CAS MANUFACTURING

INTRODUCTION
 HISTORICAL BACKGROUND

Banana is the most popular fresh fruit all over the world and its name comes from the

Arabic word 'banan', which means finger. The scientific name of Banana is Musa acuminata and

Musa balbisiana. But the old scientific names of banana are Musa sapientum and Musa

paradisiacal. Bananas are rich source carbohydrates and potassium. Banana is a large perennial

herb with leaf sheaths that form the trunk like pseudo stem. Banana was first domesticated in the

tropical regions of South East Asia. Banana is a nutritious gold mine. Its high Vitamin B6

content helps fight infection and is essential for the synthesis of ‘heme’, the iron containing

pigment of hemoglobin. The fruit is also rich in potassium and a great source of fiber too. In

recent years, considering the adverse impact of indiscriminate use of chemicals, new trend of

organic banana production has been adopted worldwide. In the fields of banana, when fruits are

harvesting, the banana stem are cut off and let it down nearby fields because each banana plant

cannot be used for the next harvest. There are three reason of cutting of stems, the very first

reason is that banana stem are cut off when fruits are harvested, the second reason of cutting off

banana stem is due to diseases (that is because attack of fungi which are grown in result of waste

banana stem) and female banana stem are also cut off after the maturity of male plant. So that a

massive organic waste is produced because the banana stems cannot be used as an animal feed or

other alternative. The waste is then causes of emission of toxic gases including CO2 and also

gives growth to the harmful fungi which attack on remaining banana trees.
 In this modern age, the consumption of paper and boards has increased tremendously.

Conventionally, paper is manufactured from cellulosic materials like bamboo, hardwood, cotton

rags, etc. The ever-increasing demand, especially of the advanced countries has resulted in

continued denudation of forests causing severe environmental imbalances. In this context,

cellulose technologists are searching for alternative raw materials. Agricultural residues of non

woody nature like cotton stalks, wheat straw, rice straw, sorghum stalks, hemp, jute, etc., are

possible raw materials which could be used for paper and board making. However, all these

require to be digested at high temperature and pressure, employing energy consumptive and

costly processes. Thus the search for other raw materials and cost effective processes continues.

One of the materials found to be promising was banana stem waste, which is a very good source

of cellulose. Banana production in India is the highest, and the area under its cultivation is

second largest, among all fruit crops grown in India. About 9.8 lakh tons of dry residue is

produced from this huge production, all of which goes waste due to non-availability of suitable

technology for its commercial utilization. Taking into consideration the large availability of

banana stem waste in the country, Dharamitra (Wardha, Maharashtra), an eco-technology group

for sustainable development, took up the production of boards and thicker varieties of paper from

this agro-waste. That comes up to the study of making corrugated box from banana stem.

Corrugated Box is the most popular shipping container, now-a-days. The box is manufactured

from corrugated board which consists of 3 or more layers of Kraft paper. The middle fluted layer

is pasted with two flat parallel sheets of paper. The boxes find their number of applications in the

packaging of chemicals & drugs, tobacco, engineering goods, canned & bottled goods, food

products, lamps, electrical appliances, glassware’s, etc.

 Packaging plays a very important role in the country's economy. Till recently only the

western world, more particularly the developed countries cared about proper packaging.

However, now even developing countries like India have changed their outlook towards

packaging and in the last few years increasing stress have been laid on improved and proper

packaging. In fact, today, packaging is as important as the contents.

 BANANA PLANT DESCRIPTION

Banana plant can be found very easily in one's yard or gardens as they are very easy to

cultivate and it is the largest herbaceous flowering plant. It can grow up to 6 to 6.7 meters (20 to

24.9 ft.) tall and its leaves can grow up to 2.7 meters (8.9 ft.) long and 60 cm (2.0 ft.) wide.

The banana plant is a large perennial herb with leaf sheaths that form trunk-like pseudo stems.

