Industry Overview
Sandwich panels consist of a low-density insulating core positioned between two metal layers and bonded under pressure. They are widely used in industrial buildings, commercial buildings, cold storage facilities, warehouses, and other construction applications. Sandwich panels provide thermal, sound, and water insulation while helping prevent moisture condensation. They can also offer a more economical solution than conventional construction methods when evaluated through cost-benefit analysis.
The buildings and construction sector is a major end-user industry for sandwich panels. Rapid industrialization in emerging economies is increasing demand for construction solutions that reduce installation time. The panels are lightweight, easy to install, and cost-effective compared with many conventional wall assemblies. Their adoption in residential, commercial, and infrastructure development is expected to support continued market growth.
The report covers PPGI, polyurethane foam (PUF), polystyrene, and mineral wool sandwich panels, along with panel profiles, manufacturing processes, testing, plant and machinery, raw materials, plant layout, location factors, waste management, health, safety and environment requirements, and project financials. PUF panels use polyol and isocyanate and are available in various thicknesses and configurations for wall and roof applications. The report also addresses the expected growth of the sandwich panel market during the forecast period from 2018 to 2023, driven by increasing awareness of energy-efficient buildings, improved thermal performance, and energy conservation requirements.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 2000 SQM/Day |
| Land & Building (2750 sq.mt.) | 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 | 33% |
| Break Even Point | 55% |
Content Index
- 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
- 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)
Frequently Asked Questions
A sandwich panel is a prefabricated building component made by bonding an insulating core between two metal sheets. The report describes panels using materials such as polyurethane foam (PUF), polystyrene, and mineral wool. The core provides insulation, while the outer skins provide protection and structural performance. Depending on the configuration, sandwich panels can be used for walls, roofs, partitions, and façade cladding. Their factory-made construction also supports faster installation compared with many conventional building assemblies.
Sandwich panels are used for industrial, commercial, storage, cold-room, and other building applications. The report identifies industrial buildings, commercial buildings, cold storage facilities, warehouses, large factory buildings, exhibition halls, freezing stores, and purification workshops among their applications. Panels can serve as roof and wall systems, partitions, or façade cladding. Their insulation properties and relatively quick installation make them useful where thermal performance, construction speed, and controlled building environments are important.
Sandwich panels can use different insulating cores and metal facing materials depending on the required application. The report covers PUF, polystyrene, and mineral wool cores, with metal skins including pre-painted galvanized steel, aluminium, and other specified facing options. PUF is described as polyurethane foam produced from polyol and isocyanate. Mineral wool is highlighted for applications requiring fire-resistant insulation characteristics, while polystyrene panels are described as lightweight and easy to install.
The main advantages of sandwich panels include insulation performance, relatively fast installation, low structural weight, and suitability for prefabricated construction. The report notes thermal, sound, and water insulation as important benefits and identifies their ability to reduce moisture condensation. Their factory-manufactured form can simplify construction and reduce installation time. Depending on the core, profile, and facing system selected, panels can also provide structural support, weather resistance, fire performance, and compatibility with architectural features and building services.
The report covers several sandwich panel types and profiles, including Coldwell wall panels, Strupan roof panels, Isoclad panels, polystyrene sandwich panels, mineral wool sandwich panels, and polyurethane-based panels. Coldwell panels are described with single- and double-groove systems, while Strupan is a structural roof panel with a trapezoidal outer profile. Isoclad panels are intended for partition walls and façade cladding. The selection of panel type depends on factors such as insulation, structural requirements, fire performance, finish, and the intended building application.
A continuous sandwich panel production line generally requires equipment for coil handling, forming, insulation processing, panel assembly, cutting, and unloading. The report lists equipment including uncoilers, loading coil cars, roll forming units, pre-heating ovens, metering machines, reactive mixture distribution equipment, flexible face uncoilers, double conveyor belts, panel cutting units, and panel unloading and stacking lines. Additional plant equipment can include material-handling systems, electrical equipment, compressors, cranes, testing instruments, and environmental and safety systems.
Quality control for sandwich panels includes dimensional and physical checks to confirm that finished panels meet specified requirements. The report specifically identifies dimensional tolerance and transverse bow or cupping of panels, along with testing of finished PUF panels. Appropriate quality control also involves checking panel dimensions, surface condition, bonding, profile accuracy, and other characteristics relevant to the selected product specification. Testing requirements should be established against the applicable product specifications and relevant standards used for the project.
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