PLASTIC CRATES

INTRODUCTION
Plastic crates are used for storage, transportation and distribution and handling of
products. Previously wooden crates were used which are now being substituted by
HDPE and PP crates. The crates are manufactured by injection moulding process..
Injection moulded components are widely used automobile parts and accessories,
computer peripherals, telecommunication components, T.V. cabinets, gears, cones and
textile industry components, housings and parts in electronics and electrical industry.
Thermoplastic materials are being converted into injection moulded engineering
components.
Automatic injection moulding machines are preferred where precision moulding
requirements are high; where high production rate with minimum cycle time is required
and where the weight of the component injection moulded generally exceeds 150 gms,
which could not be injection moulded in semi-automatic machines.

MARKET
The plastic crates have the following advantages.

• Light weight and rigid as compared to wood and metal

• Convenience and ease of handling
• Hygienic and non-toxic
• Space saving-stackable and Nestable
• Resistant to chemicals/soaps
• Anti-rusting
• Wide choice of shape, size and colours tailored for each end-use
• Withstands wide range of temperatures (-35 to 750C) and climatic conditions
encountered during service
• Environment friendly
• Longer service life as compared to wooden crates.

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 Following types of crates are generally available in Market and are popular amongst
end-users.
a. Fully closed crates - with all surfaces of crates in solid except top.
b. Grilled crates - with all sidewalls grilled and bottom close.
c. Totally grilled crates - with all sides and bottom also grilled.
d. Crates with lids - a lid on top to protect the contents.
e. Folding crates - entire crate can be folded to a flat assembly to save space when
not in use.
f. Stacking and nesting crates - height of crate can be reduced when stored in
nesting positions.
g. Soft drink crates - these are available with partitions to separate bottles rattling
with each other.
h. Milk pouch crate.
i. Tetra pack crates.
j. Crates for handling PCB.
k. Bins - modified shape of crate so that contents can be removed from front without
unloading the bins stacked over it.

Sector Use

1.Soft drink industry Storage, handling, transport and distribution.

2.Milk and dairy products Handling, transport, distribution.

3.Fisheries, marine and Storage, handling, transport and meat products distribution.

4.Automobile industry Storage

5.Fruits and vegetable Storage, handling, transport.

6.Electronic and electricals Storage, handling.

7.Pharmaceuticals Storage, handling.

8.Agro-products Storage, handling

9.Yarn and textiles industry Storage, handling

10.Defense Sector Storage, handling of bombs

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Indian Petrochemical industry is one of the fastest growing sectors of the economy. The
petrochemical sector has o grown at a rate of 13% per annum, which is more than
double the growth of GDP. The usage of polymers for injection moulding and other
components used in engineering plastics is bound to increase with the increase in
production of automobile vehicles, machinery and other electrical machinery and
consumer durables.

INSTALLED CAPACITY
Product Installed capacity No of working Capacity Capacity per annum
per hour hours per day per day 300 days per annum
Plastic crates 50 kgs 8 400 kg 120 MT

PLANT AND MACHINERY

No. Description Qty Price
(Nos.) (Rs.)
1. Automatic injection moulding 1 50,00,000
machine with accessories
(400 gms, screw type)
2. Scrap Grinders (cap. 40 Kg/hour) 1 1,10,000
3. Dry colour Mixer 1 1,00,000
4. Mould lifting equipment (2 MT cap.) 1 50,000
5. Water cooling arrangement 52,000
6. Weighing scale 1 16,000
7. Moulds 4 sets 10,00,000
Total 63,28,000

MANAFACTURING PROCESS
The plasticised and homogenised thermoplastic material is injected into a locked
(clamped) mould with sufficient injection speed and pressure. After the melt is cooled in
the mould, it is opened to remove the moulded articles. This is a cyclic process.
Automatic injection moulding machine is the basic machinery involved in this project.

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RAW MATERIALS
For MTs 120
Qty-MTs Rate/MT Value Rs. Lakhs
LDPE,HDPE 126 58000 73.08
Master batches & colour 4 100000 4.00
TOTAL 77.08
Packing materials 120.00 2000.00 2.40

LOCATION LAND AND BUILDING

Built up area-Sq.ft 4000
Rent p.m.-Rs per .5 per sq.ft 20000
Advance-10 months. Rs 200000

UTILITIES
Three phase- KW 100.00
Power charges Rs. lakhs p.a 22.80
For process-Litres per day 0
For human consumption - litres/day 200

MANPOWER
Monthly wages Total
Manager 1 10000 10000
Supervisor 1 8000 8000
Skilled 3 5000 15000
Unskilled 3 3000 9000
Accounts Assistant 1 4000 4000
Sales Executive 1 5000 5000
Security 2 2000 4000
sub total 55000
Add benefits 20% 11000

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 Total per month 66000
TOTAL PER ANNUM-Rs. lakhs 7.92

COST OF PRODUCTION AND PROFITABILTY

Assumptions

Installed capacity 120 MT of Plastic crates per annum.

Capacity utilisation
Selling price
Raw materials
Packing materials
Power
Wages and salaries
Repairs and Maintenance
Depreciation
Selling general and
administrative expenses
Interest on Term loan
Interest on working capital
Income tax
Year-1 -60%
Year -2 -70%
Year-3 onwards- 80%
Rs.125.00 per kg
As per the details given above
As per details given above
Rs.22.80 lakhs per annum at 100%
Rs. 7.92 lakhs with increase 5% every year.
Rs.0.60 lakh per annum with 10% annual
increase every year
Written down value method -15 % on machinery
Rs.30000 per month with 5% annual increase
11% per annum
11 % per annum
33.66 % on profits

LIST OF MACHINERY SUPPLIERS:

1. M/s. Brimco Plastic Machinery Corpn. Ltd., 55, Govt. Industrial Estate,
Kandivilli (E), Mumbai-400 006.
2. M/s. Faroni Enterprises,10, Anderson Street, Chennai - 600 001.
3. M/s. Neptune Plastics & Metal Industries,18, R.N. Mukherjee Road(7 th Floor)
Calcutta - 700 001.

