CONTINUOUS SANDWICH PANEL LINE
[EIRI/EDPR/4343] J.C.: 2528XL
INTRODUCTION
A Sandwich Panel consists of a core/insulating material of low density sandwiched between two layers of metal, bonded under pressure. The sandwich panel market is expected to witness a high growth rate during the forecast period, 2018 to 2023. The major end-user industries of sandwich panel market include industrial buildings, commercial buildings, cold storage facilities, warehouses, amongst others. Sandwich panels provide a quite level of thermal, sound, water insulation, and also prevent moisture condensation. Sandwich panel is more economical than the conventional methods when assessed with the concept of cost-benefit analysis. Increasing awareness about the energy efficient buildings, improvement in thermal performance of sandwich panels and implementation of stringent energy conservation regulations are expected to be the major drivers for the growth of sandwich panel market during the forecast period.
Buildings & construction is one of the major end-user industries driving the growth of sandwich panel market. With rapid industrialization in the emerging economies, the need for less time-consuming construction solutions is growing which in turn increases the demand for sandwich panels. Due to their easy installation property, sandwich panels are cost-effective and inexpensive when compared to other wall assemblies. The average growth in the global construction spending has been recorded at 8.1% in the last five years. The non-residential construction spending has increased to 4.1% in 2016, and this trend is expected to continue in the coming years. Increasing adoption of the sandwich panels for residential, commercial, and infrastructure development is expected to boost the market in the coming years.
Sandwich Panel
Sandwich panels are made of two colors coated metal sheets with an insulation material sandwiched in between. Sandwich panel made of
PPGI
• Pre-painted Galvanizing Iron / Galvalume
• Total Coated Thickness: 0.35mm /0.4mm /0.45mm /.5mm PUF
• Short form of Polyurethane Foam.
• Composition of 2 chemical: - Polyol and Isocynate
• Density: - 40kg/cu.m +/- 2 kg/cu.m
Continuous sandwich panels are single piece, prefabricated, modular, factory made units which consist of an insulating layer of rigid polyurethane foam between two layers of metal sheets. The panels comprise of PUF bonded between two sheets of Pre-coated GI sheets of 0.5 mm thick to produce straight-to-finish panels. Insulation core provides effective insulation and strong bonding for better structural stability to facilitate higher loading and wider spans. These panels are available for both wall and roof.
The system can incorporate all types of architectural features like coving, boxes, cantilevers, projections, infill walls, mezzanine floors etc. This system can also incorporate all types of services viz. electrical, gas and plumbing etc. The design and engineering of the structures is executed by following the norms & guidelines stipulated in relevant Indian Standards.
Typical Isometric views of both roof and wall panels are shown in Figs. 1 & 2 respectively
Fig. 1 Roof Panel
Fig. 2 Wall Panel
Size of Panels
Panels are available in thickness from 25mm to 150mm, width 1000mm and length as per requirement of the customer
Profiles of the Panels
(A) Coldwell Wall panels
Coldwell wall panels are tongue-n-groove joinery for air-tight, effective panel to panel interlocking which provides an effective seal. Two types of panels – single groove and double groove systems are manufactured. While single groove panels are suitable for general purpose and application in buildings and shelters; double groove panels are suitable for cold room and cold chamber applications. Double groove ensures precise interlocking, dimensional accuracy and also eliminates the risk of air gaps and thermal bridging. Coldwell panels are in higher thicknesses are self-supporting free standing upto 6 metres. All joints are covered with flashings.
Profiles of these panels are given below:
Inner & Outer skin: 3 types of rib configuration – Micro-rib, Wave and Mini box.
Facing Options: Pre-painted galvanized steel/aluminium, stainless steel and craft paper and perforated metal sheet for inner skin
Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings.
Coldwell-1
These panels are available in thickness of 30, 40, 50, 60, 80 & 100mm. Detail of this panel is shown in Fig. 3.
Coldwell -2
These panels are available in thickness of 80, 100, 120 & 150mm. Detail of this panel is shown in Fig. 4.
(B) Strupan Roof panel
Strupan is a structural roof panel with a trapezoidal profile on the top surface and a ribbed liner tray on the underside and a sandwiched insulation cover.
Profile of this panel is given below:
Inner skin: Ribbed liner, aluminium foil/craft paper
Outer skin: 35x250mm trapezoidal profile with 2 secondary ribs and anti-capillary flute.
This panel is available in thickness of 30, 40, 50, 60, 80 & 100mm
Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings. Detail of this panel is shown in Fig. 5.
(C) Isoclad
Isoclad panels act as partition walls as well as façade cladding with permanent finishing and can be integrated well with structural glazing, curtain walls, windows and other type of fenestrations and openings.
Profile o this panel is given below:
Skins: 3 types of rib configuration – Micro-rib, Wave and Mini box
This panel is available in thickness of 40, 50, 60 & 80mm.
