Project Report On Pu Foam Mattress
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EIRI Board of Consultants and PublishersProject Report On Pu Foam Mattress
Uploaded by
EIRI Board of Consultants and PublishersPU FOAM MATTRESS
[EIRI/EDPR/4024] J.C.: 2154XL
INTRODUCTION
A mattress is a large, rectangular pad for supporting the reclining body, designed
to be used as a bed or on a bed frame, as part of a bed. Mattresses may consist of
a quilted or similarly fastened case, usually of heavy cloth, that contains materials
such as, foam rubber, or a framework of metal springs.
Mattresses are usually placed on top of a bed base which may be solid, as in the
case of a platform bed, or elastic, such as an upholstered wood and wire box
spring or a slatted foundation. Popular in Europe, a divan incorporates both
mattress and foundation in a single upholstered, footed unit. Divans have at least
one innerspring layer as well as cushioning materials.
Advancement in science and technology has created so many products that have
enhanced the quality of human life in every passing year. The human race is
largely dependent on industrialization for up gradation in quality of life. Progress
of the nation is judged through its economic growth which is largely dependent on
industrial productivity. PU Foam is used in a large number of strongly diversified
applications, such as filler for seats, chairs and seat cushions, mattress centres,
car seats, encapsulation of car windows, shoes and textiles, thermal insulation
(buildings, industrial installations, refrigerators, etc.), sound insulation, adhesives
and paints/coatings, etc. The great advantage of PU foam is its great flexibility in
meeting the various applications and requirements. Polyurethane owns some
extremely exceptional material qualities such as: density, elasticity, durability,
weight, safety, design and of course its attractive price.
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Since PUF is mainly used together with other materials, such as textiles, metal,
wood and other polymers, it is not always visible in the end products.
Polyurethanes are used throughout cars. In addition to the foam that makes car
seats comfortable, bumpers, interior “headline” ceiling sections, the car body,
spoilers, doors and windows all use polyurethanes. Polyurethane also enables
manufacturers to provide drivers and passengers significantly more automobile
“mileage” by reducing weight and increasing fuel economy, comfort, corrosion
resistance, insulation and sound absorption.
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CONTENTS
INTRODUCTION
MARKET PROSPECTIVE
CONSTRUCTION
SIZES
PROPERTIES OF PU FOAM MATTRESS
RESILIENCE
SOLVENT RESISTANCE
ANTIBACTERIAL PROTECTION
YELLOWING AND DISCOLOURATION
LOW FIRE RETARDANCY
ADVANTAGES AND DISADVANTAGES OF A POLYURETHANE MATTRESS
ADVANTAGES
DISADVANTAGES
USAGE AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS DESCRIPTION
FOAMING PROCESS:
FOAM CURING:
QUALITY CONTROL
PLANT AND MACHINERY
REQUIRED MACHINE FEATURES
MARKET POSITION
MAJOR COMPANIES
MATTRESS MARKET IN INDIA
MATTRESS MARKET IN INDIA (USD BN)
BRANDED MATTRESS MARKET IN INDIA (% OF OVERALL MARKET)
BRANDED MATTRESS MARKET BY MATTRESS TYPE (% OF BRANDED
MATTRESS MARKET)
MATTRESS MARKET BY PRICE POINT (% OF BRANDED MATTRESS MARKET)
MATTRESS MARKET BY DISTRIBUTION CHANNEL (% OF BRANDED
MATTRESS MARKET)
MATTRESS MARKET BY DISTRIBUTION CHANNEL-2018
MATTRESS MARKET BY REGION (% OF OVERALL MATTRESS MARKET)
MATTRESS MARKET BY DISTRIBUTION CHANNEL-2018
MATTRESS MARKET BY CONSUMER TYPE (% OF OVERALL MATTRESS
MARKET)
MATTRESS MARKET BY CONSUMER TYPE
GROWTH DRIVERS OF MATTRESS MARKET IN INDIA
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PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF PU FOAM MATTRESS
SUPPLIERS OF RAW MATERIALS
SUPPLIER OF CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIER OF PRODUCTION LINE
SUPPLIER OF STITCHING MACHINE
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
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SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EXHAUST FAN
SUPPLIERS OF TESTING EQUIPMENTS
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)
COST ESTIMATION
Plant Capacity 240 Nos./Day
Land & Building (11075 sq.mt.) Rs. 2.46 Cr
Plant & Machinery Rs. 1.97 Cr
Working Capital for 2 Months Rs. 4.16 Cr
Total Capital Investment Rs. 8.96 Cr
Rate of Return 74%
Break Even Point 32%
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