Sunday, 17 June 2018

Sample Project Report on Waste Plastic Reinforced Concrete Block.


             INDUSTRIAL CONSUSLTANCY &
              MARKETING SERVICES REGD.
                               OPP R D O OFFICE, CHENGANNUR

    Waste Plastic Elimination Project

Index
1.            Introduction
2.            Market & Selling Arrangements
3.            Project Details
4.            Cost of project & Means of Finance
5.            Finacial Viability
6.            Conculsion & Recommendations
7.            List of Annexures
               Annexure             I              Bio-data of the promoter
               Annexure             II             Locational details
               Annexure             III           Paln of the factory building
               Annexure             IV           Estimate of the Factory Building
               Annexure             V            Details of Machinery and Equipments
               Annexure             VI           Details of Miscellaneous Fixed Assets
               Annexure             VII          Product Mix & Sales realisation
               Annexure             VIII        Raw materials & Consumables
               Annexure             IX           Utilities
               Annexure             X            Manpower requirement
               Annexure             XI           Calculation of working Capital
               Annexure             XII          Repayment schedule
               Annexure             XIII        Projected Profitability Statement
               Annexure             XIV        Projected Cashflow Statement                     
               Annexure             XV         Projected Balance Sheet
               Annexure             XVI        Calculation of Income Tax
               Annexure             XVII       Calculation of Depreciation
               Annexure             XVIII     Break Even Analysis
               Annexure             XIX        Performance Ratio
               Annexure             XX         Risk Analysis

   Waste Plastic Elimination Project
Project Report
1.  Introduction
        1.A.     Plastic is non-degradable.  So when it is thrown away, it creates havoc that is potentially eternal.  Polybags, disposable plastic tubmblers and several such items that thrown away recklessly pose formidable threat to all locations such as mountains, plains, water etc. in several ways.  Sometimes they create backflow in sewage.  Plastic bags are found to be causing immeasurable harm to marine life.  Streams and rivers too are affected.  In mountainous areas the scourge intensifies. As an omnipresent danger, the waste plastic is to be eliminated.
                    Unfortunately there is no safe way to eliminate this threat. Recycling is unlikely for two reasons. Firstly at about six microns of thickness it takes upwards 250 bags to make one kilo of plastic which at best fetches only one rupee. Secondly, plastic cannot be continuously recycled since most carry bags are made of recycled materials and their future use to the reprocessing industry is limited. Incinerating and burning for other purposes result in air pollution and toxic ash.
                    The short - cut way found out by authorities has been to ban use of plastic as far as possible. Further, some Non Government Organizations have tried to urge the public to limit the use of plastic with little effect. In some cases, Governments have come forward to check the use of plastic  through legislature. This adversely affect livelihood of certain people.
                    Inspite of all these efforts, the crucial situation remains unaffected because of non availability of a suitable alternative. No cheap and convenient substitute for plastic has so far been evolved. Without presenting a suitable substitute, it is not legitimate to ban such a useful item.
                    Regarding waste management, including disposal, in several cases, it is done without any earning. Land filling is one example. But in the present case, the project is planned to be run in good profit to the implementing agency. The project is suggested to implement in each and every district. In a district, there may be several self governing local bodies who may be in bad need of waste management solutions. They all can be benefited with one centralised project.
1.  b            The disposal of Municipal Solid Waste (MSW) is a universal problem.  In India, the situation relating to disposal of municipal waste is generally alarming.  The Municipal Corporations in India are unable to manage the quantities of wastes generated every day which are increasing in geometric proportions year after year. A number of methods have been tried without much success.
                    The quantity of MSW generated depends upon a number of factors such as food habits, standard of living, degree of commercial and industrial activity.  Besides, the quantity of urban solid waste generation varies seasonally also.  For the city of Delhi, generation of MSW is reported to be 6500 tonnes day and is likely to reach 10,000 t/day by another decade.  Physical characteristics of Municipal Solid Waste generated by the Metro cities vary from place to place.  As reported in 1994, the composition of MSW for Delhi in percentages is given below:
Name of Metro Paper Textile   Leather   Plastic   Metal   Glass   Ash,fine Bio gradable
Delhi                  6.6       4.0          0.6           1.5         2.5        1.2         51.5           31.78
1.C. Processing Systems :
                    Here the project envisaged is to consume the waste plastic in the form of filler mixed with cement, and glue if necessary, to create a paste form to be filled in the cavities of concrete hollow blocks and other construction blocks during its automatic manufacturing process. The waste plastic - cement paste can be put inside the blocks during the manufacturing of pavement blocks, sewage duct wall blocks etc. The waste plastic is proposed to be cut into minute pieces in an automatic cutting machine. Then it will be mixed with cement, stickers & water in a chamber to form a paste form. Simultaneously, the hollow blocks or other blocks will be manufactured fully automatically and the paste so manufactured will be filled in the vacant cavities & inner parts of other blocks & will be sealed with concrete so as to make no contact with outer world anytime in future. The entire process is fully automatic so as to minimise the number of labour into twenty or so as per the size of the plant.
. 1.D.          It is proposed to be implemented at least in all 14  Districts in the State and then in important metros in India in phased manner.  The project is proposed to be taken up as a whole and implemented one by one in accordance with the gravity or pollution.  As such calculations are given for 14 units  so as to assess the total implication of funds.
1.E. Solid Waste Management

                    Till now, there has not been any answer to the problem of disposal of MSW in an environment-friendly manner. The Romelt technology, developed by Moscow Institute for Steel and Alloys (MISA), though primarily developed for extraction of iron from any iron bearing material/wastes, has now been made suited to cover MSW as well.  There is now an answer to the vexing problem of MSW treatment. However, the management of mSW does not come in purview of the present project.

                    The existing methods adopted for waste management are as following:

        1.F. 1. Land Filling
                    Generally, MSW is disposed off by dumping in low-lying grounds as a land fill.   This is the cheapest and the easiest form of disposal, nevertheless, it requires huge area of low lying, preferably fallow lands, around the city which is increasingly becoming scarce, particularly for a small state like Delhi.  Besides, this method leads to various types of communicable diseases and ground water contamination in the vicinity of the dumping area.

        1.F. 2. Composting
                    The  method segregating biodegradable wastes and using them for biodegradation to produce Composite, which can be used as manure.  This is a viable method, but has not achieved the desired results so far.  The compost plants in Delhi are facing problem in  selling the compost, which in turn is hampering plant operation.            

        1.F. 3. Fuel pelletization / Reuse derived Fuel (RDF)
                    Another tried technology is to manufacture Reuse Derived Fuel (RDF) from the combustible component of MSW by Pyrolysis, which can be used as domestic fuel and used in the industrial ovens, etc.  this method also has its problem of selling the product in the cities, where these can be produced.

        1.F. 4. Incineration
                    Low temperature incineration produces toxic gases and the ashes thus produced, need environment friendly disposal.  Moreover, the bio-degradable fraction of MSW cannot be easily incinerated because of low calorific value and high moisture content, without support of external fuel.

