PROJECT REPORT

Cost analysis of setting up a waste paper recycling unit And some suggestions to generate revenue and Environment friendly system

1) INTRODUCTION TO PAPER AND HISTORY OF RECYCLED AND VIRGIN PAPER:Paper is a thin material mainly used for writing upon, printing upon, drawing or for packaging. It is produced by pressing together moist fibers, typically cellulose pulp derived from wood, rags or grasses, and drying them into flexible sheets. Many people assume that tree-free and recycled paper are new environmental "fads." But paper has only been made from wood pulp since the 1850s. The first recycled paper dates back almost 2,000 years to when a Chinese court official, Ts'ai Lun, developed paper made from rags, old fishing nets, hemp and China grass for the Chinese Royal Court in the second century. (Clearly, this was tree-free and chlorine-free paper as well!) 2) WHY MAKING RECYCLED PAPER? Recycling paper has several benefits both for humans and the earth. * Using recycled paper to make new paper reduces the number of Trees that are cut down , conserving natural resources. *In the landfill , where 80% of the discarded paper ends up, the Decomposition of paper produces methane, a greenhouse gas With 21 times heat-trapping power of Carbon dioxide . Paper Recycling recovers used paper from the waste stream directly Reducing the amount of landfill .

* Cost of recycled paper will be less than the virgin paper as the Demand for recycled paper increases. * There is no reason not to use recycled papers. They print as well As virgin papers work well on laser printers.

3) Uses of Recycled paper:Office grade paper and files for office uses Sessional files Decorative and Fancy paper Carry bags Gift wrapping paper Marble paper and blended fibre paper Invitation cards, greeting cards, hotel menu cards etc. Stationery items like pads, envelopes, price tags, diary, Note books.

4) INDIAN DOWMESTIC MARKET:The present domestic market presents divergent scenario with persistent and sustained demand for quality products on one hand and scarcity of such quality items on the other Central Govt. & State Govt. are main purchasers of file covers, flaps, file boards etc.Govt. of India reserved 50% to purchase file cover and office stationery from KVIC/KVIB units which is to be implemented in an organized way. If only 10% of this supply is reserved for handmade paper industries, it will be about 7 times the present quantum of production. Besides, there is the non-captive market which can be classified into institutional and non-institutional. Institutional market demands bigger quantities while non-institutional smaller. There are the eco-conscious buyers who purchase environment friendly produces to enhance its image. There are the quality

conscious buyers who purchase handmade paper for its exclusiveness in texture, long lasting quality and beauty. There are the price conscious buyers who purchase handmade paper because it is cheaper than mill made products for some varieties.

5) IMPORTANCE FOR COLLEGE:Copies of minor exams, major exams, sessionals, practical files, office work paper(need not to be of same year if there is restriction) can easily converted to files which can be used as sessional files and office grade files. CALCULATION OF COLLEGE WASTE PAPER(KG):Weight of 1 minor copy = 0.015 Kg Weight of 1 major copy = 0.060 Kg Weight of 1 practical copy = 0.2 Kg Weight of 1 sessional file = 0.05 Kg Total no of students = 4300 1-Minor copies =No of subjects* No of students*No of minors/year*weight of one minor copy =6*4300*4*0.015 =1548 Kg 2-Major copies =No of subjects*No of students*No of majors/year*weight Of one major copy =6*4300*2*0.060 =3096 Kg 3-Sessionals One sessional have weigth equal to a minor copy. Each student submit 1 sessional in the semester in 1 Subject. =No of subjects*No of students*weight of one sessional* 2 (for 2 semesters) =6*4300*0.015*2 =774 Kg

4-Practical files =No of labs in year *No of students*weight of practical file =4*4300*0.2 =3440 Kg 5-Sessional files = No of subjects in sem*2*No of students*weight of 1 Sessional file = 6*2**4300* 0.05 = 2580 Kg 5-Acadamic and administrative waste = 5000 Kg Total waste paper weight =1548+3096+774+3440+2580+5000 = 16438 Kg 6) PROCESS DESCRIPTION: FOR HOSIERY WASTE & WASTE PAPER LINE RAG CHOPPING: The hosiery waste is chopped in to small pieces With the help of rags cutter.Cotton is used to Strengthen the fibre of waste paper. 15% of cotton will be sufficient for waste. BEATING: The chopped raw material is loaded into the Beater for beating of raw material so as to make It into pulp form for sheet making . Additives Rosin and alum can be added for writing papers Generally rosin is added before alum. Sodium silicate is another additive used for Giving hardness to the paper.Bleach can also Be used for removing ink and making writing Paper.

HYDRA-PULPER: The waste paper is loaded in the Hydra-pulper And mixed with water. The waste paper is Converted into pulp slurry. Water added 2 times the waste paper. SHEET MAKING: Both the pulps of hosiery waste and waste paper Are mixed in desired proportions and sheets are Formed on auto-vat manually and couched on Couching table using felt between every sheet. PRESSING: The pile of sheets from the couching table is Taken for the squeezing press for squeezing Excess water. DRYING: The pressed sheet are dried in the Dryer Room By hanging the sheets or under the sun in open. CALENDERING: The dried sheets are having very uneven Surface, therefore passed through calendar rolls For smoothening the surface. CUTTING/FINISHING: The calendered sheets are cut in to the required Size and packed in a proper way so as to be Transported to the customer safely.

