BIODEGRADABLE PACKAGE USING RICK HUSK

[EIRI/EDPR/3811] J.C.: 1916

INTRODUCTION

Biodegradable disposable flatware and utensils manufactured from wood-based or

plant-based raw materials, including materials that may be traditionally discarded
such as sawdust, plant stalks, seed or grain hulls or the like. The process
includes the use of a resin made from the discarded materials to form disposable
utensils and flatware.

Today consumption of Disposable products is breaking records. Disposable

products are easy to handle, economical and can be disposed easily. With the
changing lifestyle of Mankind, the use of disposable products is raising like
anything. Plastic Disposable products are very popular because it can be carried
easily and very low in prices too.

The products include food containers and tableware – like plates, bowls, meal
trays and cups – which decompose within 30-60 days after being discarded. The
company sources processed bagasse from other organizations. This material is
then moulded, dried, heated, and given other final touches. Heat-induced pressing
during the manufacturing process gives structural strength to the cutlery.
Additionally, the inter-fibre bonding makes the products water and oil resistant. It
is a completely natural process and involves no binders, additives, coatings or
chemical residues, resulting in a nontoxic, harmless and healthy alternative to
plastic. The cutlery also does not impart colour, odour or taste to food. The
products are microwave-safe and have an estimated shelf life of two years. Users
cannot wash the tableware or containers after use; they have to be discarded.

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This is 100% biodegradable & compostable tableware, which is widely used in
various functions ,restaurants , festivals as ECO FRIENDLY single time (Use &
throw) crockery , it’s produce by Plant extract or residue like Sugarcane Bagasse
(SCB) etc., which is Proven Environment friendly 100% Biodegradable and
Compostable and not harmful for food, human , soil and Nature. This is becoming
more popular due to environment awareness ,climate change & NGT/State govt.
bans on recyclable plastics. This can be use in microwave and refrigerator also.

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10 inch Bagasse Round Regular Plate

Disposable products are made of various materials such as dry leaves, pulp,
papers and plastic etc.

Thermoformed fiber is a material made by forming paper fibers or other natural

fiber in a mold. The end product can be made into almost any shape for any type
of solution. In the process of making thermoformed fiber, the product begins with
a process similar to transfer molding. During the process of thermoforming fiber,
the product is transferred to a set of heated metal molds that dry the fiber under
intense pressure and heat, making an extra drying process unnecessary. The
process of thermoforming the pulped fiber delivers parts that have a smooth finish
on both sides of the thin and dense walls of the product. There are many
advantages to having a thermoformed fiber product with smooth walls. They
include: reduced freight and storage costs and the ability to use mechanical
denesting. The use of thermoformed fiber is very desirable when visual appearance
is preferred.

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140ml Bagasse Cup

The process of pulp thermoforming is employed to develop sturdy and smooth

packaging. This type of packaging can be used in various industrial and
commercial uses. Thermoformed pulp is a desirable alternative to petroleum-
based products. American Fiber Packaging has invested in the latest equipment
technology and has developed a process to manufacture high-quality
thermoformed fiber solutions. Through this process we are able to deliver
environmentally responsible products to our customers.

Thermoformed molded fiber products can be customized to specifications and can

include clamshells, trays, inserts, and many other types of packaging.
Thermoformed pulp is a great alternative to petroleum-based foam products like
expanded polystyrene (EPS) for protecting and positioning products inside
packaging.

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Range & Variety

The present project report is fully based on biodegradable cups and plates from
Sugarcane bagasse, wood pulp. These products have got good demand in
throughout the country. The project many be setup in small scale sector. All the
required plant & equipments and Raw materials are easily available in India.

The plastic industry in India plays a very important and key role in
Industrialization. Wide spectrums of plastics and articles manufactured by the
industry have touched the life of every Indian in many ways through consumer
plastics. Now we have entered into another era of plastic consumer goods
continuously replacing the traditional items. The items cover from furniture to
medical sciences from lutchen equipment to daily use articles.

Biodegradable cups and plates from Sugarcane bagasse, wood pulp or bamboo
pulp are used in daily life now a day. In addition to be used at home these are
largely used during at hournies, parties and other functions.

The use of disposable items is increasing day by day because of better hygienic
conditions, low cost, easy usability and impressive appearance.