                    In choosing the method for solid water disposal, the following factors may be taken into consideration.
  u  The solid waste disposal method should lead to sustainable development of the urban areas and not choke these to slow death.
  u  Making the best possible use of natural resources, either by recovering energy or by-products.
  u  avoiding secondary pollution, which may generate more hazard than they by the original waste.
  u  obtaining the best balance between substantiality, economy and efficiency.
1. G.       Promoters : The promoter of the project is a Consultancy Organisation  located in Chengannur,named INCOMS, Opposite of R. D. O office, Alappuzha Dist, Kerala, India. The Director of the firm is Mr. S. K. Vijayan, who is having his post graduation in English Literature. Further he is doing his MBA. Moreover, he is  having several certificates in Management Studies. He has some scientific back ground while he was in school studies.SHe posses a patent for one  of his meritorious inventions. Another of his inventions has been approved by the NRDC for Patent Assistance. Some other inventions are underway too. The present project is also another project propounded by himself and is under consideration for approval by the Government of Kerala & Government of Karnataka. A United Nations agency viz APCTT has recommended this project as an “ideal solution” against the havoc of waste plastic. APCTT has published a write - up in their International Magazine viz. Vatis update : waste technology. Further details on the bio - data of the promoters are available in Annexure No - 1. The other foundes of the trust are well educated and experienced in their respective fields.
        1.H.    The products:  The products proposed to be manufactured in the unit are given below. Basically this project is proposed to set up with a view to eliminate the dangers of waste plastic and municipal solid waste. As such, all ways will be exploited to use the waste plastic and MSW in harmless way. At present the following items are proposed to manufacture using waste plastic & MSW.
        I.H. 1. Blocks filled with waste plastic paste: This may be called waste plastic filled cavity-less blocks. The cavity will be filled with plastic concrete paste so that no cavity will be left there. The present day cavity blocks are not safe for construction because the empty place in side the blocks will develop air pressure and will cause breakage to the walls. More over, if not plastered well it will give place to survive harmful insects etc. They also do not present a beautiful finishing touch. However, the proposed blocks do not present any type of problem. They are well finished and without air cavity. The cost of the same will be lower than the ordinary type too.
        1. H. 2. Pavement blocks: Pavement blocks can be manufactured by concealing the cement paste inside it. These blocks will be strengthy and cost effective.
        1. H. 3. Sewage duct wall blocks: The Self Governing Local Bodies require large quantity of sewage duct walls. At present they built them at site or use readymade blocks. If these are replaced by plastic waste concealed wall blocks, cost can be minimized and the greatest danger of waste plastic can be eliminated too.
    1. I. Technology :
        1. I.     1. Waste Plastic Consumption : The process introduced is a very new one with a Provisional patent to the proposer. The technology involved in the process is briefed as following:-
                    The collected waste plastic is arranged without any dirt and subjected to cutting into very minute pieces in an automatic cutting machine.  The small cut pieces are mixed with cement and stickers for making a paste form.  While this is formed and passed to the block making machine, concrete blocks will be ready on the block making machine to receive this past which is pushed in to the cavity formed in the block making machine itself.  At this point, the paste in the cavity, it is passed forward to seal the plastic paste with ordinary concrete.  This makes the paste not to come in touch with outer world.  Then it is allowed to get set and passes to curing tank.  When it is cured, it can be passed for selling.  (The designs and specifications are kept confidential and are available for examination only after entering into an agreement.)
                    It is purely a mechanical process which an experienced engineer can perform effectively. Arrangements are made with a Bangalore based firm to manufacture these machines as per the designs & specifications supplied by us.
                    Consumption of MSW   (As published in the CDE Journal)
                    The process takes place as follow: The furnace lining is dried and preheated.  Then a slag bath is formed in the furnace by charging and melting granulated blast furnace slag from steel plants. After the slag bath temperature is brought up to the working level of 1350-15000C, the furnace charging with wastes starts.  The furnace temperature should be 50-1000C above the slag liquidous temperature for the slag to be tapped from the furnace.
                    The wastes are discharged from the bunkers by proportioning devices onto the collecting conveyors, then these get into the furnace through a hole in the furnace dome and get into the slag bath in the furnace.
                    The slag bath is blown through the side tuyeres by a blast which is a mixture of oxygen and air.  In doing so, the slag bath divided into an upper bubbled zone and a lower under tuyere zone of slowly mixed slag.  After getting into the bubbled zone, the wastes are mixed into the melt and distributed along the slag bath volume by streams of slag.
                    The mineral portion of the wastes gets dissolved in the slag melt.  To correct the slag chemical analysis and to ensure its fluidity at the furnace operating temperatures, flux is added depending on the composition of the mineral content of the waters.  Lime, lime stone, convertor (LD) slag etc. are common fluxes which are used.
                    Carbon remaining in the wastes after the exit of the volatile components is oxidized by the blast oxygen through the blowing tuyeres. The carbon is usually oxidised to carbon monoxide and partly to carbon dioxide. The carbon monoxide as bubbled through the slag reduces the iron oxides present in the waste (scale etc.) to liquid iron along with the iron scrap available in the waste and settles at the reactor bottom after carbonization.
                    Additional fuel may be required to support the system if the carbon content in the waste is not sufficient. Natural gas  supplies along with the blast to the blowing tuyeres can be used as an additional fuel. Other carbon rich wastes like spent automobile tiers, Coal rejects or coal, oil refining wastes, wood processing wastes can be also used,.
                    Combustible gases generated during exit of the volatile components, partial burning of waste carbon and additional fuel in the slag melt volume are subject to post combustion above the melt Surface by oxygen supplied to the second tuyere system. The post combustion heat generated between slag bath, furnace water cooled elements and fuel gases. 50-70% of the post combustion heat generated to the slag bath.
                    The post combustion gases are removed from the furnace at the temperature of 1400-1600.c with the help of ID fan via a waste heat boiler and dust  cleaning system.
                    Among the different metals Present  in the waste, FeV, Ni,Cr and Cu mostly go to metal and some to slag. While, most of alkali, Zn Cd, Hg,Pb and Sn go to the waste gases. S present in the waste, mostly is arrested along with the dust in the catchers and thus, the toxicity of the flux reduces.
                    Low dust discharge (less than 1%) is a salient feature of the technology.  Since the process uses oxygen or enriched air.  The low volume of waste gases along with the effect of liquid slag drops ensures low dust generation .Further, usage of oxygen ensures low Nitrogen oxide in the waste gases after complete post combustion in the boilers. The level of Nitrogen Oxide is lower than 100mg/nm3 and usually it is 50-70mg/nm3.
                    The accumulated slag is tapped in continuous or batch mode.  The slag is tapped from the poorly agitated area under tuyeres.  It helps to avoid contamination of slag by carbon matters present in the wastes.  This is because the density of these carbon matters is lower than the density of slag and these will be kept in the zone of barbotized slag till their complete incineration.
                    The slag is homogeneous, is of low iron content and suitable for the production of various construction materials like crushed stone, mineral wool, stone casting, cement etc.
                    The Romelt process is the latest in the ‘Waste  to Energy’ systems now gaining popularity in the world and now encouraged by the Govt. as a means of non-conventional energy source.
                    This process can simultaneously process all types of MSW, viz. bio- degradable, recyclable and inert, along with hospital wastes and non toxic industrial wastes.  However, non-combustible materials in the MSW may be segregated from the feed to improve thermal efficiency of the process.  No other process does have the same range of MSW that can be simultaneously treated.
II.  Market & Selling Arrangements
        A.  Market
        1.         Plastic Reinforced Products : The promoters proposes to sell the products through Liaisoning & Selling Offices to be established in every state with district offices connected with manufacturing centres and all the centres will be connected through internet/intranet so that the entire activities can be controlled from a central controlling office.  In India the construction of Institutional Buildings, Rural Housing Programme, Urban Development Programs etc. are in progress.  Several million rupees are planned to be invested in rural development, housing etc. by the government of India.  State PWDs & Railways have ambitious construction programmes.  As such the market is very wide & selling of the products will be very easy to the promoters. The Governments are required to promote the sale of these items owing to the fact of social service involved.
                Market for each item : The basic purpose of the project is to eliminate the menace of waste plastic. As the waste plastic cannot be eliminated without consuming, it has been proposed to use it in useful activities.  The life of plastic is eternal.  So it is usable in long life products.  The safest way is to use it in construction materials in concealed form.  The construction materials proposed to manufacture are widely used hollow blocks, pavement blocks, sewage duct wall blocks etc.  These products have very high demand.  The main customers shall be Railways, PWDs, Gramapanchayats, Municipalities etc.  Civil construction companies shall also be very potential consumers of the said items.
        a)        Hollow Blocks : Concrete hollow blocks are extensively used by construction companies.  However, it is having a draw-back that it is vulnerable to air and insects if not plastered well. If the cavity is filled with a filler, this problem can be solved.  So it is considered that waste plastic-cement paste shall be filled in the cavities so as to fill the void and make an end to the problem of waste plastic.  Thus the hollow blocks will get more popularity and shall be sold profitably.  It is a very suitable item for low cost construction of houses for the poor. Slum housing programme of the Central Government may be benefited with this largely.
        b)        Pavement Blocks: Pavement blocks are used largely by Railways for construction of platforms.  PWD will also require pavement blocks for construction of  roads & other constructions, separation walls etc.  Hollow blocks can also be used for a number of their uses.  Local bodies can use this item largely for their civil works.
        c)        Sewage Duct Wall Blocks: The normal practice now a days is to make walls for sewage ducts using burnt bricks or ready made slabs.  Instead of this practice, plastic waste concealed blocks may be used.  This blocks will remain in the earth for longer period.  This may reduce the construction cost considerably.  This is also required largely by PWDs, Railways, Local Governing bodies etc.
                    As such it can be found that the market for the proposed items is very wide and the products are having very good selling scope.
        d)        Market for items obtained through Romelt Technology is just emerging and will be sold profitably in the inter national market.
B)    Selling Arrangement : Selling arrangement depends up of the way of functioning the unit.  The unit can be set up and run by the local governing bodies or by the licenced company.  In the event of any run unit by the Government bodies, they can make arrangements by issuing instruction to the customer- -organizations to purchase these items as and when required.  In the case of running the unit by licensed companies, they can make their own arrangements for selling the products.  In that case, the profit will go to that company.  However, in both the cases, it is advisable that the Government can consider to give subsidy to these products in view of the service rendered in the way of waste problem-solving factor involved in it.  Railways and PWDs can be instructed to give preference to these items.  As such the selling is not at all a problem in this case.
                    The promoters propose to sell these items through the production centres.  Sales Managers & Sales representatives will be appointed for canvasing orders for the product.  The company can consider to deliver the product in their own vehicle. They can also consider subsidised rates to push up the sales.
C)    Profit : Profit will, if there is any, be appropriated for loan repayment and for investment in the development of other units.
III. Project Details
        1.         Location, Land  & Building:
       a)      Location : The project is proposed to be located some-where near the Corporation area/District Head Quarters area.  The Lactational Details will be in accordance with location selected subsequently. The proposed location should be suitable for the project. It may be far away from the congested dwelling areas of the public. Even if there may be no pollution problem caused by the project, it is proposed to be at a location little far away from dwelling areas.  The proposed site should have access to electric power line with sufficient capacity, water facility, transporting facility etc.  The plastic waste is proposed not to be dumped up for long period at the production site.  It is proposed to consume the entire waste plastic & MSW as and when it is arrived  in the site.  Even if it is kept for one or two days, it will not affect the public.  There will be no type of emission from the unit so that the project will not make any type of nuisance to the public.  It is a completely closed process also.  There shall be ample road to the proposed site so that transportation of raw materials and finished goods will be easy.  Sufficient water facility shall also be available in the proposed site.  As such the location must be suitable for the project in the view of infrastructural facilities required for the project.
       b)      Land: The minimum requirement of land is estimated to be maximum 5 Hector.  This is for accommodating buildings to comprise production, store, curing tanks, office, rest house for workers, park area for vehicles etc.  The cost of land is estimated to about 10,000/- rupees per cent.  However, this much land is required to be made available by the local governing body free of cost so that no cash flow will be there from the promoting company towards land cost.  The land will be utilized for construction of production centre, store, curing tank, office, testing houses for workers etc.  The Trust proposes to avail so much land on permanent lease @ Rs. 1/- per cent.  
                The land will be protected by a compound wall with gate and lock.  It is assumed that the areas mentioned above is sufficient for setting up & functioning the project satisfactorily.
                    The land can be made available by the local body on a nominal fee as lease for a period of about 99 years or for a period that the local body wishes to continue to eliminate the threat of waste plastic menace.  As the land is made available at consideration up to the period of paying out the term loan, this can be offered as security for the financial assistance if proposed to be availed from any financial institutions.  The local body is required to give sanctions for offering the land as security for the financial assistance as well as mortgaging the super structure to the financial institution in the event of loan.
       c.       Building : A built up area of 13,500 sq ft is required for satisfactory working of the project.  The cost estimated for all civil construction is Rs. 50,00,000/-. This much built up area is required for accommodating plant and machinery, office, store, lavatory, rest houses for workers etc. A compound wall a well, overhead water tank etc. are also required to be constructed.  A curing tank is required for curing the blocks. A closed area is proposed to stock raw materials so that it will not pilfered to the nearby premises. However, the construction cost of building has been avoided from the present calculations since it may vary from place to place.
                    Detailed Plan and Estimate are given as Annexure III & IV.  The building will be constructed as soon as the land is availed, picking of the waste plastic & MSW will also be started and stored safely in the premises for onward processing.
                    The building will be constructed by contractors for speedy implementation.  Details of the buildings proposed to be constructed are available from the detailed plan and estimate.
2.    Machinery & Equipments
        The details of machinery & Equipments are as given below:
        1.         Fully Automatic Block Making Machine : This is the main machine on which all functions for forming blocks are performed.  This machine is supported by other helping machines like placing machine for dies, die lifting machine etc.  The dies for making items like hollow blocks, pavement blocks etc. are to be changed according to the item produced.  However, separate machine for each item can be installed so that every item shall be manufactured simultaneously.  The capacity of the machine can be regulated according to the availability of waste in  a particular area.  In a city where the generation of waste is high, there the capacity of the machine will have to be increased.  The cost of ordinary single size machine is calculated to Rs. Rs.5, 50,000-00               
