Detailed Project Report on discontinuous puf panels manufacturing unit

DISCONTINUOUS PUF PANELS MANUFACTURING UNIT

[CODE NO.4164]  

Thermally insulated composite building elements for roof and wall cladding in buildings, thereby forming the building envelope. They consist of an inner and outer galvanised sheet metal cover, coated on one side. They are manufactured in continuous production plants. The application is in industrial construction i.e. construction of industrial halls and cold storage facilities. Sandwich panels are also suited for other fields of application.

Sandwich panels are by now in common use as cladding elements in the building industry, creating building envelopes and partition walls. They fall under the class of composite elements and consist of an insulating foam core and a metal layer on either side, solidly glued to the core. The core is usually made of polyurethane foam (PUR) or mineral fibre wool (MIWO). Sandwich panels with a polystyrene core are also available, however. The sandwich panel has a high load-bearing capacity and is very rigid - due to the bonding (bonding or adhesion) of the covering layers to the shear-resistant core. The core simultaneously lends the building envelope excellent thermal insulation properties. Sandwich structures are quick to install and are used mainly for roofing and walls for industrial, office and administration buildings, as well as for cold storage and freezing units. Sandwich panels are of late being thoroughly tested for application in residential housing.

Polyol  is  a polyhydric alcohol, Containing three  or  more hydroxyl  groups.  Polyurethane systems  Comprising  polyol  and isocyanates used for thermal insulation for Refrigeration.

Polyurethanes  are  addition  polymers  obtained  from   the chemical  reaction of an polyol and an isocyanate,  which  occurs readily  at  room  temperature.   Major  polyurethanes   products i.e Rigid low density polyurethane, foams are the most  efficient  Šcommericially  available insulation material.

Insulated metal panels are structural panels used in the construction of buildings. They are sandwiched composite panels where a light-weight insulating foam core is inserted between the metal skins. These panels are light-weight, exhibit exceptional insulating properties, and can be installed easily and quickly. Due to its easy installation property, insulated metal panels are cost-effective and inexpensive as compared to other wall assemblies. They help in improving the energy efficiency of buildings and in reducing carbon footprint. They are generally used for construction of roofs and walls in commercial buildings, architectural buildings, cold storage buildings etc. Different panels with varying attributes are employed depending on the type of buildings for which they are used. The commercial & industrial segment includes recreational buildings, institutional buildings, government buildings, and manufacturing plants. These buildings require energy-efficient insulation and light-weight construction. Schools or power plants constructed with insulated metal panels benefit from energy efficiency. Architectural buildings require specially designed insulated metal panels, including the attributes required for commercial and institutional buildings such as higher insulation values, light-weight constructions, quick assemblies etc. Additionally, they require customization in shapes, colors, finishes, and fabrication such as bent corners, curved panels, and trim less ends. Insulated metal panels are a highly efficient option for applications that involve temperature control. In the food & beverage industry, where temperature is a crucial parameter, having a direct impact on the quality and perishability of the food articles, insulated metal panels demonstrate to be a cost-effective and beneficial option. Demand for insulated metal panels has been on the rise at a steady pace, due to the growing influence of sustainable building initiatives. However, with insulated metal panels, the choice of material used has a crucial role to play in the overall structural stability of the construction. Aluminum metal panels attached with galvanized steel fasteners have high chances of corrosion. Furthermore, insulated panels employed in buildings exposed to extreme temperatures possess high risks of undergoing deformation.

Based on application, the insulated metal panels market can be segmented into commercial & industrial, architectural, cold storage, and insulated roof.  At present, the commercial & industrial buildings segment dominates the insulated metal panels market. It is projected to retain its position during the forecast period. The cold storage segment is anticipated to expand at a significant pace in the near future as temperature control, which is crucial in such buildings, can be easily achieved with the help of insulated metal panels.

Based on geography, the insulated metal panels market can be divided into North America, Europe, Latin America, Asia Pacific, and Middle East & Africa. North America presently dominates the market, owing to the availability of advanced technologies in the region. The U.S. contributes to a major share of the market in the region. Furthermore, Asia Pacific is projected to show significant growth during the forecast period, owing to its rapid industrial and infrastructural progress and economic development.

Key players operating in the insulated metal panels market are Metl-Span an NCI Building Systems company, Kingspan, MBCI, an NCI Building Systems company, Huntsman International LLC, ATAS International, Inc. Centria.

The insulated metal panels market is projected to provide lucrative opportunities, especially in Asia Pacific, led by the infrastructural, industrial, and economic development in the countries such as China and India in the region. Moreover, countries such as Japan and Korea are expected to contribute significantly to the insulated metal panels market in Asia Pacific.

COST ESTIMATION

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%

• 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 – 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)