom we will sell PET bottles and
PET flakes. It will contribute more than 60% of our sales. We will also focus on
the household plastic business which is the part of our portfolio. The initial set
up cost will be Rs 45, 00,000.

Ayushman Plastics will be a Partnership Business run by the promoter Manish

Kumar Singh and Ayush Bisht who are MBA graduate with marketing and
finance respectively as specialization.

Since plastic material does not carry any brand name so it will give us an
addition benefit in long term to establish our brand name. To exploit the market
we will use penetration pricing as our marketing strategy and utilize our
stringent distribution network and strong industrial relationship.
As a future plan in coming years we will increase the variety of plastics like
LDPE (Low density polyethylene) and HDPE (High density polyethylene). By
doing this we will be able to produce plastic carry bags and raw material for
production for plastic chairs and tables and other fiber based products.

Objectives-
 Develop a business that survives on its own cash.
 Create a company which exceeds customer satisfaction level.
 Expand the service to whole UP in first five years and then to Delhi.
 Extending the services to electronic component manufacturing companies
for production of capacitors printed circuit boards etc.

Key to success-
The main keys to the success of the Company are:
 Secure Supply- Contract for supply of post-consumer bottles and post
industrial manufacturing waste for PET raw material feed stock.
 Satisfy our customer so that we can retain them
 Maintain low overhead and operating costs
 Provide better prices than all our competitors

·
Problem and Solution –
1- Unavailable or scarce raw material feed stock for production

 Ayushman is confident that it has secured good availability of low

cost post-consumer PET bottles (feed stock) derived from post-
consumer beverage bottles from Lucknow and nearby areas based
recycling collectors, and has back up sources identified.

2- Technology employed may be unreliable or unproven

 Ayushman will use a proven, patented technology for the cleaning

and recycling phase. The extrusion division will employ
 commercially proven technology - the industry is employing unique
recycled PET technology which is used by prominent
manufacturers of PET extrusions.

3- There may not be a market for the Company's products

 The Industry-wide experience of the Management Team has allowed

them to identify markets for the Company's products. Their expertise
and reputations have allowed them to obtain commitments for
virtually all of the planned initial production. 

4- The location may not be near enough to markets

 The markets that have been identified are primarily in province of

Lucknow, which will provide a distinct advantage to the Company
because of freight costs and delivery timing.

5- Company may not meet environmental standards

 This environmentally-favorable venture provides for the development

of technically feasible and economically viable solutions to PET
plastic beverage bottle recycling, as well as environmentally aware
in-house re-use practices which filter and return nearly all of the
process water to the production lines.

6- The Company may not be able to sell all of its production

capability

 Through the Management's industry-wide contacts, the Company has

identified potential customers and received commitments for all of
the production potential of the initial facility. 
Market –
The plastic products usually do not carry a brand name so intruding in the
business like plastic will not be too hard with low price strategy. The population
of Lucknow and the cities around it like Barabanki , Sandila , Sitapur is around
3Cr. and this area is basically comprises of low to middle income group families
so they focus on plastic products rather than fiber since it is cheaper. Hence it is
huge market to exploit.

From Lucknow city 1500 tons of solid waste is produced from that 90tons of
plastic bags and around 25 tons of plastic bottles is generated per day. So the
supply of raw material will be continuous.

Apart from this we will sell raw material for packaging to the various small
companies in this area. Around 50 small and medium scale companies are
working in this region. So a large amount of industrial customer is also
available.

There are two folds of products that we are providing one is industrial and other
is household.

Competition –
In plastic manufacturing market there is no specific brand name is existing so
the market is flooded by small companies which are in this business. So they are
our biggest direct competitors.

