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)
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