3.     Block and Die lifting and placing Machine : This is set of supporting machines to the Block making machine.  As soon as the machine begins to function, a block will be placed on the main machine automatically by this machine.  During the next movement, the block will move to the second position where the base of the block is formed and make ready to the next move.  At this stage, the cavity making dies will be placed. After this, the space between the block die and cavity dies will be filled with concert by the automatic machine.  After this the cavity making dies will be lifted automatically. This is the function of the machine and cost of the machine comprising 8 sets is calculated to. Rs 8, 00,000-00 for eight sets are required for one double size machine.
        4.         Plastic Cutting Machine: This is an automatic device by which waste plastic of any kind coming upto 5mm thickness will be cut to 1mm square pieces.  These pieces will be received in a cavity of the machine from where it will be flown to a chamber bit by bit where it will be mixed with cement to form a perfect mixture.  The cost of this machine is calculated to Rs. 2, 25,000-00The plastic will be received by the mouth of the machine and it will be pressed to pass to the cutting portion of the machine.  All the functions are automatic.
        5.         Dies & Block Shifting Machine : Block and dies are lifted from the block making machine for the next step operation.  During this time blocks and ides are shifted to its original position for placing to the block making machine for the operations to be continued.  Both lifting & placing are done by two separate systems.  Two sets of this machine are required to one manufacturing unit.  Both are functioning at two sides.  The cost of one machine is estimated to Rs. .2, 25,000-00.
        6.         Fabricated Structure for Shifting Machine : The shifting machine is functioning on fabricated structures and geared wheel sets.  The height of the structure varies according to the size of the machine.  The cost of the structure including material cost and labour charges comes to Rs.1, 42,500-00         
        7.         Concrete &  Paste supplying Conveyors: The concrete and paste are proposed to be supplied through automatic conveyers.  These conveyors are special type for scattered spraying in the block making die.   These are the combination of two types of conveyors.  One is horizontal and the other is vertial.  Horizontal types will collect concrete from its manufacturing points and supply to the vertical type.  The vertical type will supply to the blocks and dies.  The cost of each items is estimated to Rs. .1, 50,000-00
        8.         Waste plastic mixing Machine : This is one of the main machines used in the project.  This machine will receive the plastic mixed cement in its cavity.  Then it will mix it firmly and will be passed to the next chamber where water mixed with glue will be received for mixing with Cement Plastic Ingredients.  In this chamber, they will mix firmly and create a solution for passing forward to the block making machine for filling in the cavity.  The cost of  one machine is estimated to Rs. 50,000/- Two numbers of machine are required for one double size type units.  So the cost of the machine is estimated to 1, 00,000-00
        9.         Plastic Paste Filling Machine:  This machine will inject the paste into the cavities of blocks.  This machine receives the paste and injects it into the cavities according to the size of the cavity.  The cost of the machines comes to Rs50.000/-.  Two  numbers are required for Double size project.  So the cost cames to Rs.1, 00,000-00
        10.      Concrete Mixing Machine: This is ordinary type concrete mixing machine.  The concrete is required to be mixed thoroughly for which an automatic concrete mixer is required.  The cost comes to Rs1, 00,000-00
        11.      Dies and Blocks: The block making machine comprises a 95 feet Long special type rubber conveyor.  This  is to be die cast for which a Die is to be prepared.  Further, block dies and cavity forming dies are to be manufactured. The cost of these die is calculated to Rs.1, 00,000-00.
        12.      Electrical & Electrification : All the machine are functioning with electricity.  About 12 electric motors of difference capacity are required.  Efficient controlling system is required to be installed.  Factory is to be electrified.  Cost of all these items has been estimated to Rs. 1, 00,000-00/-.  this expense is added with the cost of fixed assets. 
        13.      Erection & Fabrication: There is a lot of fabrication work to be executed in the unit.  The machine is functioning on a heavy metallic frame.  Conveyors are to be aligned suitably. Workers are to be positioned according to the position of operation on the fabricated structures.  The cost of fabrication and erection are estimated to Rs. 2, 50,000-00
        14.      Transportation and Miscellaneous Exp.: The machinery will be manufactured in Bangalore.  They are to be transported to the location of the factory.  The cost of transportation of the machinery is calculated to Rs.1, 00,000-00
        .           As such, the total cost estimated for Plant & Machinery for a single type unit is Rs.29, 42 ,000 x 14 Districts = 4,11,88,000-00 – Say Rs.4.12Crores
3.    Miscellaneous Fixed Assets:
        A         There are a number of miscellaneous items to be arranged.  They include working furniture, fire fighting equipments, water supply systems, vehicle for bringing raw materials and supply of finished goods etc. They all are summed up as following.
              Sl. No.                          Particulars                     Rate     Nos       Amount (Rs)           
                   1.           Office furniture including
                                 computers                                                                       1,75,000.00       
                   2.           Office Electricals                                                              20,000.00                     
                   3.           Office Settings                                                                   25,000.00       
                   4.           Water supply systems
                                 including storage tank                                                      25,000.00       
                   5.           Fire Fight Equipments                                                      50,000.00       
                   6.           Vehicles 1 No.                                                                 6,00,000.00       
                                 Total                                                                                 895,000-00
                                 For 14 District level units 895,,000 x 14 = 125,30,000 Say Rs. 1.25 Crore
This items are optional and it is to be provided as a second stage in the implementation of the project. As such this amount has not been included in the cost of the project at present  .
B.  Miscellaneous Fixed Assets in detail
        1.         Office Furniture : A well established office set up is required for every unit.  Computers are required for correspondence and net working.  The total amount expected to incur is Rs. 175,000/-
        2.         Office Electricals : Office is to be functioned with fan, light etc.  It may cost Rs. 20,000/-
        3.         Office Settings : Office is to be well arranged with cabins etc.  An amount of rs. 25,000/- is proposed to be invested in this.
        4.         Water Supply arrangement : Water supply arrangement including life pump,  over head tanks etc, are to be arranged. The cost comes to this is Rs. 25,000-
        5.         Fire Fighting Arrangement : An amount of Rs.50,000/- is proposed to be invested in fire fighting arrangements.  Waste plastic & paper will be stored in the compound for a very limited period.  As a precautionary measure, it is advisable to provide fire fighting arrangements.
        6.         Vehicles : At least 5 truck are required to collect waste plastic from all parts of district on daily basis.The cost for this is calculated to
Rs. 6,00,000/-..  In certain cases, finished goods will have to delivered to the customers also.
                    As such the total cost for miscellaneous fixed assets is estimated to
Rs 8.95 lakhs. For one Unit.
4.     Product Mix, Sales Realisation & Other incomes
                    The project is basically intended to eliminate the menace of waste plastic & MSW currently confronted universally by National Governments, State Governments, local self Governments etc.  As the waste elimination is hugely expensive, no Governments seemed to be interesting to under take such projects.  Understanding this aspect, the promoters have decided to use plastic waste for constructive uses such as manufacturing civil construction materials and sell end products obtained through Romelt Technology and plastic reinforced construction materials. So this serves both the purposes of making profit and eliminating waste plastic 8 MSW.  It is solving a great problem at the same time making profit by doing business.  As such it should be remunerated both the ways too i.e., it should be remunerated for lifting the waste as well as the product should be sold profitably.
Accordingly the promoters expect income in the following ways.
        1.         An allowance for lifting the waste plastic & other waste from the dumping locations.
        2.         Sales Revenue from the sale of blocks of different types.
        3.         Sales of products obtained from Romelt process
These have been calculated as following:
        1.         Vehicles have to be traveled to collect waste on daily basis in big cities and once in two or three days in smaller cities & towns.  Employees are to be engaged to collect the waste.  For meeting this waste lifting expenses every local body may pay an amount as decided mutually by the local bodies and  the promoters.  The promoters expect an amount from all the municipalities, Panchayaths, cities etc.  in every district. A district may have a number of major cities, town, municipalities etc.  They can share the amount and pay to the promoters.
                    As such, an amount of Rs. 1.00 lakhs per month is expected from every Municipality or a District Panchayat should provide Rs. 10.00 lakh per months so that an amount of Rs. 120 lakhs will be received from any District.
        2.         Sale of Products
                    1. Basis : Capacity of the machines is 500 Nos per hour thus
8Hrs  = 4000 Blocks per day.
                    2. Bricks/Blocks : These are waste plastic-cement filled concrete blocks. These can be sold to construction companies.  The standard sizes are as following.
                                                            400mm x 200mm x  200mm
                                                            400mm x 150mm x  200mm
                                                            400mm x 100mm x  200mm
                    They are sold at Rs. 18, 15 & 13 respectively.  However they are very competitive now a days and the promoters will be compelled  to sell at lower rates.  However for calculation purpose, the selling rate has been taken at 18/- per block  that is the cost of biggest one. So that the income will be Rs. 72,000/- per day. X 365 days Rs. 262.80 lakhs per annum at 100% capacity utilisation.  A double capacity machine will produce this much bricks and turnover shall be Rs. 262.80 lakhs.
                    The main product is block and the manufacturing cost will be same for the other items also.  But there will be difference in unit price.  The installed capacity of the machine is calculated to one block in 30 seconds.  So that one machine will produce 960 blocks per day.  Further details are given in annexure No. VII.  The promoters also expect an allowance of Rs. 2.5 lakhs in the district level per months as waste lifting allowance.  All the municipalities & corporations can contribute jointly as per their approach and the payment of this much amount will be very easy.
                    The products received from MSW is the extracted goods like iron, copper, nickal etc. The degradable items are turned to other useful products.  As such it will at least Rs. 100 lakhs per annum.
                    Total income per annum is calculated as following:
                      Sl.No.                                      Particulars                                                  Rs in Lakhs
                          1.      Allowance from local bodies                                                         547.50
                          2.      Sales of plastic reinforced blocks                                                262.80
                                    Total                                                                                                   810.30
5.     Use of the product
                    The products proposed to manufacture is construction materials like concrete blocks, pavement blocks, sewage duct wall blocks etc.  filled in with waste plastic paste and concealed with concrete so as to make no contact with outer world.  The use of these items are well evident from the name itself.  The demand for the item is being increased continuously.  They are used in construction of civil structures, road making, sewage ducts making etc.  The MSW will yield metals like iron, copper, nickel and other useful products.
6.     Manufacturing Process
                    Waste Plastic reinforced construction material.
                    The process of manufacturing is fully automatic.  At first, waste plastic is collected from all the corners and made clean.  Then it will be cut to small pieces and mixed with cement & glue so as to form a paste form.  This will be filled in the cavities of hollow blocks automatically.  This will be sealed with concrete itself.  Then they will be subjected to drying through hot wind.  On setting firmly, it is subjected to curing in curing tank.  On setting firmly, it will be ready for disposal.
                    The technical aspects are kept confidential.  The process along with concept, machinery and designs etc are patented provisionally.  They are available for examination on entering into an agreement for execution of the project by making firm arrangements for remuneration for the technology.
        7.         Technical Know How
        a.         Waste plastic
                    Technical know how is a provisionally patented asset of the promoters.  The promoters will execute the project after entering into an agreement for execution.  They will manage to manufacture plant & machinery and manufacturing of the product will also be done by them.  However, in case of requirement by the parties who wish to execute the project by themselves, the promoters will provide technology, training to the personnel, onward consultancy etc.  All these services are a part of the agreement on payment.
        8.         Specification & Standards
        1.         Waste Plastic
                    The products are proposed to be manufactured according to the standards specified by the Indian Standards Institution/World  Standard Institutions.  All the products are proposed to be sold to government agencies, railways etc. in addition to the private construction companies.  All the products will be in accordance with their standards.  The blocks are of standard size and the common size blocks are 400m x 200mm, 400mm x 200mm x 150mm x 400mm  200mm.  Pavements blocks and sewage duct wall blocks are of various sizes and are made according to the requirements.  However, the content ratio will be as per the approved standards.
        9.         Raw materials and consumable
        1.         Waste plastic
                    a. Availability : Waste plastic & MSW are available in scattered from everywhere in all localities.
                    b. Collection of waste plastic: The collection of waste plastic is one of the main problem to be faced.  Now the waste plastic is lying everywhere and to be collected.  Municipal workers usually collect them in vehicles and threw away in some remote areas to inflaming or land filling.
        1.         Waste plastic will be made a demanded item by taking it at a cost of Rs. 5/- per Kg. MSW will be packed up from the dumping yards.
                    As far as the promoters are concerned, the  plastic will be picked up every day from all localities employing labors.  Now it is lying in accumulated or scattered manner.  It will take at least six months to finish the present accumulated waste lying everywhere. After finishing them, the picking will be adjusted according to the availability.
                    At least 10 trucks will be employed in a district for collecting waste on daily basis.  Main cities will be given more attention while from smaller places, waste will be collected once in two or three days regularly after finishing the present level of accumulated waste.
                    After finishing the level of dumped up waste, the municipal authorities will have to give striet instructions to citizens to deposit these waste in special bin/ containers which proposed to be distributed by the promoters. As such plastic & paper waste can be collected from such containers provided by the promoters. The municipal authorities may give direction in the line of guidance issued by Central Pollution Control Board. The promoters will employ sufficient employees to collect waste from the dumping areas.
                    The local authorities are at present spending a lot of money for taking away the different kinds of wastes repeatedly every month. This is required to be stopped and they should decide to spend once for installing such a permanent waste destroying system. This will help to save a lot of money every year as recurring expenses.
        2.         Cement : Cement is another raw material for manufacturing blocks. Cement is sufficiently available everywhere. The requirement of cement for the project is calculated and given in Annexure No. VII.
        3.         Sand / quarry chips are also required for the project. This is sufficiently available in the localities. The details are available in Annexure No. VIII
        4.         Synthetic glue is also planned to be used in the manufacturing. This will give a sticky nature to the plastic particles. This will act as reinforcement agent and will give extra strength to product.
        5.         MSW : All types of degradable waste