As we are also not alone as a supplier of PET to the companies as raw materials
there are many companies in this region which are supplying PET. Aadishakti
Associates is one of them who is currently selling all types of plastics items. So
in case of business to business market they are our direct competitors. Kanpur is
plastic recycling city of UP. The direct threat we will also have is with the
companies operating in Kanpur. But as the distance between Kanpur and
Lucknow is 110km , so it will not affect much.
Financial Highlights –

The startup cost of our business is as follows –

Requirements Amount

Start-up Expenses
Legal 20,000
Stationery 2500
Business Cards 1000
Initial Mailing 500
Process Funding 1000
Office Equipment 5,000
Total Start-up Expenses 30,000

Start-up Assets
Cash Required 5,00,000
Long-term Assets 39,70,000
Total Assets 44,70,000
Total Requirements 45,00,000
GENERAL COMPANY DESCRIPTION –

Company Ownership –

Ayushman Plastics will be a Partnership firm owned by Vinod Bisht , a MBA

graduate with specialization in Marketing and Ayush Bisht , a MBA graduate
with specialization in Finance.

At the time of formation , Ayushman Plastics plans to invest Rs 45,00,000 to

buy land at Bakshi ka Talab which is at the outskirts of Lucknow and start the
business with all assets and equipments required to start production.

Ayushman Plastics will be shared 50% by both the Partners with Investment to
Profit sharing at ratio of 1:1

Type of Business Organisation –

Partnership –

A partnership is a business with several individuals, each of whom owns part of

the business. The partners may be active participants in running the business or
they may be passive investors. The relationship between the partners, the
percentage and type of ownership, and the duties of partners is clarified in
the partnership agreement.

In any partnership, each partner must "buy in" or invest in the partnership.
Usually, each partner's share of the partnership profits and losses is based on his
or her percentage share of ownership.

Depending on the type and amount of participation in the business, partners

may be liable for debts of the business and for lawsuits against themselves
personally. The new partnership types created in the past few years are intended
to help reduce liability issues with partnerships.
Ayushman Plastics will be in General Partnership with only general partners
investing in day to day operations. Each general partner must actively
participate in managing the business and any partner may sign a contract on
behalf of the partnership. The partners must agree to major decisions, acting as
a corporate board of directors.

Because general partners actively participate, they all must take personal
responsibility for the liabilities of the business and for debts incurred by other
partners. If one partner is sued, all partners are held liable. A partner's personal
assets may be taken by a court or creditor.

Steps to Register the Business –

1- Register Your Partnership With Your State –

When you have all the information you need for your partnership, go to your
state's Secretary of State website and look for the business or corporations
section. Here's where you register your business as a partnership. Most states
will allow you to complete this registration online.
If your partnership will be doing business in more than one state, you will need
to complete this registration process with each state. The main state is done first
as a "domestic" partnership, then register in other states as a "foreign"
partnership.
2- Get an Employer ID Number –
You can get an employer ID number (EIN) from the IRS after you have the
business name and type and location. Almost all businesses need an EIN, even
if they don't have employees. The process of getting an EIN is simple, and you
can apply for an EIN online or by phone and get the number immediately.

3- Create a Partnership Agreement –

Don't skip this important step in starting your partnership. A partnership
agreement sets out in writing all the processes and decisions that the partners
have agreed to. It answers all the "what if" questions that could come up in the
life of a partnership.
 4- Get Other Registrations, Licenses, and Permits –
Here's a quick list of some of the other legal and regulatory tasks you'll need to
do as you start your partnership: 
 Register with your state taxing authority for sales taxes if you are selling
taxable products or services.
 Register to pay federal taxes with the EFTPS payment system. This
registration applies to the paying of employment taxes if you have
employees. 
 You will need to file a fictitious name (sometimes called a DBA for
"doing business as") registration with your city or county. 
 Finally, depending on what type of partnership you have, you will need to
register with your locality to get business licenses and permits, depending
on your business activities.

Organisational Structure-

GENERAL
MANAGER / CEO

PRODUCTION SALES/MARKETI ACCOUNTS

MANAGER NG MANAGER HEAD

FACTORY LOGISTICS/ REGIONAL REGIONAL

/TECHNICAL WAREHOU OFFICER 1 OFFICER 2
HEAD SE HEAD
Management Team-
The company will be managed by owners and four supporting staff.

Vinod Bisht , a B Tech. graduate with specialization in Mechanical , MBA Post-

graduate with specialization in Marketing and Ayush Bisht , a B Com. Graduate
, MBA Post-graduate with specialization in Finance are the owners and General
Manager/CEO’s of Ayushman Plastics.

