I VIETNAM GENERAL CONFEDERATION OF LABOR TON DUC THANG UNIVERSITY FACULTY OF APPLIED SCIENCES GRADUATION THESIS FACTORY DESIGN TO PRODUCE HDF BOARD BASED ON PF ADHESIVES FROM CASHEW NUT SHELL OIL WITH A CAPACITY OF 1 MILLION PANELS PER YEAR Advisor Assoc prof Dr HUYNH DAI PHU Student NGO VU LOI Class 17060201 Course 2017 2021 Ho Chi Minh city, 2022 Graduation thesis Ngo Vu Loi 2021I ACKNOWLEDGEMENT The process of completing my graduation thesis is an important and meaningful period for me During.
OVERVIEW
Overview of wood-plastic composites
1.2.1 Introduce of wood-plastic composites
A wood-based composite is a manmade material primarily made from wood elements, typically bonded with a thermosetting additive Commonly referred to as engineered wood or wood-plastic composites (WPC), these materials combine the natural properties of wood with enhanced durability and performance.
Figure 1.1: Classification of wood composite panels (Suchsland and Woodson1986).
The journey of Wood Plastic Composites (WPC) began in 1983 with Woodstock of America pioneering the manufacturing of automotive interiors A significant milestone occurred in 1991 when the first international conference on WPC was held, marking the start of extensive research in the field By the late 1990s, WPC gained remarkable traction in North America, particularly in outdoor flooring applications, leading to an impressive annual market growth rate of nearly 100%.
Wood-plastic composite (WPC) materials are increasingly popular in construction and architecture, serving as an alternative to natural wood due to their quality and aesthetic appeal In Vietnam, the development of WPC has emerged only in recent years, but its adoption is growing However, a significant drawback of WPC is its relatively high cost compared to traditional materials.
1.2.2 Wood-plastic composite material characteristics a Advantages:
- Easy to maintain, can be painted or dyed
- Capable of meeting different uses
- Technical properties are generally better than conventional wood or plastic materials.
- Good durability and moisture resistance
- Surface machinability, drilling, and cutting products similar to wood
- There is no need for regular maintenance b Disadvantages
- WPC is more expensive than similar products made from other materials
- It is twice as heavy as wood
- Easily decomposed, the degree of decomposition depends on the proportion of wood
- Aging by ultraviolet rays when used outdoors
1.2.3 Production and development of the WPC industry
WPC, although a minor segment of the wood industry, is experiencing rapid growth driven by lower production costs and enhanced properties that allow it to nearly replace natural wood Its widespread application is evident in countries like Japan, the US, Finland, Germany, and China.
In 2021, Vietnam's wood and wooden products export reached an impressive 14.8 billion USD, highlighting the significant demand for these items in the market The country's wood processing industry relies on an annual import of 3.5 to 4 million cubic meters of logs Additionally, the scrap generated during wood processing varies based on raw materials, product size, and equipment capacity, typically accounting for 45% to 63% of the raw material volume This indicates a robust market demand for wood products in Vietnam, alongside a plentiful supply of raw materials for the production of wood plastic composites (WPC).
1.2.4 Applications of wood-plastic composite materials
Wood-plastic composite materials are widely utilized across various sectors, with the construction industry being the largest consumer These materials are essential in automotive component manufacturing, where they must meet high standards for mechanical strength, lightweight design, impact resistance, vibration damping, noise reduction, and customer safety Additionally, wood-plastic composites find applications in a range of consumer products.
Overview of cashew nut shell oil
The main product of the cashew industry is cashew kernels, which are separated from cashew nuts Processed cashew kernels have been roasted, have a very specific
Cashew nut shell oil, the second product of the cashew industry, is derived from cashew nut shells and boasts significant industrial applications In our country, there are more than ten facilities dedicated to processing cashew nut shells, producing an annual output of approximately 12,000 to 15,000 tons.
The cashew tree (Anacardium occidentale L.) is a resilient tropical evergreen from the Anacardiaceae family, which includes the mango This adaptable tree thrives in various climatic and soil conditions, demonstrating drought tolerance and excelling in monsoon climates, where it yields high-quality fruit.
