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)