They have intensive knowledge and vast understanding in financial areas like
Risk and Return management, Investment portfolio and Capital Budgeting,
which undoubtedly will be of intense help in the business. Apart from this They
also have a good knowledge of chemicals and their properties.

Marketing skills like convincing power, negotiating ability, creating

promotional strategies and sales skills will all be extremely helpful in taking the
business a long way and will prove intensely valuable to take Ayushman
Plastics to flaring heights.

Thus with such potential skills, and other qualities like efficient interpersonal
skills, leadership skills and decision making quality, aptly makes them the best
promoter and eligible founder and owner of Ayushman Plastics.

Along with promoters four more employees will work for the accomplishment
of company’s objective. Production and sales & Marketing work on the facility
will be handled by Manish Kumar Singh along with two supporting staff in
Production and Sales &Marketing each. Finance & Accounts related issues will
be dealt by Ayush Bisht , who are also the General Manager/CEO’s of
Ayushman Plastics.

Management Team Gaps

Each of the six employees is responsible for managing his or her area
of expertise. The problems with having only one individual in charge
of a department are as follows:
1. Lack of understanding of other departments.

2. Minimal management experience.

3. Sole control over all operations.

Personnel Plan-

In our experience, a team of eight skilled-unskilled workers works best for our
kind of business.Working as a team is critical to our success. We recognize that
human resources most valuable asset. Our personnel strategy focuses on
selecting, training, rewarding, and stimulating all employees in order to build
employee loyalty, and increase performance.

As our firm will be open Monday through Saturday from 09:00 AM to 6:00 PM.

Schedule for our Employees in week :

DAY START LUNCH END TIME NO. OF

TIME HOUR (PM) HOURS
(AM)
MONDAY 9:00 1 8:00 10

TUESDAY 9:00 1 8:00 10

WEDNESDA 9:00 1 8:00 10
Y
THURSDAY 9:00 1 8:00 10
FRIDAY 9:00 1 8:00 10
SATURDAY 9:00 1 6:00 08
SUNDAY OFF OFF OFF 0
TOTALS 58

In addition to salaries, important bonuses and incentives are included in the

personnel table, that will be used to reward employee performance, on a pay-
for-performance basis. The cornerstone of our personnel plan is to maximize
productivity and minimize labor burden of the company's operating expenses,
while maintaining strong employee commitment to the success of operations.

Trying to appropriate compensation incentives to our company's performance

targets, increases the likelihood that these goals will be achieved. Our
performance-based pay strategy takes into consideration the linking of
employee compensation to the achievement of measurable business targets.
Employees that perform well are eligible for various types of performance-
based pay, such as cash bonuses, awards, profitsharing plan, and stock option
program. The ultimate goal of all our employees is to meet or exceed our
customers'expectations.

Our continuous improvement policy encourages all employees to continually

look for ways to keep updated with the latest technology, to improve processes,
reduce costs and save time. This approach serves the goal of reducing costs and
delivery times, and increasing the service quality and customer satisfaction.

Salaries and Incentives for different level of Employees:

PERSONNEL SALARY RS PER BONUS &

YEAR INCENTIVES
1 UNSKILLED 96,000 4,000

2 SEMI SKILLED 1,20,000 7,000

3 SKILLED 1,44,000 10,000

4 FACTORY/TECHNICAL 3,00,000 20,000

HEAD
5 LOGISTICS/WAREHOUS 2,40,000 15,000
E HEAD
6 REGIONAL OFFICER 1 2,40,000 15,000

7 REGIONAL OFFICER 2 2,40,000 15,000

TOTALS 13,80,000 86,000

 Percentage of salary growth will be directly proportional to the

Percentage growth in Profit After Tax (PAT).
 Travelling Allowance will be given to Regional Officers for
Company related travels on submission of bills monthly.
OPPORTUNITY-

1- Raw Material Producers

These are chemical and petroleum companies who produce "virgin" plastic
(sometimes called resin or polymer) in huge quantities. The main influence they
have on the recycler is to fix prices and availability of virgin materials. Virgin
material is delivered in powder or pellet form, in plastic or paper sacks of
around 20 kilos weight, in large cardboard drums that hold many times that
quantity or even by road tanker.