Cashew nuts, resembling large beans, are greenish-gray when fresh and turn brown upon drying Weighing between 5-7 grams, they measure approximately 2.5-3.3 cm in length, 1.6-2.2 cm in width, and 1.3-1.6 cm in thickness, consisting of three distinct parts.
The cashew nut shell constitutes 70% of the nut's total weight and consists of three distinct layers: the tough outer shell, a porous middle shell with a honeycomb structure, and a hard inner shell that contains valuable oil Notably, the oil extracted from the cashew nut shell accounts for approximately 21% of the nut's weight.
- The velamen surround the kernel, accounting for 5% of the weight of the cashew nut.
Cashew kernels, which make up 25% of the nut's weight, are white and rich in oil Packed with antioxidants, vitamins, and essential minerals, cashew nuts support the body's normal functioning.
Cashew nut shell oil (CNSL) is a valuable by-product derived from the cashew industry, extracted during the production of cashew nut kernels Known for its versatility, CNSL is often regarded as a cost-effective alternative to unsaturated phenol.
Figure 1.2: Cashew nut shell oil (Source: Kimmy farm) 1.3.3.1 Methods of extracting cashew nut shell oil a Extraction method
The extraction of oil from nutshells using organic solvents is a time-consuming process that requires a significant amount of solvents and yields 25-36% oil relative to the weight of the nuts This method produces high-quality oil with a bright yellow hue, characterized by the absence of polymerization and a predominant composition of anacardic acid.
Roast the nuts in their oil at a temperature of 180-190 o C At that time, the nuts become crispy, easy to break, and take out the kernel inside.
The roasting method is commonly used because it is simple, fast, and easy to implement, has high oil separation efficiency, which can get 50 - 60% of the oil in the nuts.
Because the oil obtained at a high temperature is decarboxylated and partially thermal polymerized, it has a dark brown color and is mainly composed of cardanol. c High-frequency current method
The advanced oil separation method, developed by H Pothenbarg and utilized globally, involves several key steps First, nuts are perforated with multiple holes and preheated using infrared rays before being processed through an aluminum electrode Within just 4 minutes, this technique achieves a 45% oil extraction rate Following this, the nuts are washed with hot water and subjected to compressed air in a pressure cooker to effectively separate the shell from the kernel.
This method offers several benefits, including the production of high-quality, bright yellow oil and a rapid oil separation time, achieving a capacity exceeding 98% However, it necessitates the use of complex and costly equipment.
Cashew nut shell oil is an alkylphenol, its structure has a phenol hydroxyl group combined with a long unsaturated side chain in the meta position relative to the hydroxyl group.
The chemical composition of the oil varies depending on the processing method. However, it contains the following main components: Anacardic acid, cardanol, cardol 2-methyl cardol, etc.
These components have the following chemical formula [10]:
Anacardic acid Cardanol Cardol 2-metyl cardol
Depending on the processing method, the oil is obtained with different qualities and compositions.
Natural cashew nut shell oil (oil obtained by an extraction method or high- frequency current) is composed mainly of anacardic acid and cardol.
Extracted oil containing: 82% anacardic acid; 13,8% cardol; 2,6% 2-methyl cardol và 1,6% cardanol.
Pure cardanol is a viscous yellow liquid obtained through the vacuum distillation of cashew nut shell oil at pressures between 5-15 mmHg It features a boiling point of 240°C at 6 mmHg, a density ranging from 0.923 to 0.926 g/cm³, and a refractive index of 1.5112 at 25°C.
Cardanol is a compound that is insoluble in water and dilute alkaline solutions but readily dissolves in various organic solvents such as toluene and xylene The distillation efficiency for oil heat treatment ranges from 40% to 50%, while extracted oil achieves a higher efficiency of 65%-70% due to the absence of thermal polymerization Over time, cardanol undergoes a color change to yellow-brown after a few weeks of distillation, yet its viscosity remains relatively stable after a year of storage This compound is derived from the distillation of extracted cashew nut shell oil at a vacuum pressure of 5-10 mmHg and temperatures between 235°C and 245°C.
Table 1.1: Characteristic parameters of raw cashew nut shell oil and cardanol [10]
Through mass spectrometry and analysis, the composition of double bonds in the branch chain R of the above components has been determined as follows:
Table 1.2: Composition (%) of branched-chain double bonds C15 distilled cashew nut shell oil [9]
Components Cardanol Cardol 2-metyl cardol
Average number of double bonds 1.4 2.3 2.0
Chemical analysis reveals that cashew nut shell oil contains an average of 1.67 double bonds, determined by assessing the total number of bromine atoms substituted in the benzene nucleus and added to the double bonds.