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4. M/s. Jolite Industries, No.7 Meenambal Salai, Kaviyarasu Kannadasan Nagar
Chennai - 600 051.
5. M/s. Golden Engineering Industries, 8797, Shidipura Crossing, Rani Jhansi Road
New Delhi- 110 055.
6. M/s. Kolsite Machine Fabrik Ltd., P.O. Box No. 11902, Off Veeradesai Road
Mumbai - 400 053.
7. M/s. Boolani Engineering Corpn., 402, Veer Savarkar Road, Prabhadevi Indl. Estate,
Bombay-400 025.
8. D. G.P. Windsor India Ltd, 2 J, Century Plaza, Teynampet, Chennai – 600 018.
9. Europack Machines India Pvt Ltd, 52 Bindal Industrial Estate, Sakinaka, Andhari
East, Mumbai – 500 072.
10. Ambica Engineering & Wire Products, L 45, GIDC Estate, Odher, Ahmedabad–382415,
11. Hind Hydraulics & Engineers, Faridabad, Plot No. 13, Sector 74, Faridabad–121005.
12. Prasad Groups & Companies, Plot No. 14 – 16 GIDC Industrial Estate, Phase 1 Valva,
Ahmedabad – 382445
13. HMT International Ltd, 59 HMT Bhavan, Bellary Road, Bangalore – 560 032.

LIST OF RAW MATERIAL SUPPLIERS:

1. Lucky Plastics, 421-c, Sngr Road Gpathy CBE-641006,

2. Maruthi Plastic, Old – 3 Thirupali ST Sowcarpet- 600 079,
3. Reliance Industries, 501 JVL Plaza Anna Salai, Teynampet – 600 018.
4. Shri Swastic PlastIcs, 57/2, Thirupalli Street – 79,
5. Abs Plastics Ltd, 51 Gidc Industrial Estate, Nadesari – 391340.
6 Polychem Ltd, 74 Jamshedji Tata Road, Mumbai – 400 020

FINANCIAL ASPECTS

1. COST OF PROJECT
[Rs.lakhs]

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 Land & Building (Advance) 2.00
Plant & Machinery 63.28
Other Misc. assets 0.50
Pre-Operative expenses 2.00
Margin for WC 2.05
69.83

2. MEANS OF FINANCE

Capital 22.37
Term Loan 47.46
69.83

3. COST OF PRODUCTION & PROFITABILITY STATEMENT

[Rs.lakhs]

Years 1 2 3 4 5

Installed Capacity-MTs 120 120 120 120 120

Utilisation 60% 70% 80% 80% 80%
Production/Sales-MTs 72 84 96 96 96

Selling Price per MT-Rs. 1.25 lakhs

Sales Value (Rs.lakhs) 90.00 105.00 120.00 120.00 120.00

Raw Materials 46.25 53.96 61.66 61.66 61.66

Packing Materials 1.44 1.68 1.92 1.92 1.92
Power 13.68 15.96 18.24 18.24 18.24
Wages & Salaries 7.92 8.32 8.74 9.18 9.64
Repairs & Maintenance 0.60 0.66 0.73 0.80 0.88
Depreciation 9.49 8.07 6.86 5.83 4.95
Cost of Production 79.38 88.65 98.15 97.63 97.29
Selling, Admin, & General exp 3.60 3.78 3.97 4.17 4.38
Interest on Term Loan 5.22 4.57 3.26 1.96 0.65
Interest on Working Capital 0.82 0.82 0.82 0.82 0.82
Total 89.02 97.82 106.20 104.58 103.14

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Profit Before Tax 0.98 7.18 13.80 15.42 16.86
Provision for tax 0.33 2.42 4.65 5.19 5.67
Profit After Tax 0.65 4.76 9.15 10.23 11.19
Add: Depreciation 9.49 8.07 6.86 5.83 4.95
Cash Accruals 10.14 12.83 16.01 16.06 16.14

Repayment of Term loan 0.00 11.87 11.87 11.87 11.85

4. WORKING CAPITAL:

Months Values % Margin Bank

Consumptions Amount Finance

Raw Materials 0.50 1.93 25% 0.48 1.45

Consumables 2.00 0.24 25% 0.06 0.18
Finished goods 0.50 3.31 25% 0.83 2.48
Debtors 0.50 3.75 10% 0.38 3.37
Expenses 1.00 0.30 100% 0.30 0.00
9.53 2.05 7.48

6. PROFITABILITY RATIOS BASED ON 80% UTILISATION

Profit after Tax = 9.15 8%

Sales 120.00

Profit before Interest and Tax = 17.88 23%

Total Investment 77.31

Profit after Tax = 9.15 41%

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 Promoters Capital 22.37

7. BREAK EVEN LEVEL

Fixed Cost (FC):

[Rs.lakhs]
Wages & Salaries 8.74
Repairs & Maintenance 0.73
Depreciation 6.86
Admin. & General expenses 3.97
Interest on TL 3.26
23.56

Profit Before Tax (P) 13.80

BEL = FC x 100 = 23.56 x 80 x 100

FC +P 37.36 100

50% of installed capacity