2- Compounders
These specialist companies, usually small, stock various polymers and provide
the manufacturers of plastic goods with technical advice and the most suitable
materials or mixtures for each individual need. The compounder is often the
best market for the recycler because he possesses superior technical knowledge
and has a large volume throughput of virgin material, in which small
percentages of reclaim will reduce cost without seriously affecting the quality
required by the molder.

3- Stockists
These warehouses stock polymers and compounds but neither manufacture
themselves, nor provide a compounding service. They may be agents or
subsidiaries of the producer companies or departments of companies concerned
with the supply of other materials such as chemical, rubber or paper. They may
be willing to stock reclaim alongside virgin materials, especially if these are in
short supply.

4- Specialist Manufacturers or Molders

These buy their raw materials from compounders. If they do their own
compounding, or if the material is used as produced and does not need
compounding, they may buy direct from stockists or producers. They are
specialists in plastics and do not perform other types of manufacturing. They
may be an attractive market to the recycler because they operate at high volume,
but rarely have as much flexibility to vary product quality as molders who
know, accurately, the final market for the product.

5- Other Manufacturers
Many companies are not plastics specialists but employ molding operations in
the manufacture of some other product. For example shoe and boot makers use
plastics extensively and may carry out the various plastics molding operations
in the same production sequence as the work in leather, canvas, rubber etc.
Many manufacturers use plastic packaging machinery at the end of a production
operation.

6- Fabricators
These firms cut and join sheet, rod or extrusion to manufacture a variety of
products. They have no opportunity to use reclaim. Machinery and Tool
Makers. One other sector of the plastics industry justifies mention although not
customers for reclaim. The makers and suppliers of plastics manufacturing
machinery, tools, moulds and dies are well informed about who does what, who
makes what and who uses what within the local plastics industry. They may
advise who is likely to buy material.
INDUSTRY AND MARKET-

Market Segmentation-
Strong demand for plastic bottles is working in the industry's favor. Major users
of plastic packaging, apparently responding to consumer desires, have begun
incorporating at least some recycled plastic content in their products as part of
the growing interest in recycling. Resin demand is on the rise as prices for the
two major recycled resins, PET and HDPE, continue to hold value or appreciate
against their virgin counterparts. The Company has chosen its target markets
because PET is in high demand as flake resin by converters, as roll stock sheet
used to produce high visibility packaging and as high strength strapping for the
lumber industry. Sales are price-sensitive, so that proximity to markets and feed
stock source provide a competitive edge.

Target Market Segmentation Strategy-

Since we are new player in the market so we need to make some stringent
strategies to penetrate market and grab customers. The customers of the plastic
bottles industry are scattered due to lack well known brand names. So our first
priority will be to accumulate the defused customers.

The direct customers are the customers whom we are selling our product
regularly. So for us house holds whom we are selling plastic goods and
companies who are getting raw materials for packaging are direct customers
(PET bottles) . So only in Lucknow, in terms of business to business market
around 50small and medium scale companies are our direct customers. Apart
from them there are few small companies which are giving compounding
services. They use to collect various types of plastics flakes along with the
virgin plastic and suggest customer (companies) in choosing appropriate plastic.

The Company has chosen its target markets because recycled PET (RPET) is in
high demand as flake resin by converters,  as roll stock sheet used to produce
high visibility packaging and as high strength strapping for the lumber industry.
Sales are price-sensitive, so that proximity to markets and feed stock source
provide a competitive edge. Ayushman Plastics identified an opportunity to take
advantage of both circumstances.

Market Gap-
Overall there are 5 gaps in market:

1. Distance Gap: Meaning consumer and business is located at different

place geographically.

2. Time Gap: When consumers are not willing to consume when they are
produced.

3. Information Gap: When the producer/ business has no idea who needs

what, when, and where at which price while customers have no idea what
is available from producers/ business side.

4. Quantity Gap: Customers usually look for buying in small/medium

quantities, while businesses/ manufacturer opt for selling more.

5. Assortment Gap: Consumers prefer a variety of products but

manufacturer/ business has specialized narrow base in producing the
products.