7) SCHEMATIC DIAGRAM OF PROCESS:-

8) SETUP COST WITH SPECIFICATION OF MACHINES:S.NO. MACHINERY AND EQUIPMENT SPECIFICATION COST

HYDRAPULPER CYLINDRICAL BODY OF MS (D=0.6M,H=0.8M) MOTOR (5 HP,960 RPM) BLADE BELT DRIVE AND PULLEY SIZE 12*36 CALENDARING MOTOR 5HP , 960 RPM MACHINE AUTO-VAT STAINLESS STEEL TANK(complete With stands) (L=41,W=65,Depth=13) DECKLE(WOODEN)(2 in nos) (L=31,W=25,T=1/2,H=5) Mould (2 nos) (L=31,W=25,T=1/2,Bredth=1.5) Chain 4 in nos Weight lifting mechanism(2in nos) Aluminum screening for Mould

90,000

1,60,000

20,000

SMALL BEATER SIZE 15*18 ,SS BODY CAP 8-10 Kg , 5 HP MOTOR

Not neccesary

5 6

RAG CUTTER SCREW PRESS MACHINE CUTTING MACHINE STORAGE TANK TABLE

BLADE SIZE 10-12 NO OF BLADES 4/6 5 HP 960 RPM MOTOR Plate size(35*30) Motor (5 HP, 960RPM) 36 5 HP 960 RPM PLASTIC STORAGE TANK (CAPACITY=100 Liter) WOODEN SIZE 30*25 TOTAL COST

Not necessary 1,00,000

7 8

1,00,000 1000

1000 = 4, 72,000 Rs

9) ANNUAL COST ANALYSIS:ASSUMPTIONS:1-Total working days and working hours are 300 per year and 8 hours Per day . 2.2 FILES ARE PRODUCED FROM EACH SHEET. 3. Efficiency of plant is taken to be 90%. ANALYSIS 1:-According to production Capacity No of files produced by Auto-Vat/5min= 4 No of files produced per Day As efficiency is 90% hence files produced per Day = No of files produced/annum COST OF PRODUCTION LABOUR (3 , 3600 RS PER MONTH) 1,29,600 ELECTRICITY 30,000 WATER(APPROX 14000 LTR) 3,000 PRINTING 25,000 TOTAL 1,87,600 RS = 384 345 = 1, 03,680

ANNUAL SALES 4,14,720RS ANNUAL GROSS PROFIT 2,27,120 RS PROVISION FOR TAX(30% OF PRF) 68,136 RS NET PROFIT 1,58,984 RS TOTAL SETUP COST CAN BE GAIN BEFORE 3 YRS.

ABSTRACT

Waste paper recycling benefitted both the producer and the environMent. Waste paper on the road when degraded produce methane which is greenhouse gas cause the temperature of earth increases. Waste paper available at low cost than virgin paper. Natural Resources Can be saved by making recycled paper. Recycled paper can print as Well. Approximate calculated waste of more than 16,000 per year can be converted into files for office and sessional uses. If more files are Produced then they can be sold outside or in market. Hence waste paper recycling is very useful and profitable process that can be used To fulfill your and others requirements of paper.

MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY (A INSTITUTE OF NATIONAL IMPORTANCE) BHOPAL-462007

DEPARTMENT OF MECHANICAL ENGINEERING MINOR PROJECT REPORT ON

Cost analysis of setting up a waste paper recycling unit And some suggestions to generate revenue and Environment friendly system UNDER THE GUIDENCE OF PROF. R.S. RANA SUBMITTED BY PRAKHAR DEEP KULSHRESHTHA (091116122) SUDHIR KUMAR RAWAT (091116061) SATYENDRA SINGH DHAKAR(091116063) SESSION- 2011-2012

MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY

(A INSTITUTE OF NATIONAL IMPORTANCE)

DEPARTMENT OF MECHANICAL ENGINEERING CERTIFICATE SESSION 2011-2012

THIS IS TO CERTIFY THAT MINOR PROJECT REPORT ON Cost analysis of setting up a waste paper recycling unit And some suggestions to generate revenue and Environment friendly system BY PRAKHAR DEEP KULSHRESHTHA,SATYENDRA DHAKAD,SUDHIR KUMAR RAWAT SUBMITTED AT MANIT,BHOPAL,AS BONAFIDE PRESESNTATION OF THE WORK DONE BY THEM UNDER MY GUIDENCE AND SUPERVISION DURING 2011-2012 .DURING THE COURSE OF PROJECT THEY WERE FOUND TO BE SINCERE AND DILIGENT AND HAVE CARRIED IT OUT TO MY SATISFACTION.

Dr. R.M.SARVIYA HOD MECHANICAL ENGINEERING DEPARTMENT

PROF. R.S. RANA (PROJECT GUIDE)

ACKNOWLEDGEMENT We feel proud privilege to express our deep sense of gratitude and indebtedness to Prof. R.S. Rana, Mechanical Engineering Department Bhopal for providing his painstaking and untiring supervision .We owe him constant encouragement. We also wish to express our sincere thanks to Dr. R.M. Sarviya, HOD, Department of Mechanical Engineering and Director of our college Dr. Appu Kuttan for providing the necessary facilities for completion of the project. We also express our thanks to all faculty Members and the staff of Mechanical Engineering Department without Whose constant support and guidance, this project would not have been completed. We also express our sincere gratitude towards Environmental Planning & Coordination Organization (EPCO) Bhopal for demonstrating full procedure of recycled paper making.

BHOPAL Date:-

Prakhar deep kulshreshtha(091116122) Sudhir kumar rawat(091116061) Satyendra singh dhakar(091116063)