Plastic Waste Recycling Plant

Name of the Industry

Location

Sonapur VDC Sunsari

Objective

Plastic Waste Recycling into granulate form

(Bio-Tech & Materials with problematic structures)

Capacity

15000 MT annually ( 100 % Efficiency)

Major Materials to be used

PP, PE(HDPE,LLDPE/LDPE), PET,PVC,ABS,NYLON

(All types of floor wastes in rolls,loose or
bundled,bags,pipes,injection moulded parts,
profiles, fibres,fabric , Yarn and ropes,carpets)

Working Days

Total Project investment

(a) Fixed Capital
(b) Working Capital

:
:

140,000,000.00
200,000,000.00

Bank Loan

180,000,000.00

Employment Generation

300 Days

:
15
50

Skilled
Unskilled

Electricity

Financial Results
ROI
ROE
BEP

750 KVA

FIXED CAPITAL INVESTMENT

:

20,000,000.00

12,000,000.00

Raw Material Godown

15000 Sq. Ft x Rs 500/ Sq Ft.

7,500,000.00

Finished Goods Godown

8000 Sq. Ft x Rs 600/ Sq Ft.

4,800,000.00

Office Block
3000 Sq. Ft x Rs 1200/ Sq Ft.

3,600,000.00

Staff Quarter
6000 Sq. Ft x Rs 1000/ Sq Ft.

6,000,000.00

LAND & LAND DEVELOPMENT

(5 Bigha x 40,00,000/ Bigha

BUILDINGS
Machine Godown
20000 Sq. Ft x Rs 600/ Sq Ft.

33,900,000.00

Total Buildings
PLANT & MACHINERY
Main Machine
Extruder 400 kg/ hour Capacity with Ancillary

55,000,000.00

Cutter Grinder

2,500,000.00

Compressure

1,000,000.00

Chilling Plant 75TR Air Cooled

2,500,000.00

Transformer 750 KVA Cap.

1,500,000.00

Main Panel for Electrification

2,500,000.00

Generator Set 500 KVA

3,500,000.00

Spares/ Misc

1,500,000.00

70,000,000.00

Total Plant & Machineries

Furniture & Fixtures

1,000,000.00

Customs Duty/ Erection

3,000,000.00

PRE-OPERATING EXPENSES
Travelling/ Consultancy

1,500,000.00

Interest

3,500,000.00

Total Pre-Operating Expenses

Total Fixed Capital Investment

5,000,000.00

132,900,000.00

Working Capital Requirement

1000 MT/ month x 3 Months (USD 600/ MT)

200,000,000.00

Annual Operating Costs

Per Unit

(1) Depreciation

12,445,000.00

(2) Indirect Exp

500,000.00

(3) Insurance

600,000.00

(4) Interest

27,000,000.00

(5) Office Overheads

500,000.00

(6) Repair & Maintenance

1,000,000.00

Total Fixed op. Cost

(1) Raw Material

42,045,000.00
:

612,000,000.00

(2) Power & Electric

10,200,000.00

(3) Utilities/Fuel & Lubricants

3,800,000.00

(4) Direct Labour & Staff

9,880,000.00

USD 600 x 12000 MT (80 % Efficiency)

Exchage Rate @ 85/ USD

Total Variable op. Cost

635,880,000.00

677,925,000.00

Total Annual Operating Cost

PRODUCTION
Consumption
12000 MT @ USD 600 x 85/Wastage
(12-20 % rejects)
Net Production

12,000.00 MT

15%

1,800.00 MT

10,200.00

REVENUE
10200 MT X 68000/-

693,600,000.00

NET PROFIT
867000000-67925000

15,675,000.00

52,990.00

Efficiency Chart Based on Production Capacity

In Percent
100
90
80
70
60
50
40

In Units (MT)
15000
13500
12000
10500
9000
7500
6000

Efficiency Chart
16000
14000
12000
10000
8000

In Units (MT)

6000
4000
2000
0
100

90

80

70

60

50

40

Calculation of Fixed & Direct Overheads

---------------------------------------------------------------------------------------------------------------------------------Depreciation
PLANT & MACHINERY

