.
PROJECT REPORT
ON
MANUFACTURE OF PLASTIC CRATES
SIDDARTH SETHIA 24-08-2020
Introduction
PLASTIC CRATES
Plastic crates are often used for shipment of bottles of water, milk, vegetables etc. Many are designed
to stack securely and to be returned as reusable packaging. Plastic moving boxes are constructed
using High Density Polyethylene HDPE , PP , PPCP which is made from oil based petroleum products
Plastic moving crates or boxes are also becoming popular to move offices and homes.
Fruit & Vegetable Crates
These crates with over 10 different models are designed for handling of fruits and vegetables.
Considering the perishable nature of fruits and vegetables, crates have very good ventilation and
smooth interiors with sturdy exteriors to handle load. Millions of Galaxy fruits and vegetable crates are
being used in storage and transportation of Tomato, Apple, Orange, Grapes, Mango etc..
Capacity : 48 Ltr.
Size : OD - 542X360X280 mm
Capacity : 48 Ltr.
Size : OD - 542x360x290 mm
Capacity : 48 Ltr.
Size : OD - 542X360X300 mm
TOMATO CRATE
The traditional segments of crates experience stiff competition and hence, the crates manufacturers are always in look out for
newer and newer application. The demand for crates is increasing from a diverse range of businesses. The usage of crates
especially in agri business is full of promise as it has demonstrated its superiority in handling, storing and transporting of
agricultural produce by reducing the damage level of food products by almost 30%. The entry of crates in agriculture is likely to
revolutionize the crates business and this segment is expected to drive the future growth of this business.
Advantages:
Crates are material handling containers which can be used for storage, transport or distribution and handling of products.
Traditionally crates in India were manufactured from wood but with developments in plastics processing and conservation of
environment issues gaining importance in developed societies, most of the material handling crates are being manufactured
to size to suit the end use, but are predominantly made from High Density Polyethylene (HDPE) and sometimes from
Polypropylene (PP). These injection moulded crates have a long life and are easy to handle due to its light weight, and have
many other advantages over the traditional wooden crates.
The advantages of using plastic crates are:
Considerable reduction in weight and hence easy handling and transportation
Freedom from sharp corners and splinters facilitating safe handling
Complete freedom from corrosion unlike in the case of metal crates
No noise while handling unlike metal crates
Requires negligible maintenance compared to wooden and metal crates.
Have fairly long life and are suitable for multiple trips.
Good resistance to chemicals and harsh environment. Can be made in variety of colours and hence have better sales appeal.
Location & its Advantages
LAND: The proposed location of the Unit is kolar - karnataka. The location of the industry has considerable influence on
the techno-economical facility of the project. There are various factors contributing to the functioning of an industry and
following are the primary factors taken into consideration.
REASONS FOR THE SELECTION OF THE SITE:
1. Availability of labor at economically rate.
2. Adequate supply of electricity power.
3. Adequate supply of water throughout the year.
4. The site is well connected with road facility.
5. Banking facilities and Government supports.
Adequate Transport facilities for economical transportation of finished product and Spare parts.
7. Nearness to the Market.
8. As the area is developing area, the setting up of a unit in this will help the people to progress both socially and
economically. There are several Engineering Colleges around the proposed unit.
Licenses
The following licenses will be required for the Starting up the Industry:
Single Window approvals
Panchayati
Inspector of Factories
Pollution
Electricity
GST
Town & City Planning
In kolar karnataka , at present there are several manufacturers of large injection moulded crates. This segment of business is dominated
mainly by organised sector players. The major players in injection moulded crates are:
Nilkamal Crates and Bins
B k Plastic
SRK King plastics
Sri Balaji
Livolin Polymers
Vishwas plastic
Manufacturing Process
Process, Plant & Machinery (Details & List of Machinery Suppliers)
Manufacturing Process
The manufacturing process of injection moulded crate is simple in concept. The Poly Propylene granules are fed via a regulated hopper into a
homogenous molten mass by application of heat and shearing action of continuously rotating extruded screw, which also keeps pushing the
plastic melt forward. The melt gets collected at the forward end of the extruder cylinder and is pushed into the mould cavity by the screw,
now acting as a hydraulic piston. The mould is kept at pre-specified temperature and once injected, the plastic melt is held under high
pressure to ensure that the material reaches all the ends of the mould. In crates moulding, the moulds used have comparatively very large
depth.
The mould is opened after plastic melt has solidified sufficiently and the moulded item is ejected by means of ejector pins or plates. During
the cooling cycle in the mould, the extruder screw prepares another batch of plastic melt, ready to be injected, and thus the cycle goes on
continuously. The moulded articles usually do not require any finishing operation other than removal of wastage. Otherwise, after visual
inspection and then despatched.
Plant and Machinery Suppliers
The following is the list of plant and machinery suppliers
1) HAITIAN HUAYAN MACHINERY(INDIA) PVT LTD
2) Windsor Machines Limited
Project & Means of Finance
Srl No Description Unit Total Price Qty Cost /Month INR Per Month
INVESTMENT COST
1 Machine Cost: 700T 1 1,13,28,000 1,57,333 1,57,333
( Considering 6 Years Life)
Mold Cost 2 36,00,000 50,000 50,000
Cooling Tower 1 3,00,000 4,167 4,167
Loader 1 70,000 972 972
Grinder 2 500000 6944 6944
Shed Rental Cost @ INR
2 Sft 600000 6000 60000 60000
10/Sft
Total ( 1 +2) 16398000 279416
Srl No Description Unit Total Price Qty Cost /Month INR Per Month
OPERATING COST
Manpower- Operator 12 Hrs
3 Nos 25000 2 50000 50000
Basis
Manpower- Helper 12 hr Basis Nos 10000 2 20000 20000
Supervisor Nos 15000 1 15000 15000
Security: 12 Hrs Basis Nos 10000 2 20000 20000
4 Power cost , Machine @ 0.33/ Kg 125 HT 200000
Other Power cost ( Chiller , Light, 3 KW Chiller, 1.5 kw
Grinder 25000
Grinder etc)
5 Oil Cost 110 1100 10083
Total ( 3 + 5) 340083
Srl No Raw Material wt gms No of Time utilisation CT Pcs/ Months P INR Per Month
Cavity c
6 Product Details
Vegetable Crate 1500 1 492 hr/25days/ 0.33 53673
82%
Reprocessed Raw material Cost 40 Inr per month 3220380
B Sales Price/ Month Market Price/Pc Qty ( Nos) INR Per Month
Vegetable Crate: Reproceesed 90 53673 4830570
Local Transport Cost to Mandi INR 2000 per Thousand 75,142
Sales promotional Cost 2% 96611
Net Sales/ Month 4658817
Profit INR Per Month
Sales B 4658817
Expenses A 3839879
Net Profit/ Month B-A 818938
Depreciation :- Depreciation was been calculated on written down value method
Plant & machinery 15%
Interest :- Interest effective rate
Term Loan 9.50%
Working Capital 12.00%
Incentives / Subsidies
