PROJECT REPORT FOR MANUFACTURING OF

TISSUE PAPER (PAPER NAPKINS)

1. Introduction

The tissues paper sector has boomed over the last few years. With a move to more
luxurious tissue paper and ultra-absorbent paper towels the industry has been able to
increase the tissue prices and create new brands to retain consumers.

Tissue can be made both from virgin and recycled paper pulp. Majorly there are five
types of tissue papers namely; Bathroom Tissue, Facial Tissue, Paper Towel, Paper
Napkin and, Specialty and Wrapping Tissue. A napkin, serviette or face towelette is a
rectangle of cloth used at the table for wiping the mouth and fingers while eating. It is
usually small and folded sometimes in intricate designs and shapes.

Toilet paper is a tissue paper product used by people primarily for the ablution of the
anus and surrounding area of fecal material after defecation and by human females
for cleaning the perineal area of urine after urination and other bodily fluid releases.
It also acts as a layer of protection for the hands during these processes. It is sold as a
long strip of perforated paper wrapped around a paperboard core for storage in a
dispenser near a toilet. Most modern toilet paper in the developed world is designed
to decompose in septic tanks, whereas some other bathroom and facial tissues are not.

Toilet paper comes in various plies or layers of thickness, from one-ply all the way
up to six-ply, meaning that it is either a single sheet or multiple sheets placed back-
to-back to make it thicker, stronger and more absorbent. Facial tissue and paper
handkerchief refers to a class of soft, absorbent, disposable papers that are suitable
for use on the face. They are disposable alternatives for cloth handkerchiefs. The
terms are commonly used to refer to the type of paper tissue, usually sold in boxes,
that is designed to facilitate the expulsion of nasal mucus from the nose (nose-
blowing) although it may refer to other types of facial tissues including napkins and
wipes.

Tissue paper is a lightweight paper and has become one of the most essential
commodities of daily life. Tissue paper products are generally made from three main
types of raw material: Wood free (or chemical) pulp, Wood-containing (or
mechanical) pulp and Recovered paper. The tissue paper came into use in 1920’s and
since then the consumption of tissue paper has been consistently increasing. The
continuous developments in the tissue paper industry have enabled individuals to lead
a more sterile and hygienic life.

2. Market Demand
 Global Tissue Paper market to grow at a CAGR of 4.9 percent over the period 2012-
2016. One of the key factors contributing to this market growth is the increasing
demand of tissue paper for personal hygiene. The Global Tissue Paper market has
also been witnessing an increase in the number of international trips between the
western and eastern worlds. However, the increasing demand for handdrier machines
could pose a challenge to the growth of this market. Tissue and hygiene in India
witnessed strong double-digit growth in 2016 aided by increasing consumer
disposable income and consumer awareness. Tissues & wipes products have seen a
tremendous growth in the recent years in India. The global tissue paper market to
grow at a CAGR of 4.88% over the period 2014-2019.

Urbanisation has made a profound impact on our dining habbits. One of the notable
change is the increased use of paper napkins now a days, which was otherwise could
be seen only in western countries. Plain paper napkins are now being widely used in
restaurants, households, vehicles, industries, institutions etc. Tissue Paper with
colourful layout and attractive designs are having bright prospects with our
restaurants focussing on tidiness and adornment.

3. Production Targets
A. 300 Working Days in a Year /Single Shift
B. Basis of Estimation : 8 hours per shift
C. Quantity (Kg) : 150000
D. Value : (Rs) 9750000

4. Manufacturing Process

Tissue paper roll are fed to the flexographic printing machine with attachment for the
manufacturing of paper napkins wherein, these are printed and cut to the size with the
device already fixed with the machine.

The tissue paper manufacturing process only varies slightly from that of other papers.
It goes through the same underlying pulping, pressing and converting processes as
regular paper, with minute changes. The process of manufacturing are as follows :

Pulping

1. Trees are logged and cut into chips, which are then are ground into fine flakes, which
are then soaked and pulled-apart (retted). Paper pulp is generated from wood fibre or
recycled materials.
2. Stirring together these fine retted flakes in a mixer tank with a large quantity of water
and other chemicals generates.
3. The manufacturer adds chemicals such as sodium sulphide, limestone, and others
while the wood pulp is still in the mixing tank, to soften, strengthen or colour the
paper.

