CHAPTER 4: ANALYSIS OF PRODUCTION PROCESS

This chapter contains the results of production facility and marketing location analysis, machinery
and production equipment analysis, and manufacturing processes analysis of Heat Insulation for
Metals Industry owned by PT. Kreasi Tata Udara, PT. Budi Karya Agung, and PT. Airtekindo Prima,
which are located in Tangerang Regency, West Java, Sidoarjo Regency, East Java, and Denpasar City,
Bali.

4.1. Analysis of Production and Marketing Locations

4.1.1. Production and Marketing Location

The production sites of Heat Insulation Products for Metals, owned by PT. Kreasi Tata Udara, PT.
Budi Karya Agung, and PT. Airtekindo Prima, are situated in Tangerang Regency, Banten Province,
and Sidoarjo Regency, East Java Province.

4.1.1.1. TANGERANG SITE – BANTEN PROVINCE

The production site for Heat Insulation Products for Metals in Tangerang Regency, Banten Province,
is situated at Kompleks Pergudangan Hero Block B No. 2 – 3, Block E No. 1 – 5, Jalan Salembaran Jati
No. 9, Salembaran Sub-district, Kosambi District, Tangerang Regency, Banten ProvinceThe location
of the buildings is integrated in a manner that highly supports the production process.

The legalities of each building unit are as follows:

 Block B No. 2 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00168, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 25/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block B No. 3 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00169, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 26/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block B No. 4 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00170, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
 July 2038. Surat Ukur No. 27/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Madam Bong Mie Siu in accordance with Gambar Situasi, the
land area is 600 square meters.

 Block E No. 1 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00174, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 31/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block E No. 2 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00175, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 32/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block E No. 3 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00176, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 33/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block E No. 4 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00177, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 34/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

 Block E No. 5 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00178, issued by
Kantor Pertanahan Kabupaten Tangerang on 05 November 2008, and the right ends on 29
July 2038. Surat Ukur No. 35/Salembaran Jati/2008, dated 28 October 2008, lists the
property under the name of Engineer Toto Djamaludin in accordance with Gambar Situasi,
the land area is 600 square meters.

Total land area: 4,800 square meters.

The production building specifications are as follows:

 Production Building Block B No. 2-3 and Block E No. 1-5 (8 Units):
 o Foundation : Reinforced concrete footings

o Number of floors : 1 floor (partially with mezzanine)

o Construction : WF Steel Structure

o Walls : Hebel Brickwork

o Roof construction : WF Steel Structure

o Roofing : Aluminum Spandeck

o Flooring : Reinforced Concrete Plate with Ceramic Tiles

o Ceiling : Gypsum in office areas

o Doors : Steel Plates with Steel Frames

o Windows : Steel Grilles

o Area : 4,000 m2

o Year built : 2018

o Physical condition : Good

Aside from production facility for Heat Insulation for Metal products, the facility includes a
warehouse for storing finished products, located at the Kompleks Pergudangan 99 Block L No. 25
and Block L No. 35, Jalan Salembaran Jati, Salembaran Subdistrict, Kosambi District, Tangerang
Regency, Banten Province. The buildings are strategically placed to support the storage of finished
goods. Currently, these buildings are leased to a third party.

The legalities of the warehouse units are as follows:

a. Block L No. 25 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00439, issued by
Kantor Pertanahan Kabupaten Tangerang on 21 December 2012, and the right ends on 23
October 2042. Surat Ukur No. 304/Cengklong/2012, dated 05 December 2012, lists the
property under the name of PT. Airtekindo Prima, in accordance with Gambar Situasi, the
land area is 462 square meters

b. Block L No. 35 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 00398, issued by
Kantor Pertanahan Kabupaten Tangerang on 21 December 2012, and the right ends on 23
October 2042. Surat Ukur No. 263/Cengklong/2012, dated 05 December 2012, lists the
 property under the name of PT. Airtekindo Prima, in accordance with Gambar Situasi, the
land area is 462 square meters

Total land area: 924 square meters.