Facing options: Pre-painted galvanized steel/aluminium
Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings. Detail of this panel is shown in Fig. 6.
Polystyrene sandwich panels
Being a kind of new type of multi-functional building material, it consists of steel plate at both side and polystyrene sandwiched. They are bonded with high intention adhesive at high temperature and pressure through auto forming machine.
Light in deadweight: 10-14Kg/SQM, easy to install (don't need crane), short construction period and low cost.
Large load: Used as supporting structure and defense device for its characteristic of high intention rigidity.
Flexible to use: Controlled by computer in its continuous assembly line, the length of them can be chosen at your willing.
Heat and sound insulation: Average thermal conductivity not less than 0.04w/m. K.
Mineral wool sandwich panels
Mineral wool sandwiched panels is made of 2 layers weatherproof color-plating steel plates or other metal plates and mineral wool sandwiched which is the best fireproof materials. It is suitable for various roofs and walls referring to the large-size factory buildings, storages, exhibition halls, freezing stores, purifications workshops, etc, which features temp-keeping, heat insulation, weight-bearing, weatherproof with the rich colorfulness and good appearance.
COST ESTIMATION
Plant Capacity 2000 SQM/Day
Land & Building (2750 sq.mt.) Rs. 2.70 Cr
Plant & Machinery Rs. 28.44 Cr
Working Capital for 1 Month Rs. 2.68 Cr
Total Capital Investment Rs. 34.84 Cr
Rate of Return 33%
Break Even Point 55%
CONTENTS
INTRODUCTION
SANDWICH PANEL
PPGI
FIG. 1 ROOF PANEL
FIG. 2 WALL PANEL
SIZE OF PANELS
PROFILES OF THE PANELS
(A) COLDWELL WALL PANELS
PROFILES OF THESE PANELS ARE GIVEN BELOW:
COLDWELL-1
COLDWELL -2
(B) STRUPAN ROOF PANEL
PROFILE OF THIS PANEL IS GIVEN BELOW:
(C) ISOCLAD
PROFILE OF THIS PANEL IS GIVEN BELOW:
POLYSTYRENE SANDWICH PANELS
MINERAL WOOL SANDWICH PANELS
PU SANDWICH PANEL
PU SANDWICH PANEL FEATURES:
POLYURETHANE-SANDWICHED PANEL
1. PUF PANEL FORMULATION
2. SPECIFICATION OF PUF PANEL
PROPERTIES OF PUF
ADVANTAGES/DISADVANTAGES OF PUF PANEL
ADVANTAGES
DISADVANTAGES
USES/APPLICATIONS
APPLICATION (INDUSTRIES)
MARKET OVERVIEW
COMPETITIVE INDUSTRY
NOTABLE PLAYERS IN THE SANDWICH PANELS MARKET INCLUDE
REGIONAL INSIGHTS
GLOBAL SANDWICH PANELS MARKET INFORMATION
MAJOR MARKET DRIVERS
BIS SPECIFICATION
RAW MATERIALS
CONTINUOUS PRODUCTION PROCESS/PRODUCTION LINE
THERE ARE BASICALLY TWO PANEL MANUFACTURING TECHNOLOGIES:
CONTINUOUS PANEL PRODUCTION LINE
A TYPICAL CONTINUOUS LINE IS MADE UP OF THE FOLLOWING THREE SECTIONS:
MANUFACTURING PROCESS STEPS
PROCESS FLOW
TESTING
TESTING: FOR QUALITY CONTROL:
DIMENSIONAL TOLERANCE FOR SANDWICH PANELS
TRANSVERSE BOW – CUPPING OF THE PANELS
FOLLOWING TEST ARE CONDUCTED ON THE FINISHED PUF PANELS
PLANT & MACHINERY
UNCOILER
LOADING COIL CARS
ROLL FORMING UNIT
PRE-HEATING OVEN
PRE-HEATING OVEN
METERING MACHINE
REACTIVE MIXTURE DISTRIBUTION
FLEXIBLE FACE UNCOILERS
DOUBLE CONVEYOR BELT
PANELS CUTTING UNIT
THESE UNITS CAN BE EITHER:
PANELS UNLOADING AND STACKING LINE
SUPPLIERS OF CONTINUOUS SANDWICH PANEL
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PPGI SHEET
SUPPLIERS OF PUR/PIR MATERIAL
SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS
CONTINIOUS SANDWICH PANNEL PRODUCTION LINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
ELECTRICAL MEASURING INSTRUMENTS
DG SETS
EOT CRANES
POWER TRANSFORMERS
ELECTRICAL PANEL
ELECTRIC MOTOR
COOLING TOWER
EFFULENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
SUBMERSIBLE WATER PUMP
PRELIMINARY LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
SPECIFIC FACTORS
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
VULNERABILITY TO WARTIME ATTACK:
FLOOD AND FIRE CONTROL:
WASTE MANAGEMENT
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
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)