Pressing

1. The prepared pulp is then poured over fast moving belts made from highly porous
materials that are driven over huge drums heated by steam. The pulp is poured
uniformly and consistently across the width of the belt/drum. All the water escapes
through the pores, leaving just the fibres on the belt in the form of a delicate fabric.
2. The tissue is then transferred on to a massive heated roller called a Yankee. The heat
of the Yankee makes the fabric dry almost instantly.
3. The tissue paper is then transferred on to a core to form a large diameter roll.
4. Adjust the draw speed of the roll can let you get a thicker or thinner tissue as per your
goal.
5. The rolls are then put onto the converting machine.

Converting

1. The tissue is taken and its plies are split and passed through an embossing roller.
2. Embossing softens the toilet tissue and can be used to create decorative patterns.
3. The plies are removed and held together with glue. The tissue is then perforated by
doctor blades, enabling the sheets to be easily pulled apart.
4. The tissue can then be made into either flat surfaces or wound around a cardboard
tube to create a cylindrical rolls.
5. Many different roll sizes and sheet counts are produced on the winding machines.
6. The large roll is fed into a doctoring system and cut by a large rotating doctor blade
into individual rolls.

5. Land and Building

Rent for each month 5000

6. MACHINERY AND EQUIPMENT

Sr. No. Description Qty. Value (Rs.)

1. Two colour flexographic 1 400000
machine with attachment of
paper
2. Testing Equipment L.S LS -
3. Edge sealing and cutting LS -
machine
 4. Hand Tools LS -
5. GST, Freight & Insurance - 40000

7. RAW MATERIALS (PER MONTH)

Sr. No. Particulars Quantity Value (Rs.)

1. Tissue Paper 21 GSM 12.5 700000
2. Inks & Other Consumables LS 10000
3. Packaging Material LS 3000

8. STAFF AND LABOUR (PER MONTH)

Sr. No. Employee No. Amount

Administrative and Supervisory
1. Manager 1 20000
2. Peon/ Chowkidar 1 8000
Technical (Skilled-Unskilled)
3. Skilled Worker 1 10000
4. Unskilled Worker 1 8000

9. OTHER EXPENSES (PER MONTH)

1. Rent of Land & Building : 5000
2. Electricity Charges : 5000
3. Transport : 5000
4. Consumable & stores etc. : 2000
5. Postage expenses : 1000
6. Stationery : 1000
7. Repairs & Maintenance : 1000

10. WORKING CAPITAL (ONE MONTH)

1. Raw material : Rs.713000
2. Salaries & Wages : Rs. 48000
3. Other Expenses : Rs. 20000

11. TOTAL CAPITAL INVESTMENT

1. Machinery & Equipment : Rs. 440000
2. Working capital/Month : Rs. 781000

12. SOURCE OF FUNDS : Term Loan, Working capital loan and Own Contribution

13.COST OF PRODUCTION (PER ANNUM)

1. Total recurring cost per year : 9049200
2. Depreciation on machinery & equipment : 88000
 3. Interest @ 6 to 9 % : Actual

14. Tissue Paper Manufacturing Machine Specification: Approx. Price: Rs 5

Lakh / Unit having following specification:

Minimum Order Quantity 1 Unit

Voltage 230 V

Phase Single

Automatic Grade Automatic

GSM Required 15-38 Gsm

Weight 1500 kg

Electricity 3 Phase - 380 V

Dimension 2600 x 1050 x 1550 (L x W x

H) in mm

Other Features and Specifications:

1. Corrosion-resistance
2. Perfect finish
3. High tolerance
4. Moulds: Two Sets of Moulds
(Cups Size) include with the
Machine
5. Cup Size: 90ml - 330 ml
(90ml, 110ml 170ml are
highly in demand)
6. Cup Speed: 40 - 50 cups per
minute (10 lacs per month cups can be produced with 2 shifts working
hours):
7. Paper Thickness: Single PE, 180 - 230 gsm (185 gsm for 90ml - 170ml
195 to 230 gsm for 210, 250 330ml)
8. Raw Material: Virgin Pulp Board single side coated with food grade PE