How to start Manufacturing Business of Disposable …...How to start Manufacturing Business of...

How to start Manufacturing

Business of Disposable Products

(Plastic Cups, Cutlery, Paper Cups, Banana Leaf Plates, Facial Tissues, Wet Wipes, Toilet Paper

Roll, Sanitary Napkins, Baby Diapers, Thermocol Products, PET Bottles)

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Now a days Disposable Products are widely requiredand used across the world. These are highly used forcommercial and domestic purpose. Different kind ofdisposable products are available at industry leadingprices such as paper cups, cup sleeves, cup clutches,plastic lids, ceramic cups/mugs, bio disposableproducts, medical disposables, disposable gloves,disposable take-away packaging, etc.

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The fast moving life and modernizationsimultaneously lead to the necessity of disposables inone’s life. One cannot wash utensils all the time,neither can afford to arrange fine and good cutlery ofglass or steel in a party for the guest. At such times,people rush for the disposables available in the marketwith variety of colors and designs.For a manufacturer, to produce disposables is a gooddeal keeping in view the present demand and growthin the market.



This handbook is a complete well to do package for alayman to understand the basic steps to be followed forsetting up a plant for a particular disposable product.The book contains raw material details, productmanufacturing process, machinery details, images withraw material and machinery suppliers.The Disposable Products Manufacturing Handbook isabout producing Plastic Cups, Cutlery, Paper Cups,Banana Leaf Plates, Facial tissues, Wet Wipes, ToiletPaper Roll, Sanitary Napkins, Baby Diapers,



Thermocol Products, PET Bottles that are used bymasses in their day to day life. This well-established textprovides a comprehensive coverage of themanufacturing processes adopted to manufacturevarious disposable products. It gives a holistic view ofproducts produced, which has inputs from diversefields. The book discusses the importance and objectivesof processes and material used for the production ofdisposable products. Many examples have beenprovided to illustrate the concepts discussed.



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Table of Contents1. INTRODUCTIONPlasticPolypropylenePolystyrene (PS)Different Types of Disposable Products in MarketPet BottlesThermocol & Its ProductsPaper Cup



Plastic CutleryFacial Tissue, Wet Wipes and Toilet RollsPlastic CupsDisposable Banana Leaf PlatesBaby Diaper and Sanitary NapkinDiaperSanitary Napkin

2. PLASTICSIntroductionComposition



AdditivesClassificationThermoplastics & Thermosetting PolymersOther ClassificationsBiodegradabilityNatural vs. SyntheticCrystalline vs. AmorphousProperties of PlasticsToxicityPlastics & Their Uses



3. THERMOPLASTICStress Strain Graph of Thermoplastic MaterialAcrylicNylonPolyethylenePolypropylenePolystyrenePolyvinyl ChlorideTeflonProperties of Various Thermoplastic Products



4. THERMOSETTING PLASTICProcessProperties and Their UsesExamples

5. POLYETHYLENEStructure of PolyethyleneProcessMonomerPolymerizationProduction of Polyethylene



From NaphthaAs a GasPropertiesPhysical PropertiesChemical PropertiesClassificationLDPEPropertiesChemical ResistanceLDPE Quick FactsProduction of LDPE



Production of LDPEApplicationsLLDPEProduction and PropertiesProcessingPropertiesPhysical PropertiesApplicationHDPEPropertiesPhysical Properties



Chemical PropertiesHDPE ResistanceHDPE Quick FactsProduction of HDPEApplicationsProperties Comparison Chart for LDPE and HDPEProcessing Polyethylene into ProductsThe Making of Molded ProductsThe Making of FoilThe Making of Multi-Layer FoilThe Making of Sheets



The Making of Foam Applications for InsulationAdditionsJoining

6. POLYETHYLENE TEREPHTHALATE (PET OR PETE)ProductionDimethyl Terephthalate ProcessFirst StepSecond StepTerephthalic Acid ProcessGeneral Process Involved in the Manufacturing of PET



PropertiesGeneral PropertiesApplicationSustainablePolyethylene Terephthalate FilmsIntrinsic ViscosityA PET soft drink bottleFiber GradeFilm GradeBottle GradeMonofilament, Engineering Plastic



Property Chart for PETDrying of PETCopolymersDegradationAcetaldehydeAntimonySafetyBottle Processing Equipment7. POLYPROPYLENEChemical and Physical PropertiesPolypropylene Resistance



