cell cast acrylic sheet (production rate - 1600 sq.ft. per day)

CELL CAST ACRYLIC SHEET (PRODUCTION RATE - 1600 SQ.FT. PER DAY)

[EIRI/EDPR/4553] J.C.: 2770US$

INTRODUCTION

CAST acrylic, as the name suggests, is manufactured by a process whereby MMA (Methyl Methacrylate monomer) liquid is pumped into a mould made from two sheets of glass. The mould/monomer is then submerged in warm water and the process of polymerization takes place.

The result is a sheet of rigid PMMA (polymethyl methacrylate) or what is generically called Acrylic. Various trade names are applied to this sheet – in Europe we call it “Perspex”, in the USA it’s often referred to as “Plexi or Plexiglas” other brand names include “Setacryl”, “Polycryl”, “Oroglas” and many more.

Whilst CAST Acrylic sheets tend to have a greater variance on thickness tolerance (as much as +/– 30% on thickness). This is compensated by the surface finish (as smooth as glass, since it was CAST, or molded, between two sheet of glass). Furthermore, the ability to colour the clear MMA monomer by using master batch pigments allows for numerous colours to be obtained in relatively small production batches, in most cases as few as 20# sheets 3030 x 2030mm can be obtained.

In addition to the above CAST acrylic sheets lend themselves to ease of fabrication. Cutting, whether with conventional saws produce a cleaner cut and the sheets when stacked (cut in multiples) tend not to fuse or weld together. 

In addition, CAST acrylic when laser cut produces a highly polished edge, thus reducing finishing times when fabricating. Furthermore, when hot wire line bending, drape or vacuum forming CAST acrylic sheets are more malleable / pliable than Extruded acrylic sheet.

Global Cast Acrylic Sheets Market is projected to reach USD 4.41 Billion by 2023 at a CAGR of over 5% owing to the rising customer preference for lightweight materials in architecture, interior design and in cars. Moreover, the increasing use of cast acrylic sheets in sanitary ware due to their lightweight and ease of handling coupled with the growing popularity of cell cast acrylic sheets across various end-use industries is expected to propel the growth of the market during the forecast period. Based on the type, the Cell Cast Acrylic Sheets segment is expected to lead the market in the next five years, due to the quality of cell cast acrylic sheets is much better than that of continuous cast sheets and is preferred by various end-use industries. Based on the applications, the signage & display segment is projected to lead the market during the forecast period, as it is a cost-effective substitute for polycarbonate sheets and are comparatively lighter than glass which allows their use in displays and signage to increase brand awareness, and credibility of the product. Asia-Pacific is expected to dominate the Cast Acrylic Sheets market during the forecast period, due to increasing demand for Cast Acrylic Sheets from emerging economies in the region like China, Japan and India.

It is intended to prepare a Feasibility Report for Cell Cast Acrylic Sheet Production facility with an installed capacity of 1600 SQFT/Day as a Green Field Project.

COST ESTIMATION

Plant Capacity            1600 Sq.ft./Day  

Land & Building (3325 sq.mt.)    US$ 3.65 Lac    

Plant & Machinery                    US$ 2.16 Lac 

Working Capital for 0.5 Month    US$ 25.15 Th. 

Total Capital Investment          US$ 6.32 Lac 

Rate of Return                          26%

Break Even Point                      62%

CONTENTS

• INTRODUCTION

• PROPERTIES

• USES

• MARKET OVERVIEW

• RAW MATERIALS

• PROCESS

• MANUFACTURING PROCESS

• CLEANER TECHNOLOGY

• ENVIRONMENTAL IMPACT 

• SUPPLIERS/MANUFACTURERS 

• SUPPLIERS OF PLANT AND EQUIPMENTS

• ENGINEERING DESIGN CONSIDERATIONS

• ETP FACILITY

• SEWAGE AND WASTE WATER EFFLUENT 

• PRINCIPLES OF PLANT LAYOUT

• PLANT LOCATION FACTORS

• ANTICIPATED ENVIRONMENTAL IMPACTS

• MITIGATION MEASURES (PROPOSED)

• HEALTH SAFETY AND ENVIRONMENT

• PROPOSED IMPLEMENTATION SCHEDULE

• PRELIMINARY LAYOUT

• PROJECT FINANCIALS

• CONCLUSIONS

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)