10.   Utilities
         1. Electricity
            All machines are functioning with electricity. The details including capacity of machinery have been given in the following table:
  Sl. No.                                                  Particulars                         Capacity        Nos          Total
        1.         Block making machine                                                        2HP              2              4HP
        2.         Block & die lifting & placing machine                               1HP              4              4HP
        3.         Plastic cutting machine                                                       1HP              2              2HP
        4.         Dies & Block shifting machine                                          2HP              2              4HP
        5.         Concrete supplying conveyers                                           1HP               6             6HP
        6.         Plastic mixing machine                                                     1HP               2              2HP
        7.         Pate filling Machine                                                          1HP              1               1HP
        8.         Concrete mixers                                                               3HP                1              3HP
        9.         Miscellaneous use                                                            5HP               1 -            5HP
     10.         Hot chamber                                                                     3HP               2               6HP
                    Total                                                                                                                     40HP
                    Total cost comes to Rs. 2.21 Lakhs per annum.
                    2. Water: Water is required for manufacturing the blocks. Water shall be made available from own well or public distribution system. The cost of water has not been included in calculations as it is assumed to be made available free of cost. Water is also required for curing the cement blocks. Own well is desirable because water availed from public distribution system may not be economical.
                3. Fuel: Natural gas is used as fuel in the  project.  Hot air is produced by heating with electricity.  Natural gas is available sufficiency.

