Industry Overview
Sandwich panels are thermally insulated composite building elements used for roof and wall cladding, building envelopes, and partition walls. They generally consist of inner and outer galvanised sheet metal skins bonded to an insulating core, with continuous and discontinuous production methods used for manufacturing. Common core materials include polyurethane (PUR), mineral fibre wool (MIWO), and polystyrene.
The bonding of the metal skins to a shear-resistant insulating core provides sandwich panels with high rigidity, load-bearing capacity, and thermal insulation. Their lightweight construction and rapid installation make them suitable for industrial halls, commercial and administrative buildings, cold storage and freezing facilities, cooling trailers, and other applications requiring effective temperature control.
Polyurethane systems based on polyols and isocyanates are widely used for thermal insulation, while rigid low-density polyurethane foam is an efficient insulation material. Insulated metal panels also support energy-efficient construction and can contribute to reduced building energy consumption. Applications include commercial and industrial buildings, architectural structures, cold storage facilities, and insulated roofing.
The market is segmented by application into commercial and industrial, architectural, cold storage, and insulated roof segments. The report identifies commercial and industrial buildings as the leading application segment and highlights significant potential for cold storage applications. Geographically, North America is identified as a dominant market, while Asia Pacific is projected to show significant growth driven by industrial, infrastructural, and economic development, particularly in China and India.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 750 Sq.mt./Day |
| Land & Building (2000 sq.mt.) | Rs. 2.88 Cr |
| Plant & Machinery | Rs. 5.16 Cr |
| Working Capital for 1 Month | Rs. 1.14 Cr |
| Total Capital Investment | Rs. 9.73 Cr |
| Rate of Return | 35% |
| Break Even Point | 49% |
Content Index
- INTRODUCTION
- PROPERTIES AND CHARACTERISTICS
- B.I.S. SPECIFICATION
- ADVANTAGE AND APPLICATION OF PUF PANEL
- PUF PANEL APPLICATION
- MAKING PANELS FOR COLD STORAGES AND COOLING TRAILERS
- THE PRODUCTION OF STRUCTURAL INSULATED PANELS (SIPS) AND FULL WALL TIMBER
- THE PRODUCTION OF PANELS FOR INDUSTRIAL APPLICATIONS IN THE CONSTRUCTION SECTOR (MODERN METHODS OF CONSTRUCTION MMC)
- THE PRODUCTION OF PANELS FOR SPECIAL APPLICATIONS
- BENEFIT AND SPECIFICATION OF PUF PANEL IN STEEL STRUCTURE
- BENEFIT OF PUF PANEL IN STEEL STRUCTURE
- BENEFITS:
- ABOUT PUF PANEL
- BENEFITS:
- SPECIFICATION:
- INDIAN MARKET OF SANDWICH PANELS
- GLOBAL MARKET OVERVIEW OF PUF PANELS
- INCREASING DEMAND FOR BUILDING WALLS
- KEY MANUFACTURERS ARE:
- PRESENT MANUFACTURERS/SUPPLIERS OF DISCONTINUOUS SANDWICH PANEL
- RAW MATERIALS
- THERE ARE FIVE MAIN AREAS OF USE FOR POLYURETHANES:
- DIISOCYANATES
- FIGURE 2 SHOWS THE STRUCTURAL FORMULA OF DIPHENYLMETHANE 4,4'-DIISOCYANATE (MDI MONOMER) AND THE PRODUCT DERIVED FROM IT WITH A FUNCTIONALITY GREATER THAN 2 (MDI POLYMER)
- POLYOLS
- RIGID POLYURETHANE FOAM –SANDWICH PANELS
- CONSTRUCTION FOAMS
- TRANSPORTATION FOAMS
- SUMMARY OF AVAILABLE TECHNICAL OPTIONS
- THE OPTIONS CAN THEREFORE BE SUMMARIZED AS FOLLOWS:
- N- & ISO-PENTANE –
- LIQUID HFCS –
- CO2 (WATER BLOWN) –
- LESS PREFERRED OPTIONS (MEASURABLE ODP)
- HCFCS (141B & 22/142B)
- CYCLOPENTANE
- METHOD OF SANDWICH PANELS PRODUCTION
- 1. CONTINUOUS LINE PANEL PRODUCTION:
- 2. DISCONTINUOUS PANEL PRODUCTION PROCESS:
- MANUFACTURING PROCESS OF SANDWICH PANEL
- DISCONTINUOUS PANEL MAKING
- DISCONTINUOUS PANEL MAKING PROCESS:
- PROCESSING DETAILS OF DISCONTINUOUS PANEL
- DISCONTINUOUS PRODUCTION OF SANDWICH PANELS
- EXAMPLES OF PANEL DESIGNS AND CONNECTIONS
- SINGLE-SHOT METHOD
- MULTIPLE-SHOT METHOD
- SCHEMATIC VIEW OF THE DISTRIBUTION OF THE REACTION MIX WITH THE MULTIPLE-SHOT METHOD AFTER THE THIRD SHOT (40 S AFTER THE FIRST SHOT)
- SCHEMATIC DIAGRAM OF OVER-ROLLING IN THE EXPANDING REACTION MIX DURING THE MULTIPLE-SHOT METHOD (80 S AFTER THE FIRST SHOT)
- DISPENSING METHODS FOR THE DISCONTINUOUS PRODUCTION OF SANDWICH PANELS WITH A RIGID POLYURETHANE FOAM CORE
- LANCE METHOD
- WITHDRAWAL METHOD
- MULTIPLE-OUTLET POURING
- PANEL FOAMER
- MOLD POSITIONS
- DISCONTINUOUS PRODUCTION LINE (MULTI-DAYLIGHT PRESS) FOR SANDWICH PANELS
- PROCESS FLOW DIAGRAM
- DISCONTINUOUS PANEL LINE
- PRODUCTION OF PANELS WITH DISCONTINUOUS METHOD
- PUF PANEL FORMULATION
- DETAILS OF PU DISCONTINUOUS PANEL LINE
- PU DISCONTINUOUS SANDWICH PANEL LINE
- ROLL FORMING LINE
- HOT PRESS LINE
- ADVANTAGES OF PUR SANDWICH PANEL
- THE SPECIFICATION OF PANEL & STEEL
- LINE SIZE
- ELECTRIC CONSUMPTION
- PRODUCTION TECHNOLOGIES OF SANDWICH PANEL
- CONTINUOUS AND DISCONTINUOUS PANEL MANUFACTURING METHODS
- CONTINUOUS PANEL PRODUCTION LINE
- TECHNICAL SPECIFICATION OF PUF PANEL
- TECHNICAL SPECIFICATION
- PROPERTIES OF PUF
- FLOOR INSULATION BY PUF BLOCKS
- PUF PANELS AVAILABLE UNDER FOLLOWING SPECIFICATION:
- TESTING: FOR QUALITY CONTROL:
