Detailed Project Report on aluminium composite panel

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ALUMINIUM COMPOSITE PANEL

[CODE NO.4226]

Aluminium Composite Panels (ACP) are mainly light-weight composite material consisting of two pre-finished aluminium cover sheets heat-bonded (laminated) to a core made of polyethylene plastic material, available in 3mm, 4mm, and 6mm thicknesses after finishing and can be curved and bent to form corners. These panels are used widely as exterior covering of commercial buildings and corporate houses. While adding to aesthetic beauty of the structure, they are also resistant to acid, alkali salt spray, pollution and provide good thermal as well as sound insulation. These Panels are widely used due easy maintenance in almost any kind of climate through normal wash with water and mild detergent that ensures long lasting performance.

An aluminium composite panel (ACP) consists of two foil-coated aluminium sheets (typically around 0.5mm in thickness) bonded to a core (around 2 to 5mm thick). Depending on the panel, this core may be aluminium, mineral, or a thermoplastic polymer (usually polyethylene).

TYPES OF ACPS

1. FR

The FR (Fire Retardant) type panel, on the other hand, contains an interior fire retardant core made of thermoplastic resins with mineral charge.

Its reaction to fire classification B-s1, d0 (according to UNE EN 13501-1:2007), makes it a coating material that fulfils most of the architectural applications

2. A2

In the case of the A2 panel, this is a non-combustible panel composed of a mineral core developed to meet the highest regulatory requirements of fire classification

Its reaction to fire classification A2-s1, d0 (according to UNE EN 13501-1:2007), makes it the ideal cladding solution for high-rise buildings and high occupancy.

Aluminium Composite Panels consist of two thin sheets of aluminium continuously bonded to a polyethylene core. This polyethylene core of the aluminium composite panel is faced with two thin sheets of aluminium. The aluminium is bonded onto the core during the manufacturing process and it is virtually impossible to separate the layers of material once they have beenbonded

COST ESTIMATION

Plant Capacity 324 Nos/Day

Land & Building (4000 sq.mt.) Rs. 2.52 Cr

Plant & Machinery Rs. 48 Lac

Working Capital for 2 Months Rs. 4.47 Cr

Total Capital Investment Rs. 7.87 Cr

Rate of Return 592%

Break Even Point 9%

INTRODUCTION
TYPES OF ACPS
1. FR
2. A2
FEATURES
PE ALUMINIUM COMPOSITE PANEL:
MIRROR FINISH ALUMINIUM COMPOSITE PANEL:
PROPERTIES
PHYSICAL PROPERTIES
MECHANICAL PROPERTIES
INDOBOND PANEL DIMENSION
ADVANTAGES OF ALUMINUM COMPOSITE PANELS
USES & APPLICATION
WIDE APPLICATION
THE IMPLEMENTATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
COIL COATING LINES
(1) UNCOILING AND STRIP JOINING
(2) TENSION LEVELLING
(3) ENTRY ACCUMULATOR
(4) PRETREATMENT
(5) COATING
(6) DRYING AND STOVING OVENS
THE MAIN FEATURES OF OVEN ARE:
(7) EXIT SECTION AND RE-COILING
QUALITY CONTROL
QUALITY
A. PRE-PRODUCTION INSPECTION
ALUMINIUM
PLASTIC GRANULES
ADHESIVE FILM
PROTECTIVE FILM
FOLLOWING TEST ARE CONDUCTED ON THE FINISHED
ALUMINIUM COMPOSITE PANELS
MARKET POSITION
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF ALUMINIUM COMPOSITE PANELS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM COIL
SUPPLIERS OF PE GRANNULES
SUPPLIERS OF ADHESSIVE FILM
SUPPLIERS OF PVDF
SUPPLIERS OF PRIMER
SUPPLIERS OF CHROMATE CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ACP PRODUCTION LINE
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP

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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