Detailed Project Report on Laminated Sheets/Electrical Insulation Board

LAMINATED SHEETS/ELECTRICAL INSULATION BOARD

[EIRI/EDPR/1769] J.C. 611

INTRODUCTION

Decorative plastic laminate is a durable flat sheeting material used in home and industrial furnishings. It is most familiar under the Formica brand name. The Formica Corporation is the world's largest manufacturer of plastic laminate. Other well known manufacturers include the Premark Corporation and DuPont.

Decorative laminate is commonly used to surface kitchen counters, table tops, and cabinetry because of its resistance to stains, scratches, and heat. The laminate sheets are made up of three layers: the bottom layer of brown paper coated with phenolic resin, a second layer of paper decorated with the desired pattern, and a third layer of clear sheet. Both the second and third layers are coated with melamine resin.

Plastic laminate was first used as an insulating material for industrial products. Its invention is credited to two engineers, Herbert A. Faber and Daniel J. O'Conor. In the early 1900s, these two joined the Westinghouse Company in Pittsburgh as part of a dream team of scientists working on insulating material and phenolic laminate resins. Phenolic laminate resins had been developed around this time by the Belgian chemist Leo Baekeland. Baekeland condensed phenol and formaldehyde to produce the first totally synthetic plastic, Bakelite. The material was resistant to heat, water, chemicals, and electric current, thus having the properties to replace hard rubber and shellac for electrical insulation. Baekeland's many experiments included impregnating paper with Bakelite resin and then compressing it under molds at high pressure and temperature in a process known as thermosetting. The two Westinghouse engineers worked in this same vein. They began by impregnating heavy canvas with Bakelite resin, and by 1913 they had applied for a patent for a flat laminate sheet made from Bakelite and paper. Faber called the new plastic laminate Formica: "for" (in place of) "mica" (mineral used as electrical insulation material).

Faber and O'Conor left Westinghouse to found their own company in 1913, the Formica Insulating Company in Cincinnati, Ohio. The new company produced rings and tubes of plastic laminate for electrical insulating purposes, but by 1914, Faber and O'Conor were using a press to churn out flat laminate sheets. The laminate was widely used in radio sets in commercial shipping and naval vessels to insulate coils, tuners, and other parts. But plastic laminate was soon used for its decorative properties as well because its flawless, uniform character was the perfect radio exterior. By 1921, the laminate manufactured by the Formica Insulating Company had been integrated into the manufacture of home radios as well as ship radios.

In 1927, Faber and O'Conor discovered that by adding decorative paper through a lithographic printing process, their laminates could be made with patterns that simulated wood grains and marble. As the laminate became more colorful and decorative, its market expanded. Faux marble laminate was popular for soda fountains in the 1930s, and a wood grain laminate was used in place of aluminum inside airplanes in the

Decorative plastic laminate sheeting is mode of resins that react with aldehydes during the thermosetting process. 1940s. manufacturing improvements soon enabled plastic laminate to resist cigarette burns, and the material became more attractive, colorful, and durable, spurring its use by manufacturers of kitchen and dining furniture.

Decorative plastic laminate sheeting is made of resins that react with aldehydes during the thermosetting process. The resins are laminated onto layers of kraft paper topped with a decorative sheet. Kraft paper is the same brown paper used in grocery bags. The first plastic laminates were made with phenolic resin, a polymer of formaldehyde and phenol. Phenolic resins produce only dark colors. In the 1930s, a urea-based resin called melamine was developed that produced a clear surface. In the modern manufacturing process, the top two layers of paper are impregnated with melamine resin, and the lower layers use phenolic.

COST ESTIMATION

Plant Capacity            8000 Nos/Day

Land & Building (4400 sq.mt.)    Rs. 3.34 Cr

Plant & Machinery                    Rs. 1.12 Cr

Working Capital for 2 Months    Rs. 14.04 Cr

Total Capital Investment          Rs. 18.82 Cr

Rate of Return                          35%

Break Even Point                      37%

CONTENTS

INTRODUCTION

PROPERTIES

ELECTRICAL PROPERTIES

USES AND APPLICATION

B.I.S. SPECIFICATION

MARKET SURVEY

MANUFACTURERS/SUPPLIERS OF PHENOLIC LAMINATED SHEETS

PHENOL FORMALDEHYDE RESIN

MANUFACTURING PROCESS OF LAMINATED SHEET

SPECIFICATION OF LAMINATED SHEET

PHENOLIC RESIN BONDED PAPER BASED BOARD

PROCESS FLOW CHART FOR LAMINATED SHEET

QUALITY CONTROL FOR LAMINATED SHEETS

PLANT LAYOUT

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF RAW MATERIAL FOR LAMINATED SHEETS

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)