Detailed Project Report on discontinuous puf panels using cyclopentane as a blowing agent

DISCONTINUOUS PUF PANELS USING CYCLOPENTANE AS A BLOWING AGENT
[CODE NO.3690]  

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.

COST ESTIMATION

Plant Capacity            500 sq.mt/Day       
Land & Building (6000 sq.mt.)      Rs. 4.64 Cr         
Plant & Machinery                      Rs. 4.95 Cr     
Working Capital for 2 Months     Rs. 1.42 Cr
Total Capital Investment              Rs. 11.41 Cr
Rate of Return            32%                   
Break Even Point             48%            
           
             
INTRODUCTION    
PROPERTIES AND CHARACTERISTICS    
B.I.S. SPECIFICATION    
ADVANTAGE AND APPLICATION OF PUF PANEL    
PUF PANEL APPLICATION    
BENEFIT AND SPECIFICATION    
OF PUF PANEL IN STEEL STRUCTURE    
BENEFIT OF PUF PANEL IN STEEL STRUCTURE    
BENEFITS:    
SPECIFICATION:    
OVERVIEW OF INDIAN SANDWICH PANEL MARKET    
THE SIGNIFICANT DRIVERS IN THE GLOBAL INSULATED PANEL
   MARKET WILL BE:    
CYCLOPENTANE: THE ECO FRIENDLY BLOWING AGENT    
WHY CYCLOPENTANE    
CYCLOPENTANE VS CONVENTIONAL HCFC-141B:    
PRESENT MANUFACTURE OF PUF PANEL    
MARKET POSITION OF PUF PANELS    
KEY DEVELOPMENTS IN THE SANDWICH PANEL MARKET    
SANDWICH PANEL MARKET MAJOR PLAYERS    
INCREASING DEMAND FOR BUILDING WALLS    
PRESENT MANUFACTURERS/SUPPLIERS    
OF DISCONTINUOUS SANDWICH PANEL    
RAW MATERIALS    
DIISOCYANATES    
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) –    
MANUFACTURING PROCESS OF SANDWICH PANEL    
PROCESS IN DETAILS    
DISCONTINUOUS PRODUCTION OF SANDWICH PANELS    
EXAMPLES OF PANEL DESIGNS AND CONNECTIONS    
SINGLE-SHOT METHOD    
MULTIPLE-SHOT METHOD    
LANCE METHOD    
WITHDRAWAL METHOD    
MULTIPLE-OUTLET POURING    
PANEL FOAMER    
MOLD POSITIONS    
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    
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:    
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    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
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)