Market Growth-
In future we are looking for the production of a variety of plastic. These plastics
will be
 LDPE ( Low density polyethylene)
 HDPE ( High density polyethylene)

LDPE plastic is used in the production carry bags and other plastic sheets as
well as cling wrap, car covers, squeeze bottles, liners for tanks and ponds,
moisture barriers in construction. And HDPE plastics are used in production of
freezer bags, water pipes, wire and cable insulation, extrusion coating.
Our development strategy will base on timely completion of the establishment
of the business centre with low execution cost. Our strategy will focus not only
the current uninterrupted production of PVC and PET and acquisition of
customer as fast as we can, but we will also look for the future expansion plan
and execution strategy.

Our future development strategy will focus on to chart out a careful plan for the
future expansion and growth of our business. The development strategy will
address following issue:

 How will we expand our services?

 Which are the new areas we will include to provide our services?
 What will be the format of the business

Our development strategy will address all those above mentioned point. As we
will grow and our earning will increase, we will produce more of PVC and PET
as well as expand in new area. We have a development strategy to expand our
facility size in order to meet the production size.

Market Trends-
Ayushman Plastics will distribute the Products to Lucknow and various other
outlets from company agents.

 The cost of marketing the new product is expected to be the biggest

challenge for Ayushman Plastics. The initial use of Hardware shops for
sale at Departmental Stores and other wholesalers for domestic plastic
products, facilitates as a distribution channel will allow for cost savings.
 The lack of an existing recognized brand name will be an initial problem,
but in a few years Ayushman Plastics intends to have achieved powerful
brand equity - allowing it to rely on, and succeed because of its brand
name.
STRATEGY-
Business Model-
Manufacturer
A manufacturer makes finished products from raw materials. It may sell directly
to the customers or sell it to a middleman i.e another business that sells it finally
to the customer.

Ayushman Plastics is typically based on manufacturer model where customers

are direct consumers and business using products as raw materials. As explained
above , our main products are PVC, PET which are manufactured using the
scrap collected as raw materials and then separated , cleaned and then processed
to produce plastic resins and direct consumer products which is advertised and
distributed by various channels to retailers and customers in business using our
products as raw materials.

Marketing Plan-
The Company has chosen to focus on the production of plastic packaging
materials from recycled post-consumer beverage bottles. we have identified a
significant available market in the eastern part of UP. All of our initial
marketing strategy will be to secure contracts in that segment, and after
reaching full planned capacity, look to grow in concert with that segment and
related markets. We see little need at present for further market research and
development, and will focus on continually updating our production technology
in an effort to remain in the forefront of our chosen marketplace.

 Product/ service strategy

The packaging companies require high quality and highly transparent PET
bottles. The companies which are producing mineral water will reject PET
bottles with even a small impurity/ opaqueness. So we the Ayushman Plastics
provide high end PET flakes for the perfect packaging.

Ayushman Plastics will apply recycling and extrusion technology managed by

decades of industry specific expertise to create a competitive advantage for its
clients. These processes will produce clean, cost-efficient, recycled raw material
for manufacturers of thermoform, laminate and other high value-added
products, and high strength packaging strapping for shippers of large products
and pallets, thereby reducing costs and creating a clear pricing edge among their
competitors.

Plastic bags and plastic sheets are now in high demand. And this demand is
driven by continuously increasing promotional activities.

 Pricing strategy
As plastic products do not carry any brand name so only pricing and distribution
strategies will works to achieve competitive edge. The pricing strategy we will
use is penetration pricing. The price of all household plastic goods we will sell
will be lower than the market price. Also for the PET flakes and bottles the
price will be lower than the competitors. A lower price enables me to get
contracts of PET bottles and sheets from various companies.

In case of kitchenware and other household products we will provide combo

offers and discounts which a common customer expects.

 Distribution strategy
As I described before that firstly we will target Lucknow city and villages close
to it. We will have a distribution center in the Lucknow city which continuously
maintains the supply of goods. So the household plastics will be sold through
small local grocery shops from which the customers can get them easily. Apart
from this we will hire street hawkers who will roam around the city and sell the
goods door to door.