11.   Pollution & effluent disposal
                    Possibility for generation of pollution is rare in the project. All the raw materiels are completely used in the process so that nothing is remained to be disposed off.
                    Water is proposed to be sprayed sufficiently for setting in curing tank so as to avoid remaining of curing water in tank. As such nothing is remained to be disposed off.
                    The plastic cutting is performed in fully concealed chambers so that not a minute piece is escaped into the atmosphere. The cement is also handled in completely concealed chamber. After one stage the small particles of cement & plastic will be mixed with water so that the possibility for flying in the atmosphere is diminished. As such the fear of any pollution is not worthy and all possibilities of pollution are solved in its origin itself. MSW is directly supplied to the preheated machine for direction consumption.  So nothing remained outside the plant.
12    Organizational Set Up
        a)        The project is proposed to be set up in the following ways. As the menace caused by waste plastic is omnipresent, the project is required to be set up in every district. Accordingly the project will be implemented, State and National level. All project will be managed by the promoters through employees and intra net arrangements from one central office
b)     Manpower Requirement
                    The details of manpower requirement is given as Annexure No. X. Each project will give employment to about 20 personnel directly and several other indirectly.
13. Schedule of implementation
                    The promoters have taken several steps towards the implementation of the project. They have already taken steps to get approval from the government. The local administrative bodies have been approached with proposals. The remaining steps are summed up in the following table.
 Sl. No.                                 Name of Activity                                             Duration in week
                                                                                                                      Start             Complete
         1.       Allotment of Land                                                                          1                       4
         2.       Registration with  Department                                                       4                       5
         3.       Submission of loan application to Bank                                        5                       6
         4.       Power allocation                                                                            6                       7
         5.       Follow up and sanction.                                                                7                     10
         6.       Construction of Building                                                             10                    20
         7.       Calling Quotation for making  Machinery                                  10                    12
         8.       Finalizing Quotation                                                                    12                   15
         9.       Arrival of Machinery                                                                   15                   24
      10.       Availing power connection                                                          24                    26
      11.       Recruitment of personnel                                                             26                   27
      12.       Trial Production                                                                           27                    28
      13.       Commercial Production                                                              28              onwards
IV.   Cost of Project & Means of Finance
        1.         Cost of Project
                    The cost of one project suitable for a city like Cochin is calculated as following. Larger metropolitan city like Bombay will require more than one unit.
                    Stage I
                         Sl. No                          Particulars                          Amount(in Lakhs)                                                                 1.                                  Land (Free of cost
                                                              from local Bodies                           00.00                       
                            2.                              Building                                              00-00
                             3.                              Machinery &                                    29.42 x 14 =   411-88
                                                              Equipments
                          4                                Preliminary & Pre- operatives Exp.                       114--09
                                                             Total                                                             525.97 Lakhs   
          Stage II          1.  Miscellaneous Fixed Assets      Rs. 125-00 Lakhs
                                           2    Inintial Working Capital       Rs. 113,18 Lakh
                                                          Total                                                                                       238.18 Lakhs
                                             Total of Both the Stages                               764.15 Lakhs

