Detailed Project Report on Decorative Laminated Sheet (Sunmica)

DECORATIVE LAMINATED SHEET (SUNMICA)

[EIRI/EDPR/1644] J.C. 450XL

INTRODUCTION

Decorative laminates are laminated products primarily used as furniture surface materials or wall paneling. It can be manufactured as either high- or low-pressure laminate, with the two processes not much different from each other except for the pressure applied in the pressing process.

It is said that the first decorative High Pressure Laminate was produced by Marc-Anton André, who is the sixth generation of Johann Ludwig André, in 1959.

High-pressure laminate

According to McGraw-Hill Dictionary of Architecture & Construction, high-pressure laminates consists of laminates "molded and cured at pressures not lower than 1,000 lb per sq in. (70 kg per sq cm) and more commonly in the range of 1,200 to 2,000 lb per sq in. (84 to 140 kg per sq cm).

Decorative Laminated sheets are generally of two types.

1. Thermosetting synthetic resin bonded laminated sheets.

2. Mica coated or satin type decorative sheets.

Thermosetting synthetic resin bonded laminated sheet shall be of two types namely:-

a) Type-1. having only one side bearing the decorative surface the other side being roughened or given an appropriate treatment to promote adhesion to the base end.

b) Type-2 having both sides bearing the decorative surface the two sides may be different in colour or pattern or both.

The material covered by this report may be used as well as panels or as veneer for wood or other surfaces. The laminated sheets require no additional decorative finish.

The material is intended for interior use. The specification applies to sheets in which the only filter is paper and does  not cover  sheets with a core of any other material covered  by  this report is not intended for load bearing applications.

In India three types of decorative and industrial laminated sheets or products are being manufactured usually using phenol formaldehyde or melamine formaldehyde or other phenolic resins as bindiong materials for the core and the surface papers. The decorative paper for lamination is imported. The laminated products are assuming increasing popularity for table tops, sink tops, other decorative articles as also in electrical appliance.

Mica coated or satin papers are a special type of fancy and decorative sheets whose surface glisters and sparkless with thousands of tiny reflections of light. The sheet is produced in a wide range of colours and may be printed or embosed at will. The most popular colours are the postal and light shades and they are used in the fancy box and packaging field, for labels, and for various other decorative applications.

The sparkling effect is obtained by suspending finally ground mica flakes in the coating mix and these orient themselves in the coating when it is laid down on the paper so that their reflecting surfaces are parallel to the surface of the sheet with the result that they act as countless tiny mirrors which reflect the light. Mica is usually the only pigment used in these formulations as it is not desirable to cover the brilliance in any way. No coloured pigments or pulp coloured pigments or pulp colours for a similar reasons, but dyestuffs are commonly used to attain the desired shade.

The base paper for mica coatings is similar in basis weight and structure to that used for dull coats of other box papers. Its basis weight ranges from 38 to 65 pounds (25* 38-500) and the sheet should be well sized and of uniform formation and density. It should have a smooth surface finish.

COST ESTIMATION

Plant Capacity            1000 Sheets/Day

Land & Building (3000 sq.mt.)    Rs. 4.10 Cr

Plant & Machinery                    Rs. 2.68 Cr

Working Capital for 3 Months    Rs. 2.64 Cr

Total Capital Investment          Rs. 9.73 Cr

Rate of Return                          28%

Break Even Point                      51%

CONTENTS

INTRODUCTION

OVERVIEW OF DECORATIVE PLASTIC LAMINATE

PROPERTIES AND CHARACTERISTICS OF DECORATIVE LAMINATES

USES AND APPLICATION

APPLICATIONS

B.I.S. SPECIFICATION

QUALITY STANDARD OF DECORATIVE LAMINATES

MARKET POSITION

GLOBAL MARKET OF DECORATIVE LAMINATES

MANUFACTURERS/SUPPLIERS OF SUNMICA

CHEMISTRY AND TECHNOLOGY

RAW MATERIALS

MANUFACTURING PROCESS

IMPREGNATING THE PAPER

MANUFACTURING FLOW SHEET OF THE DECORATIVE LAMINATED SHEETS

PRODUCTION PROCESS OF HIGH PRESSURE DECORATIVE LAMINATES

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERIES

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR DECORATIVE LAMINATED SHEETS

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)