PET bottles will be stored in warehouse which is close to the facility itself. The
sales people will directly contact to the companies which require these bottles
for packaging and look for the contracts. In city as stated above that we will
have a distribution center, from that center we will distribute to whole sellers.

 Advertising & promotion strategy

As I described we are in both B2C and B2B so for this we will use two different
promotional strategies. For B2C business we will use flyers which will have full
detail of our product range, price, combo offers and discounts. These flyers will
circulate through the newspapers across whole city. For B2B business we will
promote through online social media and we will also develop our website
through which enable us to widely spread our contact among various
companies. the site will have full details of product which are available for
companies as well as end user.

Sales Plan-
The strategy of sales effort will be to convert potential and first time customers
into long term customers. Our sales strategy is totally based upon the
distribution channel and the pricing strategies. We will have a distribution
centre in the city that will take care of sales of household and also supply
products to the wholesalers. We will also give the industrial customers a facility
to order the products through our website which will help them in reducing the
delivery time.

To market the products, the Company will use a number of sales agents/brokers.
They have a customer base of their own, having developed successful
relationships with their client over the years. Their customer base is currently
demanding product so they can expand upon their current base. Of course, they
will expand that to new customers when product is available.

If the Company grows faster than its prime customer base, additional capacity
may be developed. We will identify additional prospective customers who can
be attracted for our products.

Location and Facilities-

The company's location is at Bakshi ka Talab at outer of Lucknow which is
very favorable, providing high visibility and low traffic . Accordingly, the cost
of land is lower than in other areas of the city.

The Plant will be located at outskirts of town, which makes it away from the big
population of the city. Other advantages of the chosen location include:

 Plenty of space for plant setup , machines additional storage area

available for inventories.
 Excellent central location with easy availability of workers , raw
materials.
 Short commute to major customers may be direct consumers or the
businesses using our products as their raw materials.
  Availability of Water supply , Electricity.
 Easy transport facility for carrying raw materials , manufactured products
, machine parts , tools.
 The climate at the location is also good and favourable to work and a
secure environment to work.
 Space for waste disposal and handling away from major population.

Technology-
The plastics waste is required to be properly sized so that those may be fed into
the extruders for processing and palletizing.

The advanced technology of separating / segregating different types of waste

plastics involves ‘Floatation Process’. The plastic is transferred to respective
unit to be recycled because PET and PVC cannot be recycled simultaneously
due to their different properties. There will be two units running parallel to each
other. On unit will recycle and produce PVC plastic and other will perform the
same for the PET plastic.

The recycled PVC is then moved for the plastic injection molding unit in the
various shapes. Since there are a variety of product is being produced so the
preference will be given to that product whose demand is high. All the products
will not be produced each and every day. There will be different products which
will be produced on different day according to the demand in market.

After the recycling process is completed one part of PET flake is moved to the
warehouse according to the demand of raw material which different companies
need and other part will move for the molding in bottles. The recycled PET
flake is then heated and made the viscous solution of it. The PET resin is then
feeded to the molder and molder will give it various shape bottles. And then it
left for drying. Those products which further need for processing like buckets,
the handle will be inserted after the bucket is dried.
Equipments and Tools-
Chippers- Cutting and making plastic waste properly sized.
Seperators/Flotation Machine- To separate different types of waste
according to different properties of materials as different materials have
different densities and also eliminate contamination.

Water Treatment/Cleaning Machine- Water is used as a medium to

clean the plastic waste such that no objectionable substance other than pure
material.

Mixers/Agglomerators- This colour master is used to colour plastics

according to the demand and requirement.

Pallet Machine- Plastics are plasticized and granulated to make the plastics
material ready for fabrication next.

Injection Molding Machine- Machine for manufacturing plastic products

by the injection molding process. It consists of two main parts, an injection unit
and a clamping unit.

Moulds- Shapes in which injection is done and plastic is molded to get

required bottles and products.

Conveyors- To carry materials from one place or one machine to other.

Other Tools- Shovels , Hand Gears , Picking and moving Apparatuses etc.