2.     Cost of Project in Details
        a)        Land:   The land is expected to be made available free of cost from the local self governing body. As such the land cost has been exempted from the cost of project. Otherwise, land may be acquired on lease basis for longer periods, say 99 years.
        b)        Building:        The cost of building & other civil structures required for the project is to be estimates as per the particulars of the district considering the quantum of waste to be processed. This is expected to be provided by the local authority. The cost will not at any rate will go beyond Rs.15.00 lakhs per shed. The building proposed is a type building suitable for the project ..
        c)        Plant & Machinery: Cost of this has been estimated and given earlier.
        d)        Misc. fixed Assets:      The cost of this comes to Rs 125 lakhs. This has not been included in the Project Cost at the 1st Stage.
        e)        Contingency: It is expected to have some escalation in the cost of plant & machinery, building cost etc. for which a provision of 8.5% on fixed asset has been made as contingency. However, this has not been taken into account in calculating the cost of project.
        f)         Preliminary & Pre- Operative Expenses.
                    This includes the following

1.Survey and feasibility study:

                              Points of study:
                             
                              a)  Waste Generation Points
                              b)  Quantity generated
                              c)  Impact of waste in the waste generated points
                              d)  Labour involved
                              e)  Infrastructure needed
                              f)   Financial implications

The following are the waste generating points and authorities to be contacted in each Municipalities, City Corporations and Panchayat.


1. Market places                 7. Local Body authorities
                              2. Streets/Road Junctions  8. Residence Welfare Associations
                              3. Bus Stands                        9. Trade & Merchants Associations
                              5. Slaughter Houses          10. Fish and Meat Markets etc.
                              5. Marriage Auditoriums 11. Industrial Area
                              6. Slums/Settlements         12. Commercial/Shopping Centers

For the purpose of studies and survey, the said areas have been divided into wards. Most of the panchayats comprise normally 10 to 20 wards, municipalities 20 to 30 wards and Corporations 80 to 100 wards. As such the average number of wards has been taken as following.

1. Village Panchayat       15 Wards   x 991 Panchayats  = 14,865 Wards
                              2. Municipalities              30 Wards x 52 Municipalities =    1560 wards
                              3. Corporations 80 Wards x 5 Corporation       =     400 Wards
                             
                                          Therefore Total Waste Generating Points =    16,825


It is assumed that at least 3 man days will be required to visit and collect the relevant data from the city and municipal corporations where the density of population and quantity of plastic waste is far higher than the rural Panchayat areas. Thus a total of 5,880 man days would be required to complete the feasibility study in the City and Municipal Corporations. We assume one man day for each rural Panchayat Ward for the above mentioned study on an average. Thus 14,865 man days would be required to complete the feasibility study in all the Punchayat wards of the state. The financial and time requirement for the feasibility study is given below.