The unsaturated degree is very important in determining oil quality The more diene and triene composition, the more unsaturated the oil, the easier it is to form a hard firm.
1.3.3.2 Physicochemical properties of cashew nut shell oil
Commercial cashew nut shell oil is characterized by its brown color, acrid odor, and insolubility in water, alcohol, and ether, while being soluble in solvents such as acetone, n-hexane, and toluene Key physico-chemical properties of cashew oil are summarized in Table 1.2.
Table 1.3 Characteristics of some types of cashew nut shell oil and the method of separating cashew oil [10]
Characteristic Method of separating cashew oil
Natural cashew nut shell oil primarily consists of cardanol, which is formed from the unstable anacardic acid that decarboxylates under heat While anacardic acid possesses a high acid value, it complicates its use as a flexible film-forming agent due to its hygroscopic nature, leading to issues like wrinkling and swelling in films, as well as poor water and environmental resistance In contrast, cardanol, an alkyl phenol with a long unsaturated R branch chain, exhibits reactivity similar to that of phenol, along with the added reactivity of its double bond, making it more suitable for applications such as paint coatings.
Phenol undergoes various chemical reactions, including condensation with aldehydes like formaldehyde, substitution reactions with acids such as sulfuric and nitric acid, and reactions with acetone to produce bisphenol Additionally, phenol reacts with epoxy groups and unsaturated oils Notably, cardanol, derived from cashew nut shell oil, can undergo auto-polymerization and co-polymerization with styrene and methyl methacrylate, showcasing its versatility in polymer chemistry.
PRODUCT DESIGN
Introduce of product
Fiberboard is a kind of WPC Fiberboard includes hardboard (HDF), medium density fiberboard (MDF), and cellulosic fiberboard.
HDF board is a high-density fiberboard, with a higher wood density than MDF, so the average density is also higher.
Figure 2.1: HDF board (source: Minh Long wood).
Product features
HDF boards, known for their high wood fiber density, offer exceptional strength and durability, making them heat and impact-resistant They are waterproof and exhibit greater hardness compared to MDF boards Additionally, HDF provides excellent sound and heat insulation properties, enhancing its overall performance in various applications.
HDF board is priced higher than other types of wood boards due to its premium grade wood composition With an average density of 1.25g/cm³, HDF board is heavier than traditional wood and other wood board varieties.
Table 2.1: Comparison of the mechanical properties of some commonly used materials on the market [11]
Table 2.2: The mechanical properties of WPC from CNSL PF adhesives under the influence of temperature [11]
S2: The test sample was annealed at 120 o C for 100 hours
The above test results show that the mechanical properties of the material increase under the effect of temperature, but the impact strength decreases.
Table 2.3 Weather resistance of WPC from CNSL PF adhesives [11]
M2: The test sample has been placed in outdoor conditions for 1 year
The above test results show that the mechanical properties of the material tend to increase after 1 year in outdoor conditions.
Table 2.4 mechanical of WPC from CNSL PF adhesives in a saline environment [11]
M4: The test sample was soaked in saltwater for 1 year
The above test results show that the material can withstand the seawater environment well.
Product design
WPC based on phenol-formaldehyde adhesives from cashew nut shell oil includes 2 layers: the surface layer and the wood plastic core layer.
The surface layer is a protective paint that safeguards the material from environmental effects while providing color to the product This layer utilizes UV paint, which cures under UV rays, resulting in a glossy finish, enhanced scratch resistance, a durable paint film, and exceptional hardness.
Wood-plastic core layer: made from wood pulp and phenol-formaldehyde adhesives from cashew nut shell oil.
RAW MATERIALS
Phenol formaldehyde (PF) resin (novolac) from cashew nut shell oil
3.1.1 PF resin characteristics and properties
PF resin has 2 forms: Novolac PF and rezol PF.
Novolac PF resin has a straight-chain structure and a low molecular weight. Rezol PF resin has a branched-chain structure, a tighter network, and a larger molecular weight.