Polypropylene Quick FactsPolypropylene FabricationDegradationSynthesisIndustrial ProcessesManufacturingProperties & ApplicationsA Common Application for Polypropylene is as Bi-Axially Oriented Polypropylene (BOPP)Other Useful PropertiesPP Structure



PP ParametersBasic Types of PPCrystallinityPresence of Selected Additives during PolymerizationAntioxidants and StabilizersNucleants and ClarifiersAntistatic AgentsChemical ResistanceStress Cracking ResistancePermeabilityOrganolepticsNotch Effects



8. POLYSTYRENEStructurePolymerizationAtactic PolystyreneSyndiotactic PolystyreneProperties of PolystyreneProperties of PolystyrenePhysical PropertiesMechanical PropertiesOptical PropertiesThermal Properties



Electrical PropertiesChemical PropertiesUsesStrength, Durability, Comfort, SafetyApplications of PSPackagingAppliancesConsumer ElectronicsConstructionMedicalOther



DegradationBiodegradationIncinerationForms ProducedSheet or Molded PolystyreneDisposable Polystyrene RazorFoamsExpanded PolystyreneExtruded Polystyrene FoamFused Cell Expanded Polystyrene FoamCopolymersOriented Polystyrene



9. INJECTION MOULDINGProcess CharacteristicsAdvantages of Injection MoldingDisadvantages of Injection MoldingApplicationsExamples of Polymers Best Suited for the ProcessEquipmentMoldInjection Molding Die with Side PullsMold DesignMold Storage



Tool MaterialsMachiningCostInjection ProcessWhat is Injection Molding Cycle?Different Types of Injection Molding ProcessesProcess CycleEquipmentInjection UnitClamping UnitMachine Specifications



ToolingMold BaseMold ChannelsMold DesignMaterialsTolerances and SurfacesPower RequirementsMolding DefectsSilver StreaksShort ShotJetting



Flow MarksColor StreaksWeld LinesFlashDelaminationStringinessSink MarksWarping or Twisting

10. EXTRUSION MOULDINGTypes of ExtrusionPlastic Extrusion



Single Screw Extrusion MachineryExtrusion DiesScrew DesignCooling and Sizing EquipmentPros and Cons of Extrusion MoldingProsConsDefects

11. COMPRESSION MOULDINGProcess Definition



Process CharacteristicsProcess SchematicPros & Cons of Compression MouldingProsCons

12. BLOW MOLDINGTypologies of Blow MoldingExtrusion Blow MoldingContinuous Extrusion EquipmentIntermittent Extrusion Machinery



Advantages of Blow MoldingDisadvantages of Blow MoldingSpin TrimmingInjection Blow MoldingDisadvantagesInjection Stretch Blow Molding ProcessAdvantagesDisadvantagesProcess ExplanationAdvantagesDisadvantages



What is PET Blow Moulding?PET Blow Moulding ProcessAdvantages of Blow MoldingDefects & TroubleshootingBlow Moulding Glossary

13. THERMOFORMINGVacuum ThermoformingProcessApplications



Pressure ThermoformingAdvantages of Pressure FormingApplications for Pressure FormingMechanical ThermoformingThin Gauge and Heavy (Thick) Gauge ThermoformingTypes of Thermoforming MoldsApplicationsBenefitsWhen and Where does Thermoforming Fit?Plastics UsedThermoforming Materials



ABSHDPEHIPSPETGPCAcrylicChart of Plastic Materials - Advantages, Disadvantages and Industry ExamplesAdvantages of ThermoformingPros & Cons of ThermoformingProsConswww.entrepreneurindia.co


14. PLASTIC CUPSIntroductionPlastic CupsManufacturing MethodThermoformingHeatingFormingCoolingTrimmingMachine TypeApplication of Thermoforming Technique



Raw MaterialStepsPolypropylene CharacteristicsCompatibility of Polypropylene with Common ProductsProperties of Poly PropyleneSpecific GravityMechanical PropertiesElectricalsChemical ResistanceSpecification of Thermoforming MachinesMoulds



GlassCupsPlatesSpoonsPrinting on PolypropylenePrinting on Cups, Glasses and PlatesRoto Gravure PrintingFor Multicolor PrintingFlow Diagram for Disposable Plastic CupsPlant and Machinery DetailsThermoforming Machine



SpecificationsThermoformable Extrusion LineMono & Multilayer Thermoformable Sheet LinesSpecificationsPlastic Cup thermoforming MachineUsageHydraulic Automatic Cup Making MachineParameterFunctions and CharacteristicsComplete Line: Extrusion + Cup Making MachinePlastic Sheet Extruder