The production building specifications are as follows:

 Production Building Block L No. 25 and Block L No. 35 (2 Units):

o Foundation : Reinforced concrete footings

o Number of floors : 1 floor (with mezzanine)

o Construction : WF Steel Structure

o Walls : Hebel Brickwork

o Roof construction : WF Steel Structure

o Roofing : Aluminum Spandeck

o Flooring : Reinforced Concrete Plate with Ceramic Tiles

o Ceiling : Gypsum in office areas

o Doors : Steel Plates with Steel Frames

o Windows : Steel Grilles

o Area : 900 m2

o Year built : 2014

o Physical condition : Good

4.1.1.2. SIDOARJO SITE – EAST JAVA PROVINCE

The production site for Heat Insulation Products for Metals in Sidoarjo Regency, East Java Province,
is situated at Sinar Gedangan Warehouse Complex Block A No. 9, Jalan Raya Betro No. 9, Gemurung
Subdistrict, Gedangan District, Sidoarjo Regency, East Java Province.

The legalities of the land unit are as follows:

a. Block A No. 9 is certified by Sertifikat Hak Guna Bangunan (SHGB) No. 455, issued by Kantor
Pertanahan Kabupaten Sidoarjo on 08 March 2005, and the right ends on 08 April 2024.
Surat Ukur No. 00009/15.05/2005, dated 16 January 2005, lists the property under the
 name of Madam Bong Mie Siu, in accordance with Gambar Situasi, the land area is 750
square meters

The production building specifications are as follows:

 Production Building Block A No. 9:

o Foundation : Reinforced concrete footings

o Number of floors : 1 floor

o Construction : WF Steel Structure

o Walls : Hebel Brickwork

o Roof construction : WF Steel Structure

o Roofing : Aluminum Spandeck

o Flooring : Reinforced Concrete Plate with Ceramic Tiles

o Ceiling : Gypsum in office areas

o Doors : Steel Plates with Steel Frames

o Windows : Steel Grilles

o Area : 700 m2

o Year built : 2006

o Physical condition : Good

4.1.1.3. DENPASAR SITE – BALI PROVINCE

The marketing office for Heat Insulation Products for Metals in Denpasar City, Bali Province, is
situated at Jalan Gunung Soputan No. 15 B, Pemecutan Klod Subdistrict, West Denpasar District,
Denpasar City, Bali Province.

The legalities of the office unit are as follows:

a. Ownership is certified by Sertifikat Hak Milik (SHM) No. 7322, issued by Kantor Pertanahan
Kota Denpasar on 17 October 2012. Surat Ukur No. 03168/Pemecutan Klod/2012, dated 08
October 2012, lists the property under the name of Caroline Djamaludin, in accordance with
Gambar Situasi, the land area is 104 square meters

The office building specifications are as follows:

  Office Building:

o Foundation : River Stone Construction

o Number of floors : 2 floors

o Construction : Reinforced Concrete Construction

o Walls : Hebel Brickwork

o Roof construction : Wooden Construction

o Roofing : Concrete Roof Tiles

o Flooring : Ceramic Tiles

o Ceiling : Gypsum

o Doors : Aluminum Frame Glass

o Windows : Aluminum Frame Glass

o Area : 120 m2

o Year built : 2014

o Physical condition : Good

4.2. PRODUCTION PROCESS ANALYSIS

Thermal Insulation is a thermal control strategy through the use of materials that can reduce heat
transfer. Heat transfer can be reduced because the material has low thermal conduction and the
ability to reflect rather than absorb thermal radiation.

Insulation materials are not dense like other building materials that are conductors. This material
has millions of tiny air pockets in the fibers or bubbles in the plastic foam insulation. These tiny
fibers and bubbles help to slow down the heat transmission process.