The plant has 8 - 12 leaves that are up to 9 ft. long and 2 ft. wide. Root development may be

extensive in loose soil in some cases up to 30 ft. laterally. Other plant descriptions vary, it

depends on the variety. Flower development gets initiated from the true stem underground

(corm) 9 -12 months after planting. The inflorescence (flower stalk) grows through the center of

the pseudo stem. Flowers develop in clusters and spiral around the main axis. In most cultivars,

the female flowers are followed by a few "hands" of neuter flowers that have aborted ovaries and

stamens. The neuters flowers are followed at the terminal ends by male flowers enclosed in

bracts. The male flowers have functional stamens but aborted ovaries. Fruits mature in about 60 -

90 days after flowers first appear. Each bunch of fruits consists of variable numbers of "hands"

along a central stem. Each "hand" consists of two transverse rows of fruits ("fingers"). The fruit

quality is determined by size (finger length and thickness), evenness of ripening, freedom from

blemishes and defects, and the arrangement of the clusters. Quality standards may differ in

various markets.
 DESCRIPTION OF BUSINESS

COMPANY MISSION AND VISION

MISSION

Our company mission is to be to design, manufacture, deliver wide range and give the
best quality corrugated products that can compete to other companies. To be the best in company
in service, and to create an employment in an environment where management and staff work
together as a team for their mutual benefits and satisfaction live in a core and values of the
company.

VISION

The company envisions leading the way to an independent corrugated manufacturer that
produces world class quality products. By exceeding our consumer’s needs, meet their demands
and have a long term relationship that are both beneficial and rewarding to all involve.
COMPANY LOGO
 CHAPTER 1
MARKET STUDY
 PRODUCTS

A. CORRUGATED BOX

Production Description:
 1.2 HISTORICAL DATA AND PROJECTED DEMAND

Historical Data of Demand of Paper in the Philippines

Demand in (000 MT)

Year Demand
2013 1416
2014 1632
2015 1625.5
2016 1619
2017 1659.5
2018 1709.3

Methods of projections are performed and the most preferable method is the arithmetical straight
line method.

Deviation
Year Y Yc
Abs Sqrd
2013 1416
2014 1632 1474.66 157.34 24755.88
2015 1625.5 1533.32 92.18 8497.15
2016 1619 1591.98 27.02 730.08
2017 1659.5 1650.64 8.86 78.50
2018 1709.3 1709.3 0 0
PROJECTED DEMAND

Year Demand
2019 1767.66
2010 1826.32
2021 1884.98
2022 1943.6
2023 2002.3
2024 2060.96
 1.3 HISTORICAL DATA AND PROJECTED SUPPLY

Historical Data of Supply of Paper in the Philippines

Supply in (000 MT)

Year Supply
2013 847.5
2014 870
2015 891.75
2016 911
2017 933.8
2018 961.8

Methods of projections are performed and the most preferable method is the statistical parabolic
method because it has the lowest standard deviation.

STATISTICAL PARABOLIC PROJECTION

Deviation
Yea
Y X X2 X4 XY X2Y bX cX2 Yc
r Abs
Sqrd
847. - 62 - 21187. - 848.7 -
2013 25 3.55 1.37
5 5 5 4327.5 5 55.85 6 1.17
- - 868.7
2014 870 9 81 -2610 7830 1.28 1.26 1.59
3 33.51 4
891. - - 889.9
2015 1 1 -891.7 981.7 .142 1.76 3.1
75 1 11.17 4
2016 911 1 1 1 911 911 11.17 .142 912.3 -1.3 1.69
933. 935.7 -
2017 3 9 81 2801.4 8404.2 33.51 1.28 3.8
8 6 1.96
62 960.3
2018 961.8 5 25 4809 24045 55.85 3.55 1.43 2.04
5 7
∑Y= 5415.8 ∑ XY= 782.2 a= 900.97
∑X2= 70 ∑ X2Y= 63269.4 b= 11.17
∑ X4= 1414 ∑ (Y-Yc) 2= 13.59 c= 0.142

PROJECTED SUPPLY

Year X X2 bX cX2 Yc
2019 7 49 78.19 .99 980.15
2020 9 81 100.53 1.28 1002.78
2021 11 121 122.87 1.56 1025.4
2022 13 169 145.21 1.85 1048.03
2023 15 225 167.55 1.13 1070.65
2024 17 289 189.89 2.41 1093.27

1.4 EXCESS DEMAND

THEORETICAL DEMAND AND ACTUAL MARKET SHARE

 1.6 PLANT CAPACITY

Plant Capacity Calculated using the equation:

∑projected demand- ∑projected supply

*.35
6

Plant cap= 307,000 metric tons/year

Using the data of 2011 of paper market growth by PPMAI, we assume that 50% of the overall
production of paper are for packaging. So the plant capacity of our corrugated box industrial
plant is:

Plant cap= 154,000 metric tons/year

 CHAPTER 2
TECHICAL STUDY
2.1 DESCRIPTION OF RAW MATERIALS
 2.2 FACTORS AFFECTING THE PLANT LOCATION

Plant location is chose using analyzation of factors given between Luzon, Visayas and
Mindanao. They are rated from ranges of 1 to 10 where 10 is the highest.