A. Main ParametersB. Configuration and Specification1. Main Extruder: one2. Non-stop Fast Screen Changer With Double-sieve: one set3. Die-HeadCalendar Roll Stack: one4. Thermostat System: Two sets (Only use for making PS sheet)5. Air Cooling Stand: one6. Trimming Unit: one7. Haul Off Unit: one8. Single-shaft Winder (One set)



9. Electronic Control Cabinet: one set10. Waste sheet re-winder: one setMain Technical DataFeatureKey Electric ComponentsAssistant MachinesAutomatic Cup Stacking MachineUsageMain Technical ParameterScrew Air CompressorIndustrial Chiller (Air Cooled)



Model SpecificationThermoforming/Vacuum Forming Sheet Extrusion LinePP/PS SpecificationMulti-Laye Cp-Extrusion Sheet LineTechnical SpecificationFeaturesHIPS / ABS / PC / PMMA / PS Extrusion Sheet LineTechnical SpecificationSuppliers of Plant & MachineryRaw Material Suppliers



15. BABY DIAPER & SANITARY NAPKINSIntroductionBaby DiaperTypes of DiapersDisposableReusable: Cloth DiaperSanitary NapkinsUses and ApplicationsBaby DiaperSanitary NapkinProperties of Baby Diapers



Properties of Sanitary NapkinsAdvantages & Disadvantages of Disposable DiaperFeatures of Disposable Baby DiapersComponents of Disposable DiaperRaw Materials for Manufacturing of Disposable DiaperAbsorbent PadNonwoven FabricOther ComponentsDiaper StructureDiaper Acceptance CriteriaFunction of Baby Diaper



Manufacturing ProcessFormation of the Absorbent PadPreparation of the NonwovenAssembly of the ComponentsMathematical Models for Disposable Diaper ManufacturingBy-Products/WasteQuality ControlProcess Flow Sheet for Baby Diapers ManufactureAbsorbent Pad FormationFormation of Tops heet and Bottom sheet from Non-Woven Fabric



Assembly of ComponentsPreparatory Processes for Sanitary NapkinsOpeningFirst Stage is OpeningSecond StageThird Stand Kiering Bleaching & WashingBleachingSterilisationDry HeatAuto ClavingExposure to Ethylene Oxide



Hydro - ExtractingDryingRaw Materials RequiredRaw Materials DescriptionRoll PulpNon-Woven FabricPolyethylene FilmTissueHot Melt & Polyextruded AdhesivePressure Sensitive AdhesiveSilicone Release Paper



Specifications of the Raw MaterialsWood PulpNon-Woven FabricSilicone Release PaperHot MeltProcess of Maufacture of Sanitary Napkins(A) Preparation of Cotton Lint Sliver(1) Cotton Opening(2) Lapping(3) Carding(4) Draw Frame



(5) Tissue Paper Wrapping(B) Manufacture of Sanitary Napkins(1) Cone Winding(2) Knitting & Insertion of Tissue paper Wrapped Sliver(3) Cutting & Looping of Both Ends of Sanitary Napkins(4) PackingProcess Flow Sheet for Sanitary NapkinsDisposable Diaper Machine PhotographsFull Servo Baby Diaper Making MachineSpecificationsFull Servo Pull-Up Baby Diaper Machine



SpecificationsMain Technical ParameterMain Function FeaturesSanitary Napkins Machinery PhotographsFast & Easy Packing Wing Style Sanitary Napkin EquipmentEquipment FunctionsStructure & ConfigurationMain Technical ParameterFast-Easy Packing Women Sanitary Pad MachineFunction & Assemble PartsStructure & Character



Main Technical ParameterSanitary Napkin Production LineMain MachineCrusherModel: Multiple-Function Machine for Sanitary NapkinMain Production LineSpecificationsSuppliers of Plant and Machinery (For Baby Diapers)Suppliers of Raw MaterialsSuppliers of Plant and Machinery (For Sanitary Napkins)Raw Materials Suppliers



16. DISPOSABLE BANANA LEAF PLATEIntroductionFunctionProperties of Banana Leaf PlatesUse and Application of Banana Leaf PlatesUtilityArea of UsageRaw MaterialBanana Tree/LeavesManufacturing Process of Banana Leaf PlatesProcess Steps