Milestones-
Because the Company is a start-up, our milestones will surround the
establishment of continuing facilities, confirmation of sourcing and sales
contracts, equipment acquisition and installation, staffing and training, and
initiating production.
THE TEAM-

Manish Kumar Singh , General Manager/CEO- has B Tech. degree in

Mechanical and Masters in MBA with specialization in Marketing will deal
with Selection of Employees , training , introduction of work in the firm, He
will also handle the post of Production Manager and Sales & Marketing
Manager with his four staff to deal with the production of products from raw
materials to finished goods and advertising , marketing & sales of products.

Ayush Bisht , General Manager/CEO- has B Com. Degree and Masters

in MBA with specialization in Finance will also deal with selection of
Employees , training , introduction of work in the firm, He will also the post of
Accounts Head to deal with all the accounts & finance related issues.

Factory/Technical Head- Under the supervision of Production Manager,

He will be responsible for all the technical issues in the firm and guidance of the
workers for the work and performance.

Logistics/Warehouse Head- He/She will be dealing with all the logistics

work in the production process and also have responsibility of properly
managing th inventory.

Skilled , Semi-Skilled , Un-Skilled Workers - There will be total eight

workers have work in Sorting , Belt Conveyor , PET Seperator and Packaging
of Products under their respective Heads.

PROCESS NO. OF EMPLOYEES PROFICIENCY

SORTING 2 UN-SKILLED

BELT CONVEYOR 2 SEMI-SKILLED

PET SEPARATOR 2 SKILLED

PACKAGING 2 UN-SKILLED
OPERATIONAL PLAN-
The operations is defined as the process used to deliver your products and
service to the customer market place and also include manufacturing
transportation logistics travel and after sales services.

The facility is located at outside the city. Facility is divided in two parts

 Recycling and Production unit

 Warehouse

The facility is located in an area of 3000 sqft..Apart from these two units there
will be an office which will look for the perpetual supply of required raw
material and also take care about the outbound logistics.

The operations will be based upon JIT i.e. just in time. We will have contracted
with the suppliers who can supply the raw material as quickly as we want. The
raw material contains post consumer beverage bottles and other plastic
materials. The bottles and other plastic material that can be recycled have a
specific sign from which it can be identified that it can be recycled or not.

Stages of Recycling and Production

The process of recycling of waste plastics into products of varying usefulness
involves the following essential steps:

 Sizing / Chipping
 Cleaning
 Segregation.
 Agglomerating / Colouring
 Extrusion / Palletisation
 Fabrication into end Product.

Chipping:

The plastics waste is then required to be properly sized so that those may be fed
into the extruders for processing and palletizing. The sizing operation depends
on the type and shape of the waste plastics.

During this process, attention is required to separate any powdery material from
the sized / chipped plastics.
Segregation:

Certain polymeric materials are compatible with each other at all proportions.
For example LDPE and Lldpe are generally compatible to each other at all
proportions.

The advanced technology of separating / segregating different types of waste

plastics involves ‘Floatation Process’. In this process the property of the varying
densities of different plastics is made use of for segregating different types of
plastics.

However in the Indian Context, this separation or segregation process, in many

cases, are done by manual process utilizing the availability of cheap and expert
labor force. In case the waste is contaminated with embedded metals, proper
method of separating the metals / other contaminants is required.

Cleaning:

The scale of cleaning depends on the type of waste. Whenever a cleaning

operation is involved, it is to be ensured that the water or any other cleaning
material used, should be discharged after ascertaining that the discharge does
not contain any objectionable substance. A proper Treatment Device may have
to be deployed – like a water treatment plant / effluent treatment plant. For
drying, a suitably designed drier is used.

Many industries situated outside the metropolises, use open space for natural
drying of the cleaned waste.

Agglomerating / Colouring

In the next operation the sized plastics waste is mixed with colour master batch
in high-speed mixers / agglomerators and the output is ready for extrusion into
pellets.

Extrusion / Palletisation

This is the most important part of the process wherein the sized / chipped
plastics are plasticized and granulated to make the plastics material ready for
fabrication next.

The type and size of the Extruder depend on the type and volume of the plastics
waste.
Fabrication into end Product

Finally the reprocessed plastics granules are used as raw material for producing
end products using similar fabrication machines like Injection Molding /
Extrusion etc., depending upon specific requirement.

Process Flow-Chart
Gantt Chart