2. Costing (Survey and Feasibility Study)
                             
The following are the points of study proposed for this project:
              
                              1. Main sources of waste generation
                              2. Places or points where the waste is dumped.
                        3. Approximate quantity of plastic waste and proportion of garbage.
                              4. What are the facilities provided by the local authority at present
5. How far the general public obeys the stipulations imposed at present by          the local   authority
                              6. How do the wastes disposal at present by the local authority.
                              7. Public reaction to the present way of waste disposal
                              8. Suggestions from the public for a suitable waste disposal.

For undertaking such a vast and in-depth research study we propose to engage qualified and trained personnel only.  Graduates with good communication skills will be engaged on a daily basis with a daily remuneration plus TA&DA, .which will be 50% of the daily remuneration. Field Co - ordination/Supervisory, Stationery, and Data feeding and analysis, Expert’s Consultancy Charges will be additional.

1.      Total Man days required to cover 5 City Corporations x 80 wards.
                            400 x 3 man days = 1200 @ Rs.550 = Rs. 6, 60,000-00       

2. Total Man days required to cover 52 Municipalities x 30 Wards
                                               1560 x 3 days = 4680 man days @ Rs.550-00 = 25, 74,000-00
`                            
3. Total Man days required to cover 14,865 Panchayat Wards
                                                   14,865 wards x 1 man day @ Rs.550/- = Rs.81, 75,750=00

(Remuneration of Data Collectors is calculated @ Rs.300 + Rs.150 as TA & DA Plus Rs.100/- against Supervisory, stationery, over head, consultancy/Thus a total of Rs.550/- per day per executive is calculated.)
              
                                    Total                                       1, 14, 09,750-00

The survey will be conducted in two phases.The first phase will cover the entire City and Municipal Corporations of the state.We propose to engage 1 person in each Municipality/corporation who will collect the secondary data from the local body authorities and then move on to collect primary data through spot visits and administering of questionnaires. We assume 35 days to complete the first phase by deploying 57 executives. The panchayat wards will be covered by these executives in the second phase .
       
        g)        Working Capital: The working capital requirement for the project has been calculated at Rs. 113.18 lakhs for 14 projects for one month of operation.
        3.         Means of Finance
                    The promoters plan to  implement the project in the following line.
The project is proposed to be financed by the authorities considering the severity of the environmental impacts posed by the waste plastic.
   
                                                                           S.K. Vijayan  M.A., (M.B.A.)
                                                                                          Consultant
                                                            Industrial Constancy & Marketing Services Regd.

Place : Chengannur
Date : 01-01-2005


Biodata of the promoters

1.       Name                               :       Industrial Consultancy &Marketing Services Regd.
2.       Address                           :       Opp. R.D.O. Office, Chengannur - 689 121
                                                            Alappuzha Dist., Kerala, India.
                                                            Ph : 0479 – 2457860 e mai. incomsr@yahoo.com
                                                            www.omnamasivaya.org
4.       Name & Address           :       S. K. Vijayan M.A., M.B.A.,
                                                            Pannipuzhayil House, Edayaranmula. P.O
          of the Proprietor                   Kozhencherry, Pathanamthitta (Dist.), Kerala, India.
                                                            Tel : 0468 - 2317011
5.       Qualification of             :       1.     M.A.
          Proprietor                              2.     M.B.A. (Continues)
                                                            3.     EDP Training
                                                            4.     Computer Education.
                                                            5.     Junior Management Trainee.
6.       Experience of                 :       1.     Worked as Chief Executive in a firm at
          Proprietor                                       Chengannur, Kerala.
                                                            2.     Worked as a Executive in several firms in                                                                                                      Bombay & Gujarat etc.
                                                            3.     At present continues as the Chief Consultant in                                                                                              his own firm as above in addition to the position                                                                                            of Trustee in Om Namasivaya Charitable Trust.


location details (optional)
(All information other than given will be furnished when location is finalised)

1.       Location                         

          a)  District                                                             -      
          b)  Taluk                                                                -
          c)  Village                                                              -
          d)  Panchayat / Corporation                             -
2.       Sy. No.                                                                    -
3.       Extent                                                                     -       2-5 Hectars                            
4.       Present ownership                                               -
5.       Street Name & Building No.                              -
6.       Approximate cost of land                                  -      
7.       Vicinity of town                                                    -       Away from twon limit
8.       Development work required                             -
9.       Availability of power                                          -
10.     Availablity of rawmaterials                              -
11.     Source of water and quantity available          -
12.     Is there the market for product near by        -
13.     Distance from the HT line                                 -
14.     Distance from LT line                                         -
15.     Nearest Railway station                                     -
16.     Nearest Post office                                              -
17.     Nearest Bank                                                        -
18.     Telephone facility available                              -
19.     Distance from District Head Quarters           -
20.     Distance from the main road                            -
21.     Is the site free of foods                                       -
22.     Availablity of local transport                           -
23.     Nearest lorry booking office                            -      
24.     Nearest hospital                                                   -
25.          Distance from the nearest water way       -
plan of the proposed factory building

1.       Appropriate Plinth area - 13500sqft or above.
2.       Plan may vary according to the location of project.

product mix & sales realisation

1.            The capacity of type of double capacity machine has been calculated to 4                                blocks per minute.  As such 4000 blocks can be manufactured per day.

2.            The selling cost block in estimated to Rs. 18.00.  As such the total sales                                    turnover cames 4000 Nos. x@Rs. 18 x 365 days = 262.80 Lakhs.

3.            Unit price of other products too will be same. So it has not been calculated                                            seperately.

4.            The local self government bodies are expected to give Rs. 1500/- per Tonnes                          as a whole for District.  Every District is having several Municipalities,                                       Gramapanchayets, City Corporation, Town etc. All these institution can allot                       certain amount in accordance with their capacity & generation of waste. Under                   this head the promoters expect Rs. 547.50 lakhs per annum per unit.
               (1500 x 100 TPD x 365 days). 
               The total turnover comes to Rs. 810.30 lakhs per annum per unit at 100%                                             capacity utilisation.
5.            The capacity utilisation will be as followings :
               70%, 80%, 90% shall be capacity utilisation from 1st, 2nd, 3rd year and onwards.
                                                                                                                                                                   