DescriptionFlow DiagramMachinery DescriptionLeaf Plate Making MachineDescriptionMaterialsConstructionWorkingLeaf Plate Making MachineMachinery DetailsSuppliers of Plant and MachinerySuppliers of Raw Materialwww.entrepreneurindia.co


17. FACIAL TISSUE & BABY WET WIPESIntroductionWhat is a Tissue Paper?PropertiesProductionApplicationsHygienic Tissue PaperFacial TissuesPaper TowelsWrapping TissueToilet Tissue



Table NapkinsFacial TissuePropertiesManufacturing Process for Facial TissuesStepsPulping and RettingPressingCrepingReeling and CuttingUses of Facial TissueSize



EffectsWet WipesIntroductionProductionUsesBaby WipesCleansing PadsIndustrial WipesPain ReliefPersonal Hygiene



Manufacturing Process Flow Diagram for Facial Tissue & Wet WipesPet CareHealthcareFacial Tissue and Wet Wipes Machine DetailsFacial Tissue MachineSpecificationsProfessional Facial Tissue MachineSpecificationWallet Pocket Facial Tissue MachineSpecification



Full-Automatic Box-drawing Facial Tissue MachineDescriptionsFunction and FeaturesTechnical DataThe Name of Spare Part of the MachineSpecification of Raw MaterialIndustrial Facial Tissue Making MachineSupplier of Plant and MachinerySuppliers of Raw Material



18. PAPER CUPSIntroductionAdvantages of Paper CupsWaterproofingPrinting on Paper CupsProperties of Paper CupsEnvironmental ImpactRecyclingPaper vs. PlasticEmissionHabitat Loss Trees Used



LidsUses & ApplicationsPer Case Contents MeasurementsManufactureProcess Flow ChartOther Processes1. Paper Cup Manufacturing ProcessCup Forming Process2. Paper Cup Making Machine Technical DataComplete Production Line for Paper Cup FormingFlow Chart



1. High Speed Extrusion Laminating MachineProcess 12. Four Color Flexographic Printing MachineProcess 23. Computerized Micro-Gap Flat Creasing and Die Cutting MachineProcess 3: Cut the Printed Roll Paper into Small Pieces4. High Dpeed Paper Slitting MachineProcess 4: Split the Big Roll PE-Coated Paper into Small Roll Paper5. Middle Dpeed Paper Cup Forming Machine



Machinery with Specifications1. High Speed Extrusion Laminating MachineFeatures of High Speed Extrusion Laminating MachineMain Parameters of High Speed Extrusion2. Four-color Flexographic Printing Machine Laminating MachineSpecifications of Four-color Flexographic Printing Machine3. Creasing & Cutting MachineDescription of Creasing & Cutting MachineFeatures of Creasing & Cutting MachineTechnical Parameters of Creasing & Cutting Machine



4. Middle Speed Paper Cup Forming MachineCharacteristicsAdvantages of Middle Speed Paper Cup Forming MachineTechnical Parameters5. Paper Cup Forming MachineMain Parameters of Paper Cup Forming Machine6. Double Side PE Coated Paper Cup MachineDescription of Double Side PE Coated Paper Cup MachineTechnical Parameters of Double Side PE Coated Paper Cup MachineSuppliers of Plant and MachinerySuppliers of Raw Material



19. PET BOTTLESIntroductionUses & ApplicationsProduction of Base (Amorphous) Pet ChipsPropertiesMain Advantage of PETFood GradeAestheticsStrengthWeightAirtight & Leak Proof



Chemical ResistanceManufacturing ProcessPlasticizing the PETInjection Molding the PET PreformHeating the PET PreformProcess Flow DiagramStretch Blow Molding the PET ContainerPET Container EjectorMachinery SuppliersPet Stretch Blow Molding MachineTechnical Specifications



Pet Blow Molding MachineSpecificationPET Bottle Making MachineTechnical SpecificationsHigh Pressure Three Cylinder Air CompressorSpecificationAutomatic Pet Blow Moulding MachineTwo Stage PET Blow Moulding MachineFeatures of Automatic Pet Blow Moulding MachineMachine Technical SpecificationsAir Recovery System



Hydraulic Injection Moulding MachineInjection Moulding MachineInjection Moulding MachineHorizontal Injection Moulding MachinesInjection Moulding MachineInjection Moulding MachineInjection Moulding MachineSuppliers of Plant and MachinerySuppliers of Raw Material



20. THERMOCOL & ITS PRODUCTSIntroductionTypical PropertiesApplicationsUses & ApplicationsFood PackagingProperties of ThermocolLight WeightDurabilityMoisture ResistanceThermal Efficiency