Phenol-formaldehyde products derived from cashew nut shell liquid (CNSL) are viscous, reddish-brown liquids When using oxalic acid as a catalyst, the resulting product is less viscous and lighter in color compared to the use of hydrochloric acid Unlike conventional PF resin, CNSL-based PF resin is nearly non-polar, allowing for easy mixing with dry oils and various other resins, as well as solubility in numerous solvents Additionally, CNSL undergoes partial polymerization through heat treatment, resulting in a PF resin that exhibits high viscosity, making it difficult to stir and prone to gelatinization.
For optimal results in the PF condensation reaction, it is essential to use a 60% concentration solution at temperatures between 96-97 °C, as this promotes a faster reaction and leads to higher molecular weight products If conducted at a lower 45% concentration, the reaction proceeds slowly, prolonging the condensation period, even at elevated temperatures For further enhancement of product quality, deep condensation should be performed at 120 °C.
PF from CNSL features a methyl cardanol group, which demonstrates a greater reactivity compared to the phenol hydroxyl group This enhanced reactivity makes PF an ideal candidate for further modification with various substances, including vegetable oil, epoxy, and styrene.
The reaction between the hydroxyl group of cardanol and the mobile hydrogen in the para position relative to the -OH group of phenol-formaldehyde (PF) resin derived from cashew nut shell liquid (CNSL) occurs in conjunction with the oil's double bond This interaction highlights the potential for enhancing the properties of PF resin through the incorporation of cardanol, a natural phenolic compound.
Polymerization of double bonds of oil with branched chains of PF resin from CNSL.
3.1.2 Curing reaction of novolac PF resin with Hexamethylenetetramine (HMTA)
Hexamethylenetetramine (HMTA) serves as the primary curing agent for novolac resins, initiating a curing process that involves various intermediates, primarily substituted benzoxazines and benzylamine The initial interaction of these intermediates with the phenolic ring dictates the resulting product, leading to the formation of methylene linkages between phenolic rings Typically, HMTA methylene groups bond at ortho or para positions, creating a crosslinked network During this crosslinking, additional molecules such as amides, imides, and imines may form, accompanied by the release of ammonia from the resin As the curing progresses, the resin transitions from a low melting thermoplastic solid to a low viscosity liquid, followed by gelation and ultimately becoming a rigid solid This process involves the formation and branching of linear chains, culminating in a three-dimensional network that results in a final product that is both insoluble and thermally non-re-moldable.
Table 3.1: Effect of temperature on the curing process of wood-plastic composite from CSNL PF adhesives [11]
From the data in the preceding table, we chose the appropriate temperature for the pressing process of the HDF board to be 140 o C.
Figure 3.1 Cure reactions sequence of phenol - formaldehyde novolac resins with HMTA [12].
Phenolic resin (PF) is a versatile material utilized across various industries, primarily in the production of circuit boards, including printed circuit boards (PCBs) Its applications extend to electrical equipment, where it is essential for manufacturing components such as caps, handles, buttons, radio cabinets, furniture, knobs, vacuum cleaners, cameras, ashtrays, and engine ignitions Additionally, PF is integral to laminated materials, including sheets, rods, and tubes, which can be made from diverse substrates like fabric, paper, and wood veneers, all impregnated with phenolic resins to achieve a wide range of properties.
Phenol-formaldehyde resin is a versatile adhesive used for bonding materials like wood, metal, plastic, ceramics, and glass Known for its high joint strength and resistance to moisture and bacteria, PF glue does have the drawback of creating a brittle film Currently, phenolic glue is often combined with other polymers, including urea-formaldehyde, epoxy, polyvinyl acetate, rubber, and nylon, to enhance its performance.
Phenol formaldehyde resin is a synthetic resin used to produce paint [13,14].
3.1.4 Synthetic process of phenol formaldehyde (novolac) from CNSL a Raw materials and chemicals
Table 3.2: Raw materials and chemicals for synthesizing CNSL PF (novolac) adhesives
Raw materials and chemicals PHR
Antistalling agent, additives 3 b.Synthesizing apparatus [15]
The equipment used in the production of CNSL PF adhesives (novolac) includes:
The reactor, a cylindrical device with elliptical lips and bottom, is primarily heated using Castrol HT5 oil and cooled with water, ensuring optimal temperature control for efficient operation.