There are many insulation materials readily available on the market today. Many of them have been
around for a long time. Each of these insulation materials has its own advantages and
disadvantages. Here are the 5 most common types of insulation materials:

Table 4-1

Types of Insulation Materials

 Insulation Material Environmentally Flammable Notes
Friendly

Polyurethane Foam No Yes A good soundproofing material

Mineral Wool Yes No Non-melting and fire retardant

Cellulose Yes Yes Contains the highest amount of recycled content

Fiberglass Yes No Non-water absorbent

Polystyrene (EPS) No Yes Difficult to use around imperfection

1. Fiberglass

Fiberglass is the most common insulation used in modern times. Because of the way it is
made, by effectively spinning fine strands of glass into an insulating material, fiberglass is
able to minimize heat transfer. The main disadvantage of fiberglass is the danger in
handling it. Since fiberglass is made of a finely woven silicone, it can create glass powder
and tiny glass shards. This can cause damages to the eyes, lungs, and even skin if proper
safety equipment is not worn.

Figure 4-2

Fiberglass Materials

2. Mineral Wool

Mineral wool actually refers to several types of insulation. First, it may refer to glass wool
which is fiberglass made from recycled glass. Second, it may refer to rock wool which is a
type of insulation made from basalt. Lastly, it may refer to slag wool which is produced from
 steel mill slag. The majority of mineral wool in the United States is actually scrap wool
production.

Figure 4-3

Mineral Wool Materials

3. Cellulose

Cellulose is made from recycled cardboard, paper, and other similar materials and is
available in loose form. Some recent research on cellulose suggests that cellulose may be an
excellent product to use in minimizing fire damage. Because of its compact nature, cellulose
contains almost no oxygen in it. Without oxygen in the material, this helps to minimize the
amount of damage that a fire can cause.

Figure 4-4

Cellulose Materials
4. Polyurethane Foam

While not the most common type of insulation, polyurethane foam is an excellent form of
insulation. Today, polyurethane foam uses non-chlorofluorocarbon (CFC) gases to act as a
blowing agent. This helps reduce the amount of damage to the ozone layer. There are also
low-density foams that can be sprayed onto areas that do not have insulation. Another
advantage of this type of insulation is that it is fire resistant.

Figure 4-5

Polyurethane Materials

5. Polystyrene

Polystyrene is a waterproof thermoplastic foam that is an excellent sound and temperature

insulator. It comes in two types, expanded (EPS) and extruded (XEPS) also known as
Styrofoam. The two types differ in terms of performance ratings and cost. The more
expensive XEPS has an R-value of R-5.5 while EPS is R-4. Polystyrene insulation has a
uniquely smooth surface that other types of insulation do not have.

Typically, the foam is molded or cut into blocks, ideal for wall insulation. The foam is
flammable and needs to be coated with a fire-retardant chemical called
Hexabromocyclododecane (HBCD). HBCD has recently come under fire for the health and
environmental risks associated with its use.

Figure 5
 Polystyrene Material

Developments in modern building material innovation have been able to produce new ideas to
meet the needs of construction work to be more efficient and economical. One of the modern
building materials is the sandwich panel – a structural material that can withstand hot and cold
temperatures. This material is made of two layers: two thin layers in this sandwich structure are
called the skin/cover layer and one middle layer is called the core layer.

Some of the advantages of sandwich panels as a building material:

1. Relatively fast installation and easy maintenance

Generally, making a wall or roof layer takes a long time and requires a lot of workers.
However, this is not the case with the use of sandwich panels, which only require a few
people.
2. Energy Saving
The use of sandwich panels with wall coverings can save electricity costs, wall panels that
can reflect light optimally will save electricity
3. More Economical
Installation of sandwich panels do not require a lot of labor which makes the installation
process more economical in terms of time and energy
4. Ready to Install
Unlike installing walls using bricks that require plastering and then cementing as a
finishing. Sandwich panels do not require finishing like before.
5. Earthquake-resistant
The advantages of prefabricated buildings using sandwich panels are that they are more
flexible and stronger, so that when an earthquake occurs it will not cause severe damage.
Therefore, this prefabricated building design is very suitable for earthquake-prone areas.
6. Lighter Material
 The maximum thickness of this material is 150mm, moreover the specific gravity is much
lower when compared to other modular panels. Especially modular pre-cast panels made of
concrete. With its lightness, this sandwich panel can be easily removed and installed in a
building
7. Customizable
The production of sandwich panels is carried out in a modular but flexible manner with a
width of 1.18 m and a length that can be customized up to 10 m according to project needs.
8. Simple to Install
Installing this sandwich panel does not require a lot of additional/supporting materials
such as cement, water and sand. Prefabricated building materials are factory-assembled
materials, where you only need to assemble them at the desired location.