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 CONTENTS

INTRODUCTION
10 INCH BAGASSE ROUND REGULAR PLATE
140ML BAGASSE CUP
RANGE & VARIETY
WHAT IS RICE HUSK IN RICE HUSK PACKAGING
RICE HUSK COFFEE CUP
RICE HUSK LUNCH BOX
RICE HUSK BOTTLE
BENEFITS OF RICE HUSK PACKAGING
RICE HUSK TABLEWARE
COMPARISON OF BAGASSE VS PAPER AND OTHER MATERIAL
WHAT IS BAGASSE
HOW WELL DO BAGASSE PRODUCTS HANDLE HEAT?
SUGARCANE BAGASSE PRODUCTS
ARECA LEAF CUTLERY
RICE HUSK TABLEWARE
BAMBOO TABLEWARE
MARKET ANALYSIS, POTENTIAL & GROWTH GLOBAL BIODEGRADABLE
FOOD PACKAGING MARKET
GLOBAL MARKET POSITION OF BIODEGRADABLE CUTLERY
AND FOOD SERVICE DISPOSABLE
MANUFACTURERS ARE ACTIVELY FOCUSING ON PRODUCT LAUNCHES
MANUFACTURERS ARE ALSO LOOKING FOR EXPANSION
OF THEIR MANUFACTURING FACILITIES
US DOMINATE THE DISPOSABLE TABLEWARE AND CUTLERY MARKET
COMPOSTABLE TABLEWARE MARKET POSITION
COMPOSTABLE TABLEWARE MARKET
CLASSIFICATION OF GLOBAL FOOD PACKAGING
MARKET SCENARIO
US DEMAND TO RISE 3.6% ANNUALLY THROUGH 2017
PACKAGING PRODUCTS TO BE FASTEST GROWING TYPES
SERVICEWARE TO BE SUPPORTED BY FAVORABLE MARKET TRENDS
BIODEGRADABLE TABLEWARE IMPORT DATA IN USA
PRESENT MANUFACTURERS/SUPPLIERS OF BIODEGRADABLE
DISPOSABLE CUTLERY
KEY BIODEGRADABLE PACKAGING PLAYER IN INDIA
PROPERTIES & CHARACTERISTICS
BENEFITS OF THERMOFORMED FIBER
MANUFACTURING PROCESS OF RICE HUSK FIBER PRODUCTS

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PROCESS FLOW DIAGRAM
PULP THERMOFORMING AND MOLDED FIBER PACKAGING
DETAILS OF MOULDED PULP
ABOUT MOLDED PULP
FIGURE ONE: CUSHION CURVES
FIGURE TWO: DROP TEST
MANUFACTURING PROCESS OF BIODEGRADABLE CUPS & PLATES PLANT
PROCESS FLOW DIAGRAM
PROCESS OF MOLDED PULP
SUSTAINABILITY OF MOLDED PULP
BAGASSE PULP PLATE MAKING MACHINE
FLOW CHART OF BAGASSE TABLEWARE PRODUCTION LINE
PULP FIBRE TABLEWARE PRODUCTION PROCESS
PULP TABLEWARE PRODUCTION LINE
PLANT FIBER TABLEWARE MACHINE
PLANT FIBER TABLEWARE MACHINE
PRODUCTION PROCESS
MODIFIED PLASTICS PLANT FIBER HIGHLIGHTS
SUGARCANE BAGASSE PULP MOLDED TABLEWARE PRODUCTION LINE
(SEMI-AUTO ELECTRIC HEATED) CAP: 1 TPD
SUGARCANE BAGASSE PULP MOLDED TABLEWARE PRODUCTION LINE
(SEMI-AUTO ELECTRIC HEATED) 3 TPD
TECHNICAL SPECIFICATION OF PULP PROVIDING SYSTEM FOR 1 TPD
(150-180 KG/HR.)
TECHNICAL SPECIFICATIONS OF PULP PROVIDING SYSTEM FOR 3 TPD
(150-180 KGS/HR.)
OTHER BAGASSE/WOOD/BAMBOO PULP PRODUCTS
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
SUPPLIERS OF PLANT AND MACHINERY (INDIAN)

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 700 Kg/Day

Land & Building (1500 sq.mt.) Rs. 2.09 Cr
Plant & Machinery Rs. 1.60 Cr
Working Capital for 2 Months Rs. 45 Cr
Total Capital Investment Rs. 4.30 Cr
Rate of Return 35%
Break Even Point 54%

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