Detailed Project Report on Decorative Laminate Manufacturing Plant

DECORATIVE LAMINATE MANUFACTURING PLANT

[EIRI/EDPR/4217] J.C.: 2383XL

INDUSTRY OVERVIEW

Laminates are made using either High Pressure Laminates (HPL), or Direct Pressure Laminates (DPL). With the DPL method, all the layers are bonded together under extreme heat and pressure at one time. HPL is done in more than one step. Typically the wear layer and image layer are bonded together, and than those two layers are bonded to the core in a separate step.

Market for decorative laminates will be driven by strong demand from non-residential construction, which will benefit demand for laminate store fixtures and wall panels. For store fixtures, advances will stem from the price, performance and style advantages of laminate materials, as well as ongoing strength in retail sales activity. The development of more stylish and more realistic designs is a key element in the growth of laminate demand in store fixtures. 

Decorative laminate fixtures can be designed to meet specific design requirements, such as high-gloss and metallic surfaces, while offering retailers scratch resistance and ease of maintenance.

The demand for decorative laminates is relatively high in developing countries such as India and China in the Asia Pacific region. One of the major reasons behind the growth of the market in these two countries is a rapid increase in the population accompanied by expansion of the economy that ultimately results in increase in per capita income.

This increasing disposable income leads to an increase in the spending ability on home interiors. This factor is boosting the growth of the decorative laminates market across the Asia Pacific region.

Owing to an upsurge in the utilization of ready-to-assemble floorings as well as furniture and cabinets, the demand for high pressure laminates is likely to increase at a stable pace during the assessed period. Moreover, advanced functional properties such as scratch resistance, chemical resistance, anti-microbial and anti-fingerprint are further leading to an increase in the demand for high pressure laminates.

Besides, by facilitating advanced R & D initiatives to foster innovation, manufacturers of high pressure laminates are able to develop newer and more advanced products. Manufacturing of eco-friendly decorative laminates is expected to present lucrative growth opportunities for manufacturers to enhance the existing customer base and augment market value share.

Digital laminates are customized laminates available according to individual consumer needs to enable specific designs, graphics, and patterns to be directly printed on laminates.

With the use of latest technologies, the designer’s concept can now be transferred digitally and directly to the company facilities, which can further produce different digital sheets of any product type. Such laminates can be applied directly on walls, multipurpose furniture, stands, exhibition stalls, pictures, doors and other areas.

“Rapid growth in the residential sector in urban as well as semi-urban areas in North America and Europe is expected to contribute significantly to overall market growth. Substantial growth in the services and manufacturing sector has led to strong growth in the global GDP in the past. This, in turn, has had a positive impact on the decorative laminates market.