The skin layer and core layer in the sandwich panel are:

A. Sandwich Panel Skin Layer

The skin layer of the panel is useful for resisting tension and compression that occurs when
the panel bends. The sandwich panel skin layer has 2 types, namely:
 Fiber-Reinforced Polymer (FRP)

is a composite material made of a polymer matrix reinforced with fiber

 Galvanized Metal or Steel Material

is a steel material that has been coated/galvanized with a zinc layer to protect the surface
from corrosion/rust.

B. Core layer

Then the core layer is useful as insulation to reduce the rate of heat transfer when
temperature changes occur.

Figure 4-6

Insulation Panel Structure

 There are several types of core layers in sandwich panels as follows:

 Expanded Polystyrene (EPS)

is a lightweight, CFC-free, non-brittle foam insulation material, and has very low water
vapor transmission capacity (thus preventing evaporation) but is not resistant to hot
temperatures. The thickness options available on the market are 40, 50, 75, 100, 125, 150,
175, 200 mm.

Figure 4-7

Expanded Polystyrene (EPS)

 Polyurethane (PU)

is a rigid and hard foam material with a mixture or the result of isolating rubber and plastic
so that a material solution is obtained that has the advantages of being very resistant to
friction, wear-resistant, resistant to several mild chemicals, stable in cold and hot
temperatures and good in energy saving, and can also prevent condensation. Material
thickness options available on the market are 50, 75, 100, 125, 150 mm

Figure 4-8

Polyurethane (PU)
 Non-approved Polyisocyanurate (PIR)

Polyisocyanurate is a rigid foam material made from a mixture of isocyanurate and polyol.
PIR panels have high durability, high temperature resistance (fire resistance), and have
mechanical resistance and stable properties

Figure 4-9

Non-approved Polyisocyanurate (PIR)

 Rock wool

Made from rocks, generally a combination of basalt, limestone, and coal, which are heated to
a temperature of 1,600 degrees Celsius so that they melt like lava. In this melted state, the
rocks are centrifuged to form fibers. Rock wool is not suitable for cold storage because it
cannot withstand temperatures below 5 degrees Celsius but is suitable for use near hot
areas because it is very resistant to high temperatures.

Figure 4-10

Rock wool
 Sandwich panels are often used especially for cold storage fabrication construction
companies, because these sandwich panels are able to inhibit temperature changes
originating from outside the room. However, of the several types of sandwich panels that
have been explained above, only a few types are suitable as materials for making cold
storage. Like one of the prefabricated cold storage building manufacturing companies,
namely Koronka Nusantara, which produces sandwich panels with a skin layer using
galvanized metal and a core layer using polyurethane (PU).

Sandwich Panel Manufacturing Process

The manufacturing process of sandwich panels involves several important steps involving the main
components: external skin and insulating core. The following are the general steps in the sandwich
panel production process:

1. Making the External Skin: The external skin is made first using materials such as metal
(steel, aluminum), composite materials, or concrete. This involves cutting and shaping
according to the desired design. The surface of the external skin can also be textured or
finished for better aesthetics.
2. Making the Insulation Core: The next step is to make the insulation core which will be the
middle layer of the sandwich panel. The insulation core material such as polystyrene,
polyurethane, or mineral wool material is shaped to the required dimensions. The thermal
and acoustic insulation properties of the panel depend on the quality of this insulation
material.
3. Joining the Components: Once the external skin and the insulation core are ready, the next
step is to join these components. This process involves the use of glue, special adhesives, or
mechanical reinforcement techniques such as nails and screws, depending on the type and
purpose of use of the panel.
4. Drying and Hardening Process: After joining, the sandwich panel must undergo a drying and
hardening process. This ensures that the bonding and structure of the panel achieve the
required strength and integrity.

Figure 4-11

Flow Chart of Sandwich Panel Production

 Figure 4-12

Flow Chart of the Process of Sandwich Panel Production