70,000,000.00

15%

10,500,000.00

BUILDING

33,900,000.00

5%

1,695,000.00

1,000,000.00

25%

250,000.00

FURNITURE & FIXTURES

104,900,000.00
12,445,000.00
---------------------------------------------------------------------------------------------------------------------------------Direct Expenses
Power & Fuel
12000 MT x 1000 Unit @ 8.50

10,200,000.00

Direct Labour/ Fac Staff Salary

9,880,000.00

Lubricants & Others

1,000,000.00

Packing Expenses

500,000.00

21,580,000.00
----------------------------------------------------------------------------------------------------------------------------------

Manpower Utilisation
S.No.
1
2
3
4
5
6
7

Category
Production Manager
Asst. Prod. Manager
Shift Supervisor
Factory Official Staff
Admn Staff
Helpers
Labours

Nos of Person
1
2
6
6
2
35
25

Rate
50,000.00
20,000.00
20,000.00
15,000.00
15,000.00
8,000.00
6,000.00

Annual Payment
650,000.00
520,000.00
1,560,000.00
1,170,000.00
390,000.00
3,640,000.00
1,950,000.00
9,880,000.00

Production Manager
2

Asst. Prod. Manager

6

25

Shift Supervisor
Factory Official Staff
Admn Staff
Helpers

35

Labours

BEP CALCULATION
F/Y
Production (MT) *
Year 1
7200
Year 2
8400
Year 3
9600
Year 4
10800

Efficiency
60%
70%
80%
90%

BEP in Unit
2,801.13
2,686.39
2,588.72
2,505.47

*Assume 100 % Efficiency = 12000 MT/ Yr

# BEP = TFC/SPU-VPU
Year 1 Depreciation
PLANT & MACHINERY

70,000,000.00

15%

10,500,000.00

BUILDING

33,900,000.00

5%

1,695,000.00

1,000,000.00

25%

FURNITURE & FIXTURES

104,900,000.00

250,000.00
12,445,000.00

12000

Year 2 Depreciation
PLANT & MACHINERY

59,500,000.00

15%

8,925,000.00

BUILDING

32,205,000.00

5%

1,610,250.00

750,000.00

25%

187,500.00

FURNITURE & FIXTURES

92,455,000.00

10,722,750.00

Year 3 Depreciation
PLANT & MACHINERY

50,575,000.00

BUILDING

15%

7,586,250.00

30,594,750.00

5%

1,529,737.50

562,500.00

25%

FURNITURE & FIXTURES

10000

81,732,250.00

8000
Production (MT)
*

140,625.00
9,256,612.50

6000

BEP in Unit

Year 3 Depreciation
PLANT & MACHINERY

42,988,750.00

15%

6,448,312.50

BUILDING

29,065,012.50

5%

1,453,250.63

421,875.00

25%

105,468.75

FURNITURE & FIXTURES

72,475,637.50

4000

8,007,031.88

2000
Year 1
(1)

Depreciation

12,445,000.00

(2)

Indirect Exp

500,000.00

(3)

Insurance

600,000.00

(4)

Interest

27,000,000.00

(5)

Office Overheads

500,000.00

(6)

Repair & Maintenance

1,000,000.00

Total Fixed op. Cost

42,045,000.00

Year 2
(1)

Depreciation

10,722,750.00

(2)

Indirect Exp

500,000.00

(3)

Insurance

600,000.00

(4)

Interest

27,000,000.00

(5)

Office Overheads

500,000.00

(6)

Repair & Maintenance

1,000,000.00

Total Fixed op. Cost

40,322,750.00

Year 3
(1)

Depreciation

9,256,612.50

(2)

Indirect Exp

500,000.00

(3)

Insurance

600,000.00

(4)

Interest

27,000,000.00

(5)

Office Overheads

500,000.00

(6)

Repair & Maintenance

1,000,000.00

Total Fixed op. Cost

38,856,612.50

Year 4
(1)

Depreciation

8,007,031.88

(2)

Indirect Exp

500,000.00

(3)

Insurance

600,000.00

(4)

Interest

27,000,000.00

(5)

Office Overheads

500,000.00

(6)

Repair & Maintenance

1,000,000.00

Total Fixed op. Cost

37,607,031.88

0
Year 1 Year 2 Year 3 Year 4

PROCESS OF SCRAP PROCESSING INDUSTRY