Technical Details of 7th Generation Plastic Waste Pyrolysis Plant:

This is a system of batch process.

Plastic wastage is fed into the reactor vessel, and heated up under a controlled measure of tempera
The process brings plastic molecular re-structuring; and gaseous form furnace oil is produced along
These vaporized gases go through the heat exchanges where the furnace oil is condensed into form
During the process, gas, carbon black, and furnace oil are generated.
As a condensing medium, coolant water is used by the heat exchanger, and this water is re-circulat
The systems can be worked 24*7/365.
 a controlled measure of temperature & pressure.
orm furnace oil is produced along with some other gases.
urnace oil is condensed into form of liquid.

nger, and this water is re-circulated through the process.

 MEANS OF FINANCE
Initial Investment
A On Fixed Capital:
1 Term Loan Bank @ 75% 7,993,500
2 Term Loan component 25% 2,664,500
Total A 10,658,000

Capacity Utilization:---- 60% 70% 75% 80% 90%

B On Workin Capital GAP:
1 Promoter's Contribution @ 25% 340,490 397,238 426,728 455,653 1,087,381
2 Working Capital Loan (BanK) 75% 6,469,307 7,547,525 8,107,839 8,657,410 20,660,244
Total 6,809,797 7,944,763 8,534,567 9,113,063 21,747,625

Notes : Land & Building :------

1 Free hold land & Building. A Piece of Land and Building in already
selected for the establishment of the unit. Hence, We are not considering
the value of Land & Building
 CHAPTER - 16
MONTHLY REQUIREMENT OF THE RAW MATERIAL & ITS COST
Sl. No. Particulars Unit Qnty. Rate in Rs.

1 Waste Tyre 286,000 11

2 Coal/wood 52,000 6

3 Power(In HP) 28,080 6

4 Water 0 0
TOTAL

Value of all
Raw Material
Per month 3,633,480
Per Annum 43,601,760

EXPENSES AS ON UTILISATION OF CAPACITY OF RAW MATERIALS

Year Percent
1 60% 43,601,760
2 70% 43,601,760
3 75% 43,601,760
4 80% 43,601,760
5 90% 43,601,760
 CHAPTER-18
ESTIMATED COST OF PROJECT

The total cost of Project has been

estimated Rs. 25.00 lacs. Which
includes an amount of Rs. 11.00
lacs obtaining required Working
Capital. A detailed account of
project.
Sl. No. Head Amount in Rs.
1 land
2 Building
3 Plant & Machines
4 Misc. Expenses Like Electrification etc.
5 Furniture & Fixture
6 Preliminery & Pre- Operative Expenses

Rs. 1000000
1 W.C. Gap. As per Annes iii 1500000 RS. 1500000

TOTAL 2500000
OST
Amount in Rs.

3,146,000

312,000

168,480

7,000.00
3,633,480

RIALS
Value in Rs.
26,161,056.00
30,521,232.00
32,701,320.00
34,881,408.00
39,241,584.00
 Annexure--I
Land & Building
(A)

Free hold land and Building. A piece of land and Building

Land & Building is already selected for the establishment of the unit.
Hence. We are not taking the value of land Building.

Plant & Machinery Equipment ( all are indigenous make)

(B)

Particular
SL NO. No. Rate Total. Amt.
1
1 Hydraulic Auto feeder 310,000.00 310,000.00
1
2 Hydraulic cutter 325,000.00 325,000.00
1
3 Material handing screw 126,000.00 126,000.00
1
4 Chimney Cost Extra 100 feet 220,000.00 220,000.00

5 Cable and wire charge not including -

TOTAL :--

981,000.00
VAT@2% against "c'' form
19,620.00
Total :----

1,000,620.00

C Furniture & Fixture (Including VAT/CST)

150,000.00

D Computer & Related Equipments (Including VAT) 2 30000 60,000.00

TOTAL CAPITAL EXPENDITURE (B to D)