- Agitator: The reactor is installed with a frame agitator attached to the axis connected to the actuator.
-Condenser: A lot of steam is released because of the reaction process, so a condenser is mounted on the top of the spotlit to condense the escaping steam.
The synthesis reaction of novolac phenolic resin generates significant heat, necessitating an effective cooling water tank system Positioned at an elevated level, this device features a control unit that regulates the water flow into the reactor, ensuring optimal temperature management during the synthetic process.
Polymerization of PF resins can occur in either acidic or alkaline conditions, but to minimize production costs, we avoid using acid or alkaline catalysts due to the high anacardic acid content (up to 82%) in CNSL In acidic environments, the resin synthesis reaction results in the formation of the novolac type.
During the condensation process of PF resin synthesis, water is generated, which can impact subsequent production phases, necessitating its removal This process is divided into two periods: the first period maintains a temperature of approximately 90°C for about three hours, allowing the exothermic reaction to raise the temperature significantly before temporarily halting the heating Once the temperature decreases, the second period commences, where the temperature is increased to 150-160°C to expel water and volatile components from the resin This elevated temperature also facilitates the conversion of some resin into novolac form, as the methylol groups become more reactive, leading to the formation of methylene bonds between phenol nuclei After cooling, the novolac PF resin is mixed with Hexamethylenetetramine curing agent in a specified ratio.
Timber and wood pulp
Cellulose, hemicellulose, lignin, pectin, and waxy substances make up the chemical composition of wood In the molecules of the above elements, there are -
OH groups, so wood is well compatible with polar polymers Wood pulp can be recovered from the processing of wood products Wood pulp is eco-friendly, cheap,
Humidity significantly affects wood properties, with the ideal equilibrium moisture content for wood indoors ranging from 8-12% and approximately 15-18% in outdoor environments The amount of moisture wood absorbs is influenced by the air's relative humidity and temperature.
Density: The average density of wood is about 0.5-1.1 g/cm 3
Shrinkage: The shrinkage of natural wood is usually between 9 and 15%, Natural shrinkage makes the wood easy to crack.
Wood can absorb water from the cell wall, increasing its size, and this can be called ‘swelling’.
The anisotropic structure of wood results in varying mechanical properties across different directions Key factors influencing these properties include the wood's dimensional weight, the ratio of earlywood to latewood layers, humidity levels, and the presence of defects.
3.3.3 Wood and wood pulp for production
Both wood and wood pulp are used as the main raw materials in the plant.
The plant utilizes high-quality EURO STACK wood pulp, sourced from hardwoods with a dark brown hue and a moisture content of less than 5% Primarily, acacia and rubber wood are employed, both of which are abundantly cultivated in the Central Highlands and Southeast regions, ensuring a low-cost and reliable supply Notable suppliers of these wood types include Cuu Long Group, Phu Gia Wood, and Vietnam Wood.
Additives
Paraffin, a term used for a group of hydrocarbon alkanes with the general formula CnH2n+2 (where n is greater than 20), primarily refers to straight-chain alkanes It exists in various forms, including paraffin gel, paraffin wax, and paraffin oil In the manufacturing of HDF boards, paraffin wax plays a crucial role by softening wood chips and preventing them from swelling.
AO168 is a white solid powder with a melting point of 185 °C, composed of Tris(2,4-di-tert-butylphenyl)phosphate and having a molecular weight of 646.9 g/mol As a phosphite ester antioxidant and machining stabilizer, AO168 effectively maintains product color stability and enhances the physicomechanical properties of materials subjected to high-temperature machining.
Figure 3.2:Antioxidant AO168 (Source: Shengzhou Worthside Chemical
UV paint harnesses the power of ultraviolet rays to activate the initiator, generating free radicals that facilitate the curing process This results in a durable, high-hardness, and scratch-resistant paint film with exceptional aesthetic appeal Additionally, UV paint cures rapidly and is environmentally friendly, making it a safer choice for various applications.
Components of the UV paint system:
- Polymer: Using oligomers, with unsaturated functional groups, including many types such as polyester, epoxy, urethane, etc.
- Diluent: monomer with an unsaturated functional group (acrylate).
- Curing agent: UV curing agent
- Curing time: immediately after UV drying.
