Detailed Project Report (DPR) on Decorative Laminate Sheets from Kraft Paper and Decorative Paper

DECORATIVE LAMINATE MANUFACTURING PLANT

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

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.

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
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• 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 ASSETS
• 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)