1,210,620.00
 ANNEXURE -II
WORKING CAPITAL REQUIREMENT
A. CURRENT ASSETS 1st Year 2nd Year 3rd Year 4th year
% 60 70 75 80
1 Raw material to be in Stores 4,360,176 5,086,872 5,450,220 5,813,568
2 Raw material in process 2,180,088 2,543,436 2,725,110 2,906,784
3 Finished goods in Stock 2,847,702 3,322,319 3,559,627 3,796,936
4 Credit sale receivable :-- 854,293 996,675 1,067,866 1,139,057
10,242,259 11,949,302 12,802,823 13,656,345
B. CURRENT LIABILITY :--

Creditors for purchase of materials &

1 stores 6 day purchases 2,249,088 2,623,936 2,811,360 2,998,784
2 Advances from Customers 854,310 996,695 1,067,888 1,139,080
3 Statutory Liabilities 204,064 238,075 255,080 272,085
4 Other specified Liabilities 125,000 145,833 133,929 133,333
3,432,462 4,004,539 4,268,256 4,543,282
C. WORKING CAPITAL GAP (A-B) 6,809,797 7,944,763 8,534,567 9,113,063

D. PROMOTER'S MARGIN @25% 340,490 397,238 426,728 455,653

E. BANK BORROWINGS '@75% 6,469,307 7,547,525 8,107,839 8,657,410

Assumptions :-
1 Materials Lead time 26 days, so firm need to stock raw materials twice of its monthly requirement
Otherwise due to raw materials production may be stopped.
2 Other Specified liabilities may outstanding expenses other than statutoru dues & Sundry Creditors
3 Statutory liabilities includes CST/VAT whereever applicable & Income Tax based on projection of net profit
4 Raw Materials in progress is 50% out of total raw materials in used anr 50% Finished Goods
5 One month Production of finished gooods are in stock
ANNEXURE -II
CAPITAL REQUIREMENT
5th year
90
6,540,264
3,270,132
4,271,553
12,814,369
26,896,318

3,373,632
1,281,465
306,096
187,500
5,148,693
21,747,625

1,087,381

20,660,244
Type of material Total quantity Finish Quantity
Nylon scrap tyres 1000 kgs -550 to 600 liter of Pyrolysis oil
-50 to 80 kg of Hydrocarbon Gas
-300 to 350 kg of Carbon Black

Radial scrap tyres 1000 kgs -400 to 450 of Pyrolysis oil

-50 to 80 kg of Hydrocarbon Gas
-300 to 350 kg of Carbon Black
-150 to 200 kgs of Mild steel tyre scrap
 TECHNICAL DETAILS OF 12 TONN PYROLYSIS PROCESS PLANT :--
Sl No. ITEM CONTRACTION DESCRIPTION
6.6 Meter(l) x 2.8 Meter(w),Plate,
1
Main Reactor-12 ton 16 MM BQ Plate Capsule Type (FIRC-12Thickness-16MM
2 Pipe condenser 5 MM MS Plate OR C Class Pipe -5MM Pipe 24 Nos , diameter-6 inch
700 MM x 1550 MM ,Cera wool(1260
3 degree C) insulation covered with
Insulation tank 5 MM MS Plate aluminum sheet.
4 Water seal tank 5 MM MS Plate 1000 MM x 1800 MM
5 Gas tank 5 MM MS Plate 800 MM x 1550 MM
6 Oil Tank 5 MM MS Plate 1470 x 3000 (5.0 KL ) 2 Nos.
(15'X8" & 12'X16" ) [ 15 Feet ] ,jacketed
7
Water coolant pipe C Class Pipe -5 MM MS Pipe pipe
8 Scrubeer Reactors C Class Pipe -5MM MS Top Pipe 12" X 10 Feet
9 Scrubber Fan Pipe C Class Pipe -5MM MS 12" X 10 Feet
10 Scrubber Coolent Pipe C Class Pipe -5MM MS 12" X 15 Feet
11 Scrubber Tank 5 MM MS Plate 1000 MM x 2800 MM with coolant pipe
12 Dust Blower 5 MM MS Plate 5 HP Blower with Motor
13 Cooling blower 5 MM MS Plate 5 HP 1440 RPM ABB MOTOR
5"Gear Box With 5 HP ABB Motor With
14 Hoist 5MM MS Fabricated Wire Rop 80 Feet(L), 10MM(T)
2 Tons chain block with 10 Feet chain for
15 Chain block 2 Tons Chain block reactor door