Figure 3.3: UV coated wooden floor (Source: Mega Export Vietnam).
MATERIAL FORMULATION AND TECHNOLOGY PROCESS 33 4.1 Material formulation
Technology process description
The plant utilizes advanced hot pressing technology to manufacture high-density fiberboard (HDF) This process involves applying heat and pressure, which facilitates moisture evaporation, increases density, and cures the adhesive As a result, the components of the raw materials undergo significant physical and chemical transformations, leading to a strong bond between the fibers and ensuring the production of high-quality HDF boards.
Besides using wood pulp, the plant also uses acacia wood, rubber wood, wood scraps, etc., to diversify and reduce the cost of input materials.
Debarker: The wood is put through the debarker, and the bark is removed from the wood.
Chipper: The wood is chopped into chips after going through the chipper.
Screen: small particles and large particles are removed from the chips during the screening Only the appropriate-sized chips are fed into the process.
Chip washer: The chips are washed to remove dirt and metal.
In the defibrator process, clean chips are moved to the fiber separation section, where they are cooked at temperatures ranging from 160 to 180 °C under 6-8 bar pressure for 3-5 minutes to enhance softness To improve swelling resistance, approximately 1-2% paraffin wax is incorporated into the softened chips.
The optimal ratio of CNSL PF adhesives (novolac) to wood pulp is 3:7, with the wood pulp being dried to achieve a moisture content below 0.1 wt% Any wood pulp that does not meet quality standards will either be reprocessed or utilized as fuel.
Blowing: In this process, resin, wax, and other additives are blended with the
Fiber drying takes place in a hot air dryer, which effectively removes moisture from the fibers The hot air stream facilitates evaporation, ensuring that the final humidity levels are maintained between 10% and 13%.
Mat forming involves the uniform distribution of dry, selected fibers into a feeder bin, facilitated by a pendulum fiber distribution system This process ensures that the fibers are evenly spread out, resulting in the formation of a cohesive mat fiber.
Pre-compression involves the use of a compressor to shape the mat fiber, effectively reducing its thickness and moisture content This process ensures that the mat is nearly the ideal size for further processing.
Hot pressing: Presser operates at about 140 o C in a sufficient time to cure the resin and at the pressure to consolidate the mat to the desired density.
The HDF board undergoes a cooling process for 40 minutes, followed by a 48-hour resting period to stabilize its physical and mechanical properties After cooling, the boards are carefully inspected to eliminate any warped or unsatisfactory products.
Sanding: Panels are sanded on both major surfaces to achieve the required thickness and smoothness.
Sawing: The panels are cut to commercial specifications with a circular saw to remove defects and edges.
The panels undergo UV coating in a specialized machine to enhance their appearance and provide a protective layer Once coated, the finished products are sorted, packaged, and stored for distribution.
MATERIAL BALANCE
Introduce
Material balance is essential for calculating the quantities of wood pulp, CNSL PF adhesives, and various additives needed for production within a specified timeframe This assessment serves as a crucial foundation for selecting appropriate equipment and determining other necessary resources, such as electricity and water, for the manufacturing process.
Original material = Output product + Material loss
The total amount of original material is the total amount of resin, wood pulp, and other additives initially added.
The total amount of output products is the total volume of products in accordance with quality and requirements.
Loss is the total amount of material lost through the manufacturing process, mainly plastic and water.
To determine the mass of the original material, we begin by calculating the mass of the final product and the production capacity of the plant Next, we account for any mass lost during the production process By combining these calculations, we can accurately ascertain the necessary quality of the original material.
Calculations
Nvl: The number of working days in a calender year
N: The number of days in a year
N2: The number of holidays in a year
N3: The number of days off in a year for machine maintenance and repair
Table 5.1: Annual working times statistics
Number of days in a year Day 365
Number of weekly days off Day 52
Number of days off for maintenance of machinery
Number of working days Day 289
Number of working shifts in a day Shift 3
Number of working hours in a day Hour 24
Number of working hours in a year Hour 6936
Table 5.2: The number of HDF panels manufactured in a shift, a day and a year Model Weight
Table 5.3: Material weight for the core of HDF panels
Model Material weight in a Material weight in Material weight in a year (ton) a day (ton) shift (ton)
Table 5.4: UV coating weight required for 1 HDF panel
Model Painted area (m 2 ) UV coating weight (g) with 70g/m 2
Table 5.5: UV coating weight required for a shift, a day and a year
Model UV coating weight for a shift (kg)
UV coating weight for a day(kg)
UV coating weight for a year(kg)
Total weight of UV paint in a year: 166743 tons/year
5.2.3 Original material weight a Calculation of loss
In the production process, the drying loss is represented as a(%), while b(%) accounts for losses incurred during trimming and the handling of defective products These defective items are subsequently processed through crushing, recycling, and are mixed back into the original mixture It is important to note that the recycling process contributes to 10% of the total scrap generated.