FACTORS
LUZON VISAYAS MINDANAO
INVOLVED

Availability of RM 8 9 10
Accessibility to
10 8 8
Market
Availability of
10 8 8
Energy
Climate 9 8 8
Transportation
9 10 8
Facilities
Water Supply 9 10 9
Labor Supply 10 10 10
Taxation and Legal
9 9 9
Restrictions
Site Characteristics 9 8 10
Flood and Fire
10 9 9
Protection
Waste Disposal 9 8 9
Community Factors 9 9 7

Luzon Average Score = 9.25

Visayas Average Score= 8.83

Mindanao Average Score=8.75

 2.3 PLANT LOCATION

Location:   Quezon, Candelaria, Malabanban Sur

Lot Area: 10 hectares
Property Type: Agricultural Land Farm
Cost: Php 12,000,000
Point of interest:

 Quezon province has many banana farms that can be the source of banana trunks, the
main raw materials of our corrugated boxes.
2.4 PLANT VICINITY MAP

Figure . Vicinity map of the location generated by Google Map

2.5 PLANT LAY OUT
c

2.6 PLANT EQUIPMENT

EQUIPMENT SPECIFICATION
Equipment: Banana Trunks Shredder
Cost: ₱ 350,000
Voltage: 380 V
Power: 15 KW
Capacity: 300-600 Kg/h
Weight of Equipment: 1.5 Tons
 EQUIPMENT SPECIFICATION
Equipment: High Speed Pulp Washing Machine
Cost: ₱ 2,500,000
Voltage: 380V
Power: 5.5-7.5 KW
 EQUIPMENT SPECIFICATION
Equipment: Pulp Vibrating Screen
Cost: ₱ 250,000.00
Power: 1.1-11 Kw
Capacity: 1-30 Tons
Noise: 70-80 Decibels
Max. Material size: 300 mm
Speed: 1.5 Tons

EQUIPMENT SPECIFICATION
Equipment: Corrugator
Cost: ₱ 1,000,000.00
Power: 7.5 KW
Voltage: 220 V /380 V
Weight: 2000 Kg
Max. Speed: 40m/min
 EQUIPMENT SPECIFICATION
Equipment: Paper Cutting Machine
Cost: ₱ Php 100,000
Power: 30 KW
Voltage: 380 V
Weight: 13 tons
 EQUIPMENT SPECIFICATION
Equipment: Gluing Machine
Cost: ₱ 350,000.00
Voltage: AC220V
Weight: 1500kg
Speed: 220m/min (Adjustable)
Paper Board: 210-700g/Square Meter
Glue Type: Normal Cold Glue
 EQUIPMENT SPECIFICATION
Equipment: Creasing Slotting Machine
Cost: ₱ 500,000.00
Power: 7.5 KW
Voltage: 220V/380V
Weight: 2500Kg
 EQUIPMENT SPECIFICATION
Equipment: Printing Machine
Cost: ₱ 130,000.00
Power: 27 KW
Speed: 180-250pcs/min
Color: 1-9 pcs
Printing Area: 1400*2600mm
Weight of Equipment: 13000kg

EQUIPMENT SPECIFICATION
Automatic Carton Box Stitchery
Equipment:
Machine
Cost: ₱ 500,000.00
Power: 13KW
Speed: 180-250pcs/min
Voltage: 220V/380V
Weight of Equipment: 13000kg
2.7 PROCESS FLOW

PLANT I: BANANA STEM TO PAPER ROLL SHEET

Raw Materials
Chopping Digestion
(Banana Stem)

Felt
Dryers Absorber Screening Washing

Calendaring Paper Roll

PLANT II: PAPER ROLL SHEET TO CORRUGATED BOX

Paper Roll Corrugator Cutting

Slotting Creasing Pasting

Corrugated
Printing Stitching Box
 CHAPTER 3
FEASIBILITY STUDY
 CHAPTER 4
MANAGEMENT STUDY