Reactor Penal board with Reactor Total motor Controller, temp indicator
16 Penal board Penal board with 7.5 HP Motor and controller with hooter penal board
5 HP 3 Phase Electric Motor for cold
17 Submersible Water pump Pump Atlas brand water supply in condenser
18 Gear pump Pump Atlas brand 3 HP 3 Phase ABB Motor for oil transfer
19 Mud pump Pump Atlas brand 3 HP 3 Phase ABB Motor for scrubber systems
20 Chimney C Class Pipe -5MM 12" MS 20 Feet-2 Nos for chimney
21 Gas Blower 3 Nos Gas blower 0.5 HP 0.5 Hp Motor 3 Phase for fire chamber
22 gas burner C Class Pipe -5MM MS 100x450 MM
23 Cooling tower Capacity 80 TR 3 HP 2880 RPM Motor
Hardware for reactor pipe and pipe
24 Hardware As per annexure I fitting
25 Reactor cover Reactor cover insulation With cerawool 1260 Temp 25 MM Two layer
26 Electric Motor Standard make As per annexure II
27 Foundation As per drawing Price not including in basic Price
28 Reactor Gear box Shricon Brand 180 Center 10 HP Helical Gear
Fire Brick & Castable 500 Nos Fire Brick and castable
29 cement cement -4+4 bags For fire system
5 HP Hydraulic Auto Feeder, works with
30 Hydraulic Auto feeder 5 MM Plate and 100 MM Channel 40 tons hydraulic pressure
5 HP Hydraulic Auto Feeder, works with
31 Hydraulic cutter 16MM MS PLATE 40 tons hydraulic pressure

Material handling screw for 8"PIPE COVERD with 12"PIPE(5MM)

32 carbon with cooling system 3 Hp motor with 4'' GEAR, 18 FEET LONG.
 LAND REQUIREMENT FOR THE PROJECT :----

MINIMUM LAND REQUIREMENT FOR PLANT : 50' X 120'(FEET)

TOTAL LAND REQUIREMENT FOR PLANT : 90' x 120'(FEET)
 MODEL TYPES
SL no. Items Model
1 Equipment type FI-RC-12
2 Raw material Nylon / Radial Tyre
3 Structural form Horizontal rotation
4 24-hour Capacity 10.5 ton.
5 Oil yield [40 to 45 % oil] 4.7 ton.
6 Steel Scrap [15 to 20 %] 2.1 ton
7 Carbon [30 to 35 %] 3.1 ton
8 Operating pressure Normal ( 0.3 To 0.5 kg)
9 Material of Reactor B.Q.Plates SA 516 Gr. 70
10 Thickness of Reactor 16 mm
11 Rotate speed of Reactor 0.4turn/minute
12 Total power 33 KW.
13 Mode of Water cooling Circular cooling
14 Cooling area of Condensor 70 Sq.Meter
15 Kind of transmission VFD drive
16 Noise dB(A) ≤85
17 Size of Reactor(D×L) 2.8 × 6.6 Mt.
18 Working form Intermittent operation intermittent
19 Land Requirement 10,800 sq ft.
20 Delivery time within 2 weeks
21 Installation Time 10 to 15 Day
 INVESTMENT & CAPITAL OUTLAY

Sl.no. Details Price

1 12 Tons Machine Cost Without tax 5,200,000.00
2 Transportation cost Trailer/ trucks 150,000.00