Table 5.6: Percentage of loss in the manufacturing process
Actual factory productivity = Theoretical productivity x Ki tons
Table 5.7: Material composition norm for the core
Rate of weight/shift (ton)
Rate of weight/day (ton)
Rate of weight/year (ton)
MACHINERY AND EQUIPMENT SELECTION
Main manufacturing line
There are many technologies to produce WPC, but based on product quality requirements and the nature of input materials, we chose to manufacture HDF boards using heat processing technology.
Table 6.1: Some of the major production lines
Origin Shandong- China Jiangsu - China Shandong - China
The required capacity is, theoretically, 159m 3 /day However, to ensure the machine’s service life, we choose the efficiency of the machine at 80%, so the actual capacity is 198m 3 /day.
Based on productivity and price, we should choose 1 Sufoma line or 2 Yuequn lines.
Choosing the Sufoma line is advantageous due to its lower energy consumption compared to the two Yuequn lines, which results in significant energy savings and helps reduce production costs.
The structure of the line includes the following equipment:
- The preparation of wood chips includes the following equipment: detarker,chipper and water tank.
- Cooler, sewer, and sander: The board is passed through a conveyor to cool, followed by sawing and sanding equipment.
- Adopts reliable, steady running defibrator made under latest tech, which can control the fiber quality and met the productive capacity requirement, greatly reducing the consumption of electricity and heat.
The pre-press utilizes a met belt system with independently driven upper and lower belts, effectively eliminating issues related to speed discrepancies between the belts and preventing wind discharge problems that could compromise mat quality.
- Mat conveying line is composed of a flexible belt conveyor and saw acceleration belt conveyor, less the mat distort during accelerating and departing.
- Hot pressing adopts the technical process curve of all position control, to ensure the board section structure density and stable quality.
The electric control system utilizes a state-of-the-art PLC control system featuring on-site communication BUS control, enabling customers to set technical process data and monitor machine operations online.
Figure 6.1: Hot press machine (Source: Sufoma machinery Co.,Ltd).
Auxiliary equipment
To select the right automatic coating equipment for HDF boards, it is essential to consider the size of the boards Once the HDF boards undergo surface treatment, they are transported via conveyor into the spray chamber of the coating machine, where UV paint is applied to their surfaces.
Table 6.2: Specifications of the coating machine
Origin Vetta company Vetta company ShangHai Chanho
Machinery Co.ltd Working width
Based on power and working width, the TS-W4T-T model is the best choice.
To ensure the service life of the machine, we chose the machine efficiency to be 80% Therefore, the actual feeding speed: 15×80% (m/min)
The total length of the product to be coated in a day:
L=One product’s length ×The number of panels produced in a day
The time it takes to paint one side of the product: (min)
The total time it takes to paint both sides of the product : 11.74×2#.47 (Hour)
So the plant will be equipped with a coating machine TS-W4T-T to paint HDF boards The coating process will be done in all three shifts.
Figure 6.2: UV coating machine (Source: Vetta company).
Ninety percent of waste products are recycled, resulting in a mere 1% total loss from waste Consequently, only 0.9% of the total plant capacity is represented by recycled material reintegrated into the process.
Weight of recycled material: 0.9%×57273.6Q5.46 (tons)
The amount of scrap to be crushed per day: 1.79 tons
The scrap is only crushed in shift 1 The amount of scrap to be crushed per hour: 223.75 kg.
Table 6.3: Specifications of the crusher
XC-GP500 PC-400 KF-PP500
All 3 machines have the same capacity and power Because the PC-400 crusher of Tongsheng is the most cost-effective option, the plant will be outfitted with one.