1.            raw materials & consumables
               The followings are the material required for the unit.
1.           Waste Plastic :  It is basically a waste plastic & MSW elimination project.  As such waste plastic are considered as the main raw material.  There are  available free of cost. But collection overheads are there.  The cost of collection charge has been included in the labour charge.  Collection of MSW & plastic waste are proposed to be made by own truck so that petrol charges are taken as consumables.
2.           Cement :  The proposed ratio of raw material for block making is 1:4:8: of this ‘1’ represents cement.  The production per day is 4000 bricks of 400 x 200 = 1600 c. cm
              Cement Comes to 123 c. cm for one block.
              Sand Comes to 482 c. cm
              Chips Comes to 945 c. cm
              1 bag cement gives = 60 blocks
              4000 Blocks = 67 bags per day.
              Cost is calculated to Rs. 180/- = 12060.00
              = 12060 x 25 = 301,500-00
3.           Sand / Quarry Powder :  Quarry powder or sand requirement per day is estimated to 680 cft.  The cost of one cft is Rs. 6/- = 4080/- per day x 25 = Rs. 102,000-00 at 100% capacity utilisation
4.           Chips :  The requirement of chips comes to 1333 cft.  The cost of cft chips comes to Rs. 12/- as such the total amount for chips come to 399,900 at 100% capacity.
5.           Total cost of Raw Materials  : Rs. 803,400-00 for one month x 14 Units= 112,47,600-00


2. utilities

Sl No.     Particulars                                                                   Capacity        Nos.            Total

1.            Block making machine                                             1 HP                2                  4 HP
2.            Block & die lifting & placing machine                  1 HP                4                  4 HP
3.            Plastic cutting machine                                             1 HP                2                  2 HP
4.            Dies & Block shifting machine                                2 HP                2                  4 HP
5.            Concrete supplying conveys                                    1 HP                6                  6 HP
6.            Plastic mixing machine                                             1 HP                2                  2 HP
7.            Paste filling machine                                                 1 HP                1                  1 HP
8.            Concrete mixers                                                         3 HP                1                  3 HP
9.            Miscellaneous use                                                      8 HP                -                   8 HP
10.          Hot chamber                                                               3 HP                2                  6 HP
                Total                                                                                                                          40 HP                  
                40 HP x 0.987 = 39.48 @ Rs.6/- per Unit
                236.88 x 25 day= 5,922.99
2.Water :  Water is available free of cost from own well. Over head water supply facilities have to be arranged.
                         3. manpower requirement
1.            Works

Sl No.     Particulars                                           Salary/PM           Nos.             Amount / PM

1.            Machine Operator                                    5,000.00               4                      20,000.00
2.            Concrete Makers                                      3,800.00               3                      11,400.00
3.            Helpers                                                         1750.00               3                          5250.00
4.            Drivers                                                         2250                    1                          2250.00
                Total                                                                                          11                    38,900-00
                Administration
1.            Manager                                                      8000.00               1                          8000.00
2.            Sales Manager                                            8000.00               1                          8000.00
3.            Clerk/Computer Operator                      3800.00               2                          3800.00
4.            Helper                                                           1500.00               1                          1500.00
                Total                                                                                          5                      25,100.00
                  Total Salary                                                                             16              64,000-00                        

break even analysis(all amounts in lakhs based on yearly performance)

Sl No.          Particulars                                                                                   Amount                                     Amount    

1.                 Sales Revenue                                                                                                                                       819.27
2.                 Variable Overheads
1.                 Raw Materials                                                                                   150.00
                     Consumables                                                                                           9.39
2.                 Utilities                                                                                                     9.39
3.                 Interest on W/C                                                                                      0.00
4.                 Selling over heads                                                                               40.96
5.                 Excise duty                                                                                              0.00
                     Total                                                                                                                                                       200.35
3.                 Contribution                                                                                                                                         618.92
4.                 Fixed Overheads
1.                 Employees                                                                                             15.58
2.                 Repair, mait & Insurance                                                                 11.80
3.                 Rent                                                                                                           0.00
4.                 Contingency                                                                                            0.98
5.                 Administrative OH                                                                             40.96
6.                 Interest on TL (if applicable)                                                         144.00
7.                 Adn. salary                                                                                              3.63                                            
                     Total                                                                                                                                                       216.95
5.                 Non Cash Ovreheads
1.                 Depreciation                                                                                       235.99
2.                 Preliminary Exp.                                                                              597.00
                     Total                                                                                                                                                       832.99
6.                    Break Even Point : F.O.H CAP x 100                                          216.95 x 90 x 100                       
                                      Contn.                                                                                       618.92=                                             31.55%
                                                                                                                                        
             
RISK analysis

1.        Risk No. 1      :          It is a very new technology comes first into the world
                                               The customers require to accept the technology coupled                                                                                          with romelt technology of a Russian Institute.

           Solutions        :          1.         The technology is to solve the problem cause by one of the greatest environment contamination. As such any remedy suggested will be accepted.  Romelt Technology is a proves one.
                                               2.         The working result of the technology is clear to all who understand the process because it is purely based on mechanical device.

                                               3.         The product is just an addition to a widely used and existing products have very wide use around the world.
                                               4.         A United Nations Agency Viz.APCTT has recommend the technology as an ideal solution for waste plastic problems.  Norvagian agency has also recommended the project to be useful for elimination of waste plastic.

2.        Risk No. 2      :          Will the self governing body pay for lifting the waste ?
           Solution          :          At present they spend huge amount every year for                                                                                        deposing waste.  But if they are prepared to pay only the                                                                                         lifting charges, the present day failure can be resolved.
           Solution 2      :          The promoters expect assistance from world organisations                                                                       for solving environmental problems.  As the promoter is a                                                                         registered public trust, the project is eligible for assistance                                                                       under 35 AC. 
           Solution 3      :          The promoters are planning to avail financial assistance                                                                                         from Financial Institutions to run the unit profitability on                                                                          the security of plant and machinery.
       

References

The project was originally submitted to the following implementing agencies by the promoter  of the technology.                                                                             

            1. Government of Kerala
            2. Government of Karnataka
            3. Government of Delhi
            4. Government of India, Deptt of Environment and Forest   
            5. Asia and Pacific Centre for Transfer of Technology

1. Government of Kerala. The Director the Department of Local Administration has studied and found the proposal suitable to be implemented and recommended to the Secretary Vide their letters no. D-25222/2001 dtd.17-01-02, D-25222/2001 dtd.31-12-01 and informed the promotor that due to paucity of funds the Government is unable to implement then    project vide Letter No.3251/G3/2002/LSGD dtd.11-03-02 from the Under Secretary.


2 Government of Karnataka. The Secretary of Forest and Environment has studied the    proposal through their expert committee and found suitable to be implemented and     recommended vide their letter No.FEE20 ENG 2002 dtd 22-03-02 to the  Indo Norwegian    Environment Project (INEP) to be included in  their programmer. They informed us that they are pleased to include it in their next phase of budget.

3. Government of Delhi: The proposal has been sent by the Chief Minister to the Secretary to   Hon’ble Minister of Environment Government of NCT of New Delhi vide their letter               No.CMO/PGC/2001 dated 25-2-02 for taking immediate actions.

4. Government of India. Ministry of Environment and Forest after studying the proposal and asked us to submit further details. The same have been submitted and the same is under their custody.

5. The UNO sponsored agency viz. Asia and Pacific Centre for Transfer of Technology has examined the proposal and found to be an ideal solution for the havoc of waste plastic    and featured an article in their world famous periodical “Waste Technology”.


                                                                   The End  


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