- TECHNOLOGY SOLUTION OF PUF PANEL PRODUCTION
- OUR SUPPLY INCLUDES:
- OTHER PROCESS FOR SANDWICH PANELS SANDWICH PANELS (CONTINUOUS PROCESS)
- THE PANEL PROPERTIES:
- SANDWICH PANELS WITH A MINERAL FIBRE WOOL INSULATION CORE
- DIMENSIONAL TOLERANCE FOR SANDWICH PANELS
- DIMENSIONAL TOLERANCES (GENERAL) FOR SANDWICH PANELS:
- DIMENSIONAL TOLERANCES WITH CORRUGATIONS
- TRANSVERSE BOW – CUPPING OF THE PANELS
- SUBSIDY IN INDIA FOR SETTING UP COLD CHAIN
- WHAT IS A COLD CHAIN
- WHO CAN SETUP A COLD CHAIN
- WHAT ARE THE CRITERIA’S FOR OBTAINING FINANCIAL ASSISTANCE FOR COLD CHAIN
- WHAT IS THE AMOUNT OF FINANCIAL ASSISTANCE PROVIDED FOR SETTING UP OF COLD CHAIN BY MOFPI
- HOW IS THE FINANCIAL ASSISTANCE PROVIDED DURING THE SETTING UP OF THE UNIT
- HOW SHOULD THE APPLICATION FOR FINANCIAL ASSISTANCE BE MADE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CYCLOPENTANE
- SUPPLIERS OF PLANT AND MACHINERIES
- SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)
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
Sandwich panels are primarily used for thermally insulated roofs, walls, building envelopes, and partition systems. They are widely applied in industrial halls, commercial and administrative buildings, cold storage facilities, freezing units, and cooling-related structures. Their lightweight construction, thermal insulation, rigidity, and rapid installation make them suitable where efficient building assembly and temperature control are important. Depending on the design and insulation core, panels can also be adapted for architectural and other specialized applications.
Sandwich panels commonly use polyurethane foam, mineral fibre wool, or polystyrene as insulating core materials. Polyurethane and rigid polyurethane foam provide effective thermal insulation and are widely used in insulated building panels. Mineral fibre wool can be selected where its particular fire and insulation characteristics are required. The core is bonded between metal skins, creating a composite structure in which the core and facings work together to provide rigidity, insulation, and structural performance.
Continuous and discontinuous production are two principal manufacturing approaches for sandwich panels. Continuous lines integrate several operations into a continuous production sequence and are suited to efficient, consistent panel manufacturing. Discontinuous production manufactures panels individually or in batches using equipment such as presses, moulds, dispensing systems, and panel foamers. The appropriate method depends on required production volumes, panel specifications, product flexibility, equipment configuration, and investment considerations.
Polyurethane foam is used in sandwich panels because it provides efficient thermal insulation while contributing to a lightweight and rigid composite structure. Polyurethane systems are produced through the reaction of polyols and isocyanates, and rigid low-density polyurethane foam is recognized for its insulation performance. When bonded between metal facings, the foam core helps provide thermal resistance and structural rigidity, making polyurethane-based panels suitable for industrial buildings, cold storage, refrigeration-related applications, and other temperature-controlled environments.
Sandwich panels are suitable for cold storage because their insulated composite construction supports effective temperature control. The insulating core reduces heat transfer through walls and roofs, while the bonded metal skins provide a durable building surface. This combination is useful for cold stores, freezing units, and other facilities where maintaining controlled temperatures is essential. Proper panel selection, joint design, installation quality, and material compatibility remain important for achieving the required thermal and structural performance.
Key raw materials for PUF sandwich panel production include metal sheets for the outer and inner facings and polyurethane system components such as polyols and isocyanates. Depending on the production technology and formulation, blowing agents and other formulation components may also be used. The report discusses materials and technical options including pentanes, liquid HFCs, water-blown CO2 systems, HCFCs, and cyclopentane. Selection of raw materials and blowing technology affects insulation performance, processing, environmental characteristics, and finished-panel quality.
Panel selection should consider thermal insulation requirements, structural stability, application environment, core material, metal facings, dimensional requirements, fire and performance characteristics, and installation conditions. For cold storage and temperature-controlled buildings, insulation performance and joint integrity are particularly important. Material compatibility should also be evaluated because the report notes potential corrosion issues with certain metal combinations and deformation risks under extreme temperatures. Panel design, finish, shape, and fabrication may additionally be customized for architectural and commercial applications.
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