Shock AbsorptionVersatilityEase of UseEnvironmental BenefitsManufacturing ProcessBasic Raw Material RequiredBasic Plant and Machinery RequiredFor PlatesFor EPS Glass & CupsMethod UsedProcess



Making StyreneMaking PolystyrenePreparing the BeadsMaking Expanded Polystyrene Foam (EPF)MoldingMaking Extruded, Expanded Polystyrene FoamCutting, Bonding and CoatingEPS Products (Plates/Cups/Glasses)Raw Material & AvailabilityMouldingMain Equipment and Technical Parameter



For Plates1. PS Foam Sheet Extrusion LineComponentsA. MixerB. Automatic Feeding System (Automatic Self-control System)C. 1st ExtruderHigh pressure Butane PumpD. 2nd ExtruderE. Cooling SystemF. Hauling-off SystemG. Winding Device



2. Automatic Vacuum Forming MachineComponents3. Double Worktables Hydraulic Cutting off Machine (PLC controlling)4. Crusher5. Recycling SystemFor EPS Glass & CupsA. Material expander: (1 set)B. Dryer: 1setC. Crusher: 1setD. Central System of Sending Material: 1set



E. Foaming Machine: 4 setsF. Other Assistant Equipments1. Water Tank (10m3): 22. Cooling Water Tower3. Centrifuge4. Air CompressorManufacturing ProcessBasic Raw Material RequiredBasic Plant and Machinery RequiredFor EPS Glass, Cups and PlatesProcess Description



Process Flow DiagramFlow Diagram for EPS (Thermocol) Plates/Cups/GlassesRaw Material, Product & Machinery PhotographsFully Automatic Shape Moulding MachineFeatures & Technical SpecificationAutomatic EPS Shape Moulding MachineFully Automatic EPS Shape Molding MachineAutomatic Thermocol Packing MachineEPS Pre-Expander MachineEPS PreformerEPS/Thermocol Block/Sheet Cutting Machine



Tech DetailsPD Foam Sheet Extrusion LineAutomatic Vacuum Forming MachineFeaturesTechnical Specification of Automatic Vacuum Forming MachineAutomatic EPS Foam Cup Molding MachineEPS Foam Cup Making MachineFoam Cup Manufacturing MachineTechnical DataSuppliers of Plant & MachinerySuppliers of Raw Material



21. PLASTIC CUTLERYIntroductionImportance of Plastic Cutlery#1 - Cost#2 – ConvenienceProblems#1 – The Vast Majority of Plastic Cutlery cannot be Recycled#2 – It creates WasteProperties of Plastic Cutlery ItemsUses of Disposable Plastic Cutlery ItemsManufacturing Process



Disposable Plastic Cutlery ItemsBasic Raw Material UsedBasic Plant and Machineries RequiredStep 1: LoadingStep 2: LiquificationStep 3: Mould LoadingStep 4: MouldingStep 5: PackagingProduct SpecificationProcess Flow DiagramPlant & Machinery Details



Injection Moulding MachineComponent List for Injection Moulding MachineTechnical ParameterTypes of MachineSpare PartsMould for the Production of Plastic SpoonsCutlery Packaging MachineProduct DescriptionScope of ApplicationFeaturesUniversal Machinery



Manufacturing Factory 1Manufacturing Factory 2Packaging MachineRotary Packing MachineI. Main Performance and Structure FeaturesII. ApplicationIII. Optional DevicIV. SpecificationSuppliers of Plant & Machineries

22. TOILET PAPER ROLLSIntroductionwww.entrepreneurindia.co


DescriptionBleaching of FibersChemicalsMaterialColor and DesignManufacturing Process Flow Diagram for Toilet Paper RollUsesManufacturing Process for Toilet Paper RollsToilet Paper Machinery DetailsFull-automatic High-speed Rewinding and Perforated Toilet Paper Machine



Description of the EquipmentFeaturesTechnical DataOptional EquipmentThe Name of Spare Part of the MachineSpecification of Raw PaperToilet Paper Cutting MachineFunctions and FeaturesMain Technology ParameterToilet Roll Embossing Machine



SpecificationsToilet Paper Processing Equipments1. Rewinding Machine2. Toilet Paper Rolls Slitter3. Sealing Machine4. ProductSupplier of Plant and MachinerySuppliers of Raw Material

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How to start Manufacturing Business of Disposable …...How to start Manufacturing Business of...

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