3 Shed fabrication works [open shed] 50 Feet x 100 Feet 500,000.00

4 Oil Storage Tank 25000 Ltr. 150,000.00
5 Foundation cost only Machine As per dwg 350,000.00
6 D.G. Generation set [ 40 KW] Standard 350,000.00
7 Site Office [ medium ] 10 x 10 Feet x 2 ROOMS 325,000.00
8 Pollution certificate 50,000.00
9 Electric Connection/Cable/Wiring Connection 25,000.00
10 Other Expenses 100,000.00
11 Land Investment -
12 Raw Material Expenses 3,458,000.00
Total Investment of 12 Tons Plant 10,658,000.00
 DETAILS Amount
1 Hydraulic Auto feeder 310,000.00
2 Hydraulic cutter 325,000.00
3 Material handing screw 126,000.00
4 Chimney Cost Extra 100 feet 220,000.00
5 Cable and wire charge not including
981,000.00
CST Against "C" Form, Transportation Extra
Extra Accessories

• Terms & Condition: Payment

• 30 % Advance & 70 % Against Delivery
 Evaluation of Expenses and gross profit
S.N Other Contingent Expenses (per month) Amount (Rs.)
1 Postage and Stationery 2,000.00
2 Telephone 5,000.00
3 Travelling and freight 15,000.00
4 Consumables 10,000.00
5 Repair and Renewals 10,000.00
6 Insurance fire and Employee 10,000.00
7 Rent -
8 Selling Expenses
Total Amount 52,000.00
 (A)Utilities (per month)

S.N Personnel Salary (Rs.) Nos. Amount (Rs.)

1 Production Manager 22,000.00 1 22,000.00
2 Maintenance engineer 12,000.00 1 12,000.00
3 Semi-skilled workers 8,000.00 6 48,000.00
4 Watchman 8,000.00 1 8,000.00
5 Additional perquisites @ 20% 8,000.00 1 8,000.00
98,000.00

(B)Expenses on raw materials & others

Sn particulars quantity no of days Rate/unit
1 Waste Tyre 7000 26 11
2 Coal/wood 2000 26 6
3 Power(In HP) 1080 26 6
4 Water 0 26 0
Total Amount 0

Total Recurring Expenditure (per month) (A)+(B)

Amount (Rs.)
2,002,000.00
312,000.00
168,480.00
7,000.00
2,489,480.00

2,587,480.00
 DEPRECIATION ON PLANT & M
Rate of
Sl. No. Particulars Depreciation
%

1 Hydraulic Auto feeder 10%

2 Hydraulic cutter 10%
3 Material handing screw 15%
4 Chimney Cost Extra 100 feet 15%
5 Building 15%
6 Furniture & Fixture 5%
7 Computers 60%
8 12 Tons Machine Cost Without tax 10%
9 Shed fabrication works [open shed] 50 Feet x 100 Feet 10%
10 Oil Storage Tank 25000 Ltr. 15%
11 D.G. Generation set [ 40 KW] Standard 15%
12 Site Office [ medium ] 10 x 10 Feet x 2 ROOMS 10%
Total

Notes:--
Depreciation calculated as per Straight Line Method
PRECIATION ON PLANT & MACHINERY & OTHER ASSETS

Depreciation on Depreciation on Depreciation on Depreciation on

Value of Assets 1st Year 2nd Year 3rd Year 4th Year
Rs. Rs. Rs. Rs.
310,000 31000 31,000.00 31,000.00 31,000.00
325,000 32500.00 32,500.00 32,500.00 32,500.00
126,000 18900.00 18,900.00 18,900.00 18,900.00
220,000 33000.00 33,000.00 33,000.00 33,000.00
2,500,000 375000.00 375,000.00 375,000.00 375,000.00
150,000 7500.00 7,500.00 7,500.00 7,500.00
60,000 36000.00 36,000.00 36,000.00 36,000.00
5,350,000 535000.00 535,000.00 535,000.00 535,000.00
500,000.00 50000.00 50,000.00 50,000.00 50,000.00
150,000.00 22500.00 22,500.00 22,500.00 22,500.00
350,000.00 52500.00 52,500.00 52,500.00 52,500.00
325,000.00 32500.00 32,500.00 32,500.00 32,500.00
10,366,000 1,226,400 1,226,400 1,226,400 1,226,400
Depreciation on
5th Year
Rs.
31,000.00
32,500.00
18,900.00
33,000.00
375,000.00
7,500.00
36,000.00
535,000.00
50,000.00
22,500.00
52,500.00
32,500.00
1,226,400
 DETAILS OF TURNOVER
S no. particulars quantity no of days Rate/unit
1 Sale of OIL(42% TO 45%) 3450 26 32
2 Sale of steel scrap(15 to 20%) 2200 26 12
3 Sale of CARBON (30 TO 35%) 3190 26 1.5
4 gas RECYCLING
TURNOVER /Month

