Thermocol is formed by the synthesizing of spherical particles consisting of air (at a rate of 98%) contained within an infinite number of hollow cells. These cells, forming a structure of pellets fused together, give consistency and rigidity to the final product. The advantages are many: the product’s manufacturer requires very little energy, thereby allowing full weight to be given to ecological consideration. Of fundamental importance is the treatment with the vapor, which, as well as having a technical function during the manufacturing process, renders the product hygienic through sterilization. Thermocol is a good resister of cold and heat but since it is a petroleum product it dissolves in any solvent of petroleum.

 

Foamed plastics materials have achieved a high degree for importance in the plastic industry. Foams can be made soft and flexible to hard and rigid. Expanded polystyrene is one of such foams. It may be used such as thermal insulation material; acoustic treatments shock protective packaging, etc. Its properties can be varied widely in manufacture to meet both general and specific demands.

 

Today the demand on the global styrene market is on a gradual rise. The EPS and ABS demand rise is the key driver of the styrene market development. It is expected that the demand growth tempo will keep the significant indexes through the coming 2-3 years, supporting that way the styrene production and price in the foreseeable future. Polystyrene and Expandable Polystyrene Market is Expected to Grow at a Healthy Rate of 5.6% from 2010-2020.So any new entrants can venture in to this industry.

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Table of Contents

1.       Rourkela: City Profile & Geotechnical Site Characterization

1.1.    General

1.2.    Physical Characteristics

1.3.    Climate &Rainfall

1.4.    Map

1.5.    Culture & Languages

1.6.    Transportation and Communications

1.7.    Economy & Industry

1.8.    Major Industries

2.       Introduction

3.       Uses & Applications

4.       Properties of Thermocol

5.       Environmental Benefits

6.       B.I.S Specification

6.1.    IS : 4671 – 1968

7.       Market Survey

8.       Export & Import Statistics Data of India

8.1.    Export Statistics Data for EPS Disposable

8.2.    Import Statistics Data for EPS Disposable

9.       Raw Material & Availability

9.1.    Mould-Making

10.   Main Equipment and Technical Parameter

11.   Manufacturing Process

11.1.Basic Raw Material Required:

11.2.Basic Plant and Machinery Required:

11.3.Process:

12.   Process Flow Diagram

12.1.Flow Diagram for EPS (Thermocol) Plates

12.2.Flow Diagram for Expanded Poly Styrene Cups & Glass

13.   Suppliers of Plant & Machinery

14.   Suppliers of Raw Material

15.   Plant Layout

16.   Raw Material, Product & Machinery Photographs

16.1.Raw Material Photographs

16.2.Product Photographs

16.3.Machinery Photographs

17.   Quotation of Plant, Machinery and Equipments from Supplier

 

PROJECT FINANCIALS

·         Project at a Glance

Annexure

·         Assumptions for Profitability workings ….…………………………………………....................... 1

·         Plant Economics…………………………………………………………………………….................... 2

·         Production Schedule……………………………………………………………………….................... 3

·         Land & Building…………………………………………………………………………….................... 4

§  Factory Land & Building

§  Site Development Expenses

·         Plant & Machinery………………………………………………………………………….................... 5

§  Indigenous Machineries

§  Other Machineries (Miscellaneous, Laboratory etc.)

·         Other Fixed Assets………………………………………………………………………….................... 6

§  Furniture & Fixtures

§  Pre-operative and Preliminary Expenses

§  Technical Knowhow

§  Provision of Contingencies

·         Working Capital Requirement Per Month………………………………………………................. 7

§  Raw Material

§  Packing Material

§  Lab & ETP Chemical Cost

§  Consumable Store

·         Overheads Required Per Month and Per Annum ……………………………………................. .8

§  Utilities & Overheads (Power, Water and Fuel Expenses etc.)

§  Royalty and Other Charges

§  Selling and Distribution Expenses

·         Salary and Wages ……………………………………………………………………………................. 9

·         Turnover Per Annum ………………………………………………………………………................ 10

·         Share Capital…………………………………………………………………………………................ 11

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 1            ::        Cost of Project and Means of Finance

•        Annexure 2            ::        Profitability and Net Cash Accruals

§  Revenue/Income/Realisation

§  Expenses/Cost of Products/Services/Items

§  Gross Profit

§  Financial Charges    

§  Total Cost of Sales

§  Net Profit After Taxes

§  Net Cash Accruals

 

•        Annexure 3            ::        Assessment of Working Capital requirements

§  Current Assets

§  Gross Working Capital

§  Current Liabilities

§  Net Working Capital

§  Working Note for Calculation of Work-in-process

 

•        Annexure 4            ::        Sources and Disposition of Funds

•        Annexure 5            ::        Projected Balance Sheets

§  ROI (Average of Fixed Assets)

§  RONW (Average of Share Capital)

§  ROI (Average of Total Assets)

 

•        Annexure 6            ::        Profitability ratios

§  D.S.C.R

§  Earnings Per Share (EPS)

§  Debt Equity Ratio

 

•        Annexure 7            ::        Break-Even Analysis

§  Variable Cost & Expenses

§  Semi-Variable/Semi-Fixed Expenses

§  Profit Volume Ratio (PVR)

§  Fixed Expenses / Cost 

§  B.E.P

 

•        Annexure 8 to 11   ::        Sensitivity Analysis-Price/Volume

§  Resultant N.P.B.T

§  Resultant D.S.C.R

§  Resultant PV Ratio

§  Resultant DER

§  Resultant ROI

§  Resultant BEP

 

•        Annexure 12          ::        Shareholding Pattern and Stake Status

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 13          ::        Quantitative Details-Output/Sales/Stocks

§  Determined Capacity P.A of Products/Services

§  Achievable Efficiency/Yield % of Products/Services/Items 

§  Net Usable Load/Capacity of Products/Services/Items   

§  Expected Sales/ Revenue/ Income of Products/ Services/ Items   

 

•        Annexure 14          ::        Product wise domestic Sales Realisation

•        Annexure 15          ::        Total Raw Material Cost

•        Annexure 16          ::        Raw Material Cost per unit

•        Annexure 17          ::        Total Lab & ETP Chemical Cost

•        Annexure 18          ::        Consumables, Store etc.

•        Annexure 19          ::        Packing Material Cost

•        Annexure 20          ::        Packing Material Cost Per Unit

•        Annexure 21          ::        Employees Expenses

•        Annexure 22          ::        Fuel Expenses

•        Annexure 23          ::        Power/Electricity Expenses

•        Annexure 24          ::        Royalty & Other Charges

•        Annexure 25          ::        Repairs & Maintenance Expenses

•        Annexure 26          ::        Other Manufacturing Expenses

•        Annexure 27          ::        Administration Expenses

•        Annexure 28          ::        Selling Expenses

•        Annexure 29          ::        Depreciation Charges – as per Books (Total)

•        Annexure 30          ::        Depreciation Charges – as per Books (P & M)

•        Annexure 31          ::        Depreciation Charges - as per IT Act WDV (Total)

•        Annexure 32          ::        Depreciation Charges - as per IT Act WDV (P & M)

•        Annexure 33          ::        Interest and Repayment - Term Loans

•        Annexure 34          ::        Tax on Profits

•        Annexure 35          ::        Projected Pay-Back Period And IRR