Detailed Project Report (DPR) on Continuous Sandwich Panel Line

CONTINUOUS SANDWICH PANEL LINE

[EIRI/EDPR/4343] J.C.: 2528XL

INTRODUCTION

A Sandwich Panel consists of a core/insulating material of low density sandwiched between two layers of metal, bonded under pressure. The sandwich panel market is expected to witness a high growth rate during the forecast period, 2018 to 2023. The major end-user industries of sandwich panel market include industrial buildings, commercial buildings, cold storage facilities, warehouses, amongst others. Sandwich panels provide a quite level of thermal, sound, water insulation, and also prevent moisture condensation. Sandwich panel is more economical than the conventional methods when assessed with the concept of cost-benefit analysis. Increasing awareness about the energy efficient buildings, improvement in thermal performance of sandwich panels and implementation of stringent energy conservation regulations are expected to be the major drivers for the growth of sandwich panel market during the forecast period.

Buildings & construction is one of the major end-user industries driving the growth of sandwich panel market. With rapid industrialization in the emerging economies, the need for less time-consuming construction solutions is growing which in turn increases the demand for sandwich panels. Due to their easy installation property, sandwich panels are cost-effective and inexpensive when compared to other wall assemblies. The average growth in the global construction spending has been recorded at 8.1% in the last five years. The non-residential construction spending has increased to 4.1% in 2016, and this trend is expected to continue in the coming years. Increasing adoption of the sandwich panels for residential, commercial, and infrastructure development is expected to boost the market in the coming years.

Product

Water in its pure from is oxide of hydrogen or hydride of Oxygen. It is transparent and colourless liquid with a melting point of 0°C and a boiling point of 100°C. Its refractive index is 1.00 and specific gravity 1.0. Pure water is tasteless, however the pres­ence of minerals and dissolved salts and gases im­part taste in the water. Depending upon the quality of Raw water, suitable treatment is given to the water to make it as per the standards and packed in food grade plastic Bottles with label Indicating de­tails of composition, date of bottling, expiry date, quantity etc.

Potable spring waters containing, sulphur iron, magnesium and other mineral salts occurring in certain regions are claimed to be beneficial to human metabolism. They occur in specific and widely scattered locations best known of which are white sulphur springs (Virginia) Hot springs (Arkansas), saragoge springs (New York) Vichy (France Baden (Germany) and (U.S.S.R.) The therapitic  value of such waters is questionable carbonate mineral waters also contain lithium salts.

Juice is a beverage made from the extraction or pressing out of the natural liquid contained in fruit and vegetables. It can also refer to liquids that are flavored with these or other biological food sources such as meat and seafood (e.g., clam juice). Juice is commonly consumed as a beverage or used as an ingredient or flavoring in foods or other beverages, such as smoothies. Juice emerged as a popular beverage choice after the development of pasteurization methods allowed for its preservation without using fermentation (the approach used with wine production). The largest fruit juice consumers are New Zealand (nearly a cup, or 8 ounces, each day) and Colombia (more than three quarters of a cup each day). Fruit juice consumption on average increased with country income level. To the American food industry, fruit juice is more profitable than only fruit.

Packaged juice market has charted a high growth trajectory, thanks to its easy availability, anytime-anywhere consumption, and convenience.

COST ESTIMATION

Plant Capacity                            2000 SQM/Day 

Land & Building (2750 sq.ft.)  Rs. 2.70  Cr    

Plant & Machinery                      Rs. 28.44 Cr 

Working Capital for 1 Month    Rs. 2.68  Cr 

Total Capital Investment           Rs. 34.84 Cr 

Rate of Return                             32%

Break Even Point                        55%

CONTENTS

INTRODUCTION

SANDWICH PANEL

PPGI

FIG. 1 ROOF PANEL

FIG. 2 WALL PANEL

SIZE OF PANELS

PROFILES OF THE PANELS

(A) COLDWELL WALL PANELS

PROFILES OF THESE PANELS ARE GIVEN BELOW:

COLDWELL-1

COLDWELL -2

(B) STRUPAN ROOF PANEL

PROFILE OF THIS PANEL IS GIVEN BELOW:

(C) ISOCLAD

PROFILE OF THIS PANEL IS GIVEN BELOW:

POLYSTYRENE SANDWICH PANELS

MINERAL WOOL SANDWICH PANELS

PU SANDWICH PANEL

PU SANDWICH PANEL FEATURES:

POLYURETHANE-SANDWICHED PANEL

1. PUF PANEL FORMULATION

2. SPECIFICATION OF PUF PANEL

PROPERTIES OF PUF

ADVANTAGES/DISADVANTAGES OF PUF PANEL

ADVANTAGES

DISADVANTAGES

USES/APPLICATIONS

APPLICATION (INDUSTRIES)

MARKET OVERVIEW

COMPETITIVE INDUSTRY

NOTABLE PLAYERS IN THE SANDWICH PANELS MARKET INCLUDE

REGIONAL INSIGHTS

GLOBAL SANDWICH PANELS MARKET INFORMATION

MAJOR MARKET DRIVERS

BIS SPECIFICATION

RAW MATERIALS

CONTINUOUS PRODUCTION PROCESS/PRODUCTION LINE

THERE ARE BASICALLY TWO PANEL MANUFACTURING TECHNOLOGIES:

CONTINUOUS PANEL PRODUCTION LINE

A TYPICAL CONTINUOUS LINE IS MADE UP OF THE FOLLOWING THREE SECTIONS:

MANUFACTURING PROCESS STEPS

PROCESS FLOW

TESTING

TESTING: FOR QUALITY CONTROL:

DIMENSIONAL TOLERANCE FOR SANDWICH PANELS

TRANSVERSE BOW – CUPPING OF THE PANELS

FOLLOWING TEST ARE CONDUCTED ON THE FINISHED PUF PANELS

PLANT & MACHINERY

UNCOILER

LOADING COIL CARS

ROLL FORMING UNIT

PRE-HEATING OVEN

PRE-HEATING OVEN

METERING MACHINE

REACTIVE MIXTURE DISTRIBUTION

FLEXIBLE FACE UNCOILERS

DOUBLE CONVEYOR BELT

PANELS CUTTING UNIT

THESE UNITS CAN BE EITHER:

PANELS UNLOADING AND STACKING LINE

SUPPLIERS OF CONTINUOUS SANDWICH PANEL

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PPGI SHEET

SUPPLIERS OF PUR/PIR MATERIAL

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

CONTINIOUS SANDWICH PANNEL PRODUCTION LINE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

ELECTRICAL MEASURING INSTRUMENTS

DG SETS

EOT CRANES

POWER TRANSFORMERS

ELECTRICAL PANEL

ELECTRIC MOTOR

COOLING TOWER

EFFULENT TREATMENT PLANT (ETP PLANT)

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

SHOT BLASTING MACHINE

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

SPECIFIC FACTORS

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

VULNERABILITY TO WARTIME ATTACK:

FLOOD AND FIRE CONTROL:

WASTE MANAGEMENT

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)