Less: recurring expenses/month

GROSS PROFIT/MONTH
Amount (Rs.)
2,870,400.00
686,400.00
124,410.00
-
3,681,210.00

2,587,480.00
1,093,730.00
 ANNEXURE -IX

BREAK EVEN POINT ANALYSIS

Based on 1st year of operation :---

PARTICULARS Amount(Rs.) B.E.P. ANALYSIS:---

A. VARIABLE COST :---

Raw materials 24,024,000.00

Utility(Power) 564,480.00 B.E.P :---
Selling Expenses 1,423,851.00 26,012,331.00

B. FIXED COST :---

Direct labour & wages 1,176,000.00
Interest TL & WC 6,687,500.00
Depreciation 1,226,400.00
Repairs & maintainance 240,000.00
Other expenses 240,000.00 9,569,900.00

C. SURPLUS :---
Net sales realisation 44,174,520.00
Less:-Variable Cost(A) 26,012,331.00
18,162,189.00
 ANNEXURE -IX

BREAK EVEN POINT ANALYSIS

FIXED COST * Installed

capacity/
Contribution*100

52.69

9,569,900.00

18,162,189.00

52.69
 ANNEXURE -X
PROJECTED PERFORMANCE ,PROFITABILITY, REPAYMENT SCHEDULE

1st Year 2nd Year 3rd Year 4th year

A. Particulars
60% 70% 75% 80%
1 SALES REALISATION :-- 41,174,520 52,036,940 55,968,150 59,399,360

B. COST OF PRODUCTION
i Raw materials 34,161,056 39,854,565 42,701,320 45,548,075
ii Power & fuel 500,000 583,333 625,000 666,667
iii Direct salary & wages 770,400 898,800 963,000 1,027,200
iv Repairs & maintainance 240,000 280,000 300,000 320,000
v Overheads 3,139,326 3,662,547 3,924,158 4,185,768
vi Depreciation(SLM) 1,226,400 1,226,400 1,226,400 1,226,400
TOTAL :---- 40,037,182 46,505,646 49,739,878 52,974,109

Add: Opening Stock of Process &

Fin Goods - 5,027,790 5,865,755 6,284,737
Less: Closing Stock of Process &
fin Goods 5,027,790 5,865,755 6,284,737 6,703,720