COST ESTIMATION

Plant Capacity            10,000 Sheets/Day

Land & Building (9000 sq.mt.)    Rs. 2.49 Cr

Plant & Machinery                    Rs. 54.52 Cr

Working Capital for 1 Month    Rs. 30.79 Cr

Total Capital Investment          Rs. 88.43 Cr

Rate of Return                          36%

Break Even Point                      46%

CONTENTS

INDUSTRY OVERVIEW

LIST OF DECORATIVE LAMINATES MANUFACTURING COMPANIES

MARKET OVERVIEW

BY PRODUCT

BY APPLICATION

MARKET DRIVERS AND CHALLENGES

GROWTH INDICATORS

BARRIERS

FURNITURE INDUSTRY

GROWTH TRENDS

FORECAST

LATEST DEVELOPMENTS

THE REASON BEHIND THE GROWTH OF INDIAN FURNITURE INDUSTRY

TOP 10 BEST DECORATIVE LAMINATE COMPANIES IN INDIA

GREENLAM

SUNMICA

FORMICA

CENTURY PLY

MERINO LAMINATES

DURIAN

SUNDEK

ASIS LAMINATES

VIRGO LAMINATES

DELTA LAMINATES

APPLICATION & USES

CONSUMPTION IN INDIA

RAW MATERIALS

MACHINERY TECHNICAL DETAILS

MANUFACTURE PROCESS

LAMINATE MANUFACTURING PROCESS

BASIC RAW MATERIAL

MACHINES USED

THE LAMINATE MANUFACTURING PROCESS

STEP 1: SOAKING THE PAPER IN RESINS

STEP 2: DRYING THE PAPERS

STEP 3: HIGH-PRESSURE PRESSING AND BONDING

STEP 4: SANDING THE NON-DECORATIVE SIDE

STEP 5: TESTING, PACKING, SHIPPING

MANUFACTURING OF LAMINATES

MANUFACTURING PROCESS OF LAMINATE

TYPES OF LAMINATES

A. ACCORDING TO PRESSURE APPLIED

1. HIGH PRESSURE LAMINATES (HPL)

PRESSURE AND TEMPERATURE CONDITIONS FOR HIGH PRESSURE LAMINATE

2. LOW PRESSURE LAMINATES (LPL)

PRESSURE AND TEMPERATURE CONDITIONS FOR LOW PRESSURE LAMINATE

B. ACCORDING TO THICKNESS

1. REGULAR LAMINATE SHEETS

REGULAR LAMINATE SHEETS

2. COMPACT LAMINATE SHEETS

COMPACT LAMINATE SHEETS

C. ACCORDING TO USAGE

1. DECORATIVE LAMINATES

DECORATIVE LAMINATE USED IN BEDROOM FURNITURE

2. INDUSTRIAL LAMINATES

DUSTRIAL LAMINATES USED IN A WAREHOUSE

D. ACCORDING TO SURFACE FINISH

1. SOLID COLORED LAMINATES

COLORED LAMINATE USED IN KITCHEN CABINET

2. GLOSS FINISH LAMINATE

GLOSS FINISH LAMINATE USED IN LIVING AREA

3. MATT FINISH LAMINATES

MATT FINISH LAMINATE FOR LIVING AREA

4. TEXTURED LAMINATES

XTURED LAMINATE FLOOR

5. WOOD GRAIN LAMINATES

D GRAIN LAMINATE IN OUTDOOR PORTICO

6. METAL LAMINATES

METAL LAMINATE SHEET

7. LEATHER LAMINATE SHEETS

LEATHER LAMINATE SHEETS

8. DIGITAL LAMINATE SHEETS

E. ACCORDING TO ADVANCED PROPERTIES

1. FIRE RATED LAMINATE

2. ANTI-BACTERIAL LAMINATE

LAMINATES USED IN INTERIOR OF HOSPITAL

3. ELECTROSTATIC DISSIPATIVE LAMINATE

4. MAGNETIC LAMINATE

MAGNETIC LAMINATE ON CABINETS

5. MARKER OR CHALK BOARD LAMINATE

CHALK BOARD LAMINATE ON WALL

F. ACCORDING TO BUILT

1 UNICORE LAMINATES

2 NONCORE LAMINATES

DIFFERENT LAMINATES AND THEIR APPLICATION AREA

ADVANTAGES OF LAMINATE

ECO FRIENDLY

ECONOMICAL

CUSTOMIZABLE

VERSATILITY

DURABILITY

SEAMLESS

SAFETY

MAINTENANCE

INSTALLATION

DISADVANTAGES OF LAMINATE

RELATIVELY POOR QUALITY

TOXIC

PRONE TO ABRASION

UNSAFE

PLANT LOCATION

NEPAL IN BRIEF

LICENSES REQUIRED

LIST OF DOCUMENTS:

TOP 10 BEST LAMINATE MANUFACTURERS IN INDIA

PRINCIPLES OF PLANT LAYOUT

SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE :

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

DEPRECIATION:

FIXED ASSETS:

WORKING CAPITAL:

BREAK-EVEN POINT:

OTHER FIXED EXPENSES:

MARGIN MONEY:

TERM LOANS:

TOTAL LOAD:

LAND AREA/MAN POWER RATIO:

LIST OF DECORATIVE LAMINATE MANUFACTURING INDUSRTY

LIST OF MACHINERY AND EQUIPMENTS MANUFACTURER

OTHER RELATED MACHINES MANUFACTURERS

DRYERS:-

MACHINERY PHOTOGRAPHS

MANPOWER

GENERAL

BASIS OF ESTIMATION

WORKING

TOTAL MANPOWER AND PAYROLL

UTILITIES

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

TABLE 1. SECTION WISE REQUIREMENT OF WATER IN THE PLANT

STEAM

EFFLUENT TREATMENT AND DISPOSAL

INTRODUCTION

THE WASTE FROM THE BEER PROCESSING OPERATIONS MAY BE CLASSIFIED ON THE BASIS OF:

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

QUALITY CONTROL

QUALITY CHECKS AT ADVANCE LAMINATES

DIMENSIONAL STABILITY TEST

APPEARANCE

1 SCOPE

2 NORMATIVE REFERENCES

3 TERMS AND DEFINITIONS

HIGH-PRESSURE DECORATIVE LAMINATE

HIGH-PRESSURE PROCESS

SURFACE LAYER

CORE LAYER

SWOT ANALYSIS

ORGANIZATION CHART

PLANT LAYOUT

TURNKEY CONSULTANT

IMPLEMENTATION SCHEDULE

MACHINES MANUFACTURERS & EXPORTERS OF PLYWOOD MAKING MACHINES

DRYERS:-

MANUFACTURERS

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)