C. COST OF SALES :--- 35,009,392 45,667,681 49,320,896 52,555,126

D. GROSS PROFIT :-- 6,165,128 6,369,259 6,647,255 6,844,234

E. INTEREST :--
TERM LOAN 1,327,389 1,189,454 1,032,480 853,838
WC LOAN 841,009 981,178 1,054,019 1,125,463

1,423,851 1,661,160 1,779,814 1,898,468

Selling & administrative Expenses
3,592,249 3,831,792 3,866,313 3,877,769

F. PBT 2,572,879 2,537,468 2,780,942 2,966,465

G. Income Tax "@30% 771,864 761,240 834,283 889,939
H. NET PROFIT :--- 1,801,015 1,776,227 1,946,659 2,076,525

I. Depreciation added back:-- 1,226,400 1,226,400 1,226,400 1,226,400

J. NET CASH ACCRUALS :-- 3,027,415 3,002,627 3,173,059 3,302,925

K. REPAYMENT OBLIGATION 0 0 0 0
WITHDRAWAL BY PROMOTERS 0 0 0 0

- - - -
5th year
90%
67,761,780

51,241,584
750,000
1,540,800
360,000
4,708,989
1,226,400
59,827,773

6,703,720

7,541,685

58,989,808
8,771,972

650,539
2,685,831

2,135,777

5,472,147

3,299,826
989,948
2,309,878

1,226,400
3,536,278

0
0

-
 ANNEXURE -XI
CASH FLOW STATEMENTS

Year of
Particulars 1st Year 2nd Year 3rd Year 4th year 5th year
construction

A. SOURCE OF FUNDS
Cash Accruals - 3,027,415 3,002,627 3,173,059 3,302,925 3,536,278
Increase in Capital 3,004,990 397,238 426,728 455,653 1,087,381
Depreciation(SLM) - 1,226,400 1,226,400 1,226,400 1,226,400 1,226,400
Increase In BANK borrowing - 1,134,966 589,804 578,496 12,634,562
TOTAL :-- - 7,258,805 5,761,232 5,415,992 5,563,474 18,484,621
B. DISPOSITION OF FUNDS
Preliminary expenses 188,723 178,411 170,821 170,821 156,572
Increase in capital expenditure - - - - -
Increase in Current Assets - 556,467 1,707,043 853,521 853,522 13,239,973
Decrease in TL & WC - 999,291 1,137,225 1,294,199 1,472,841 1,676,141
Interest (TL & WC) - 841,009 981,178 1,054,019 1,125,463 2,685,831
Taxation - 771,864 (10,623) 73,042 55,657 100,008
Withdrawal By promoter - - - - - -
- 3,357,354 3,993,234 3,445,602 3,678,304 17,858,525
C. Opening Balance : - 3,901,451 5,669,449 7,639,839 9,525,009
D. NET SURPLUS - 3,901,451 1,767,998 1,970,389 1,885,171 626,096
E. Closing Balance :-- - 3,901,451 5,669,449 7,639,839 9,525,009 10,151,105
 ANNEXURE -XII
PROJECTED BALANCE SHEET
1st Year 2nd Year 3rd Year 4th year
A. LIABILITIES
Promoters Capital 3,004,990 3,402,228 3,828,956 4,284,609
Reserve & surplus 1,801,015 1,776,227 1,946,659 2,076,525
Term Loan 10,658,000 10,101,533 9,468,256 8,747,565
Current liabilities 3,432,462 4,004,539 4,268,256 4,543,282
Working capital Loan 6,809,797 7,944,763 8,534,567 9,113,063
TOTAL :-- 25,706,264 27,229,290 28,046,695 28,765,045
B. ASSETS
Gross Block 10,366,000 9,139,600 7,913,200 6,686,800
Less: Depreciation 1,226,400 1,226,400 1,226,400 1,226,400
NET BLOCK :--- 9,139,600 7,913,200 6,686,800 5,460,400

Current Assets 10,242,259 11,949,302 12,802,823 13,656,345

Advances to Raw materials 1,000,000 1,166,667 1,250,000 1,333,333
Cash & Bank Balance 5,135,682 6,021,711 7,136,251 8,144,145
pre Operative 188,723 178,411 170,821 170,821
TOTAL :-- 25,706,264 27,229,291 28,046,695 28,765,044
0 (0) (0) 0
5th year

5,371,991
2,309,878
7,927,396
5,148,693
21,747,625
42,505,583

5,460,400
1,226,400
4,234,000

26,896,318
1,500,000
9,718,693
156,572
42,505,583
(0)
 ANNEXURE -XIII
DEBT SERVICE COVERAGE RATIO
Particulars 1st Year 2nd Year 3rd Year 4th year 5th year
A. NET PROFIT 1,801,015 1,776,227 1,946,659 2,076,525 2,309,878

B. DEPRECIATION 1,226,400 1,226,400 1,226,400 1,226,400 1,226,400

C. INTEREST ON T.L. 1,327,389 1,189,454 1,032,480 853,838 650,539

D. REPAYMENT OF T.L. 999,291 1,137,225 1,294,199 1,472,841 1,676,141

Debt service coverage ratio :-- A+B+C/(C+D)

1.81

Signature of :--

Date :--
Place :--
TOTAL
9,910,305

6,132,000

5,053,700

6,579,697