Figure 6.3: Crusher (Source: Ningbo Tongsheng Machinery Manufacturing
There are two types of weight scales: large weight scales and small weight scales.
- Large weight scale: used to weigh PF glue, wood pulp, additives in large weights. -Small weight scale: used to weigh additives with a small weight, requiring high accuracy.
Table 6.4: Floor scale and counter scale specifications
Model Lila FW floor scale BSC-N counter scale
Manufacturer Lilascale (China) UTE-TaiWan
Power AC220v AC-DC220v and built-in battery
Platform dimension 80cm x 80cm 300mm×400mm
The weight scale is auxiliary equipment that is only used for a short time so that the plant will be equipped with 2 Lila FW floor scales and 2 BSC-N counter scales.
Figure 6.4: Floor scale and counter scale (Source: cancongnghiep).
Table 6.5: Fork lift truck specifications
A forklift truck is a compact industrial vehicle equipped with a powered forked platform that can be raised and lowered, significantly enhancing efficiency in factories By replacing manual labor for transporting heavy goods and materials, forklift trucks simplify operations, save time, and boost productivity For optimal performance, a factory typically requires five forklift trucks.
Figure 6.5: Komatsu forklift truck FD25T-17 (Source: Samcovina).
The hand pallet lift plays a crucial role in efficiently moving, loading, and unloading goods, thanks to its hydraulic pump system operated by a single person This equipment significantly reduces the physical effort needed for transporting goods, making logistics more manageable For optimal performance, a total of four hand pallet lifts are recommended.
Table 6.6: Hand pallet lift specifications
Width over the fork 540mm
Figure 6.6: Ichimens XT hand pallet lift (Source: Toan phat gia trading production company limited ).
Table 6.7: A summary of equipment and lines used in production
No Name Number Dimension Working hour/day
PLANT LAYOUT
Principles of designing plant premise
When selecting a location for a production plant and designing the plant layout, it's essential to evaluate several key factors, including the floor area, product characteristics, production equipment features, raw material and product volume, and production speed, among others.
To ensure efficient production, departments must be organized in alignment with the production process The initial production area should be strategically placed close to the raw material warehouse, while the final department should be near the finished product warehouse This orderly arrangement allows the product to seamlessly transition through each stage of production.
When selecting the location and layout of a manufacturing facility, it is crucial to consider the potential for future production expansion This foresight allows for the development of operations in response to increased profitability, ensuring that the plant can adapt and grow as demand rises.
Ensuring guaranteed safety in production is essential, encompassing worker safety, equipment protection, product quality, and an optimal working environment Compliance with regulations on fire protection, explosion prevention, dust control, and heat management is crucial Additionally, maximizing air circulation and natural lighting enhances workplace safety It is vital to keep flammable materials away from production areas, and the installation of safety devices for electrical and fire protection is mandatory.
- Make good use of ground and space: For construction works, it is necessary to make full use of the available floor area.
- Ensure the system can operate flexibly: The layout must take into account making changes with the least cost and avoid affecting the order of the production process.
-Avoid or minimize the opposite direction transportation [18].
7.1.2 Principles of the arrangement of production equipment
The arrangement of production equipment is a crucial phase in plant design, requiring a blend of practical experience, theoretical understanding, and creativity Key principles include organizing all machines in a linear fashion to minimize transportation distance and time, utilizing horizontal or vertical layouts to optimize space, and clustering machines with similar functions for efficiency.
- All devices must have a grounding system to prevent electrical build-up on the device.
To ensure a safe and efficient working environment, machines that produce excessive heat, dust, and toxic substances should be equipped with separating walls or adequate ventilation systems It is essential to maintain a reasonable distance between machines and to establish both vertical and horizontal aisles, as well as aisles adjacent to walls This layout facilitates smooth operations for workers, minimizes the risk of accidents, and simplifies machine maintenance.
To ensure safety and efficiency in machine placement, maintain a minimum distance of 1.8 meters between two machines, with a recommended safe distance of 3 to 4 meters Additionally, ensure that the empty space between rows of machines exceeds 1.8 meters Production lines should be positioned at least 1.6 meters away from walls, and the first machine in each line must be situated 2 to 3 meters from the wall.
The principles outlined serve as general guidelines for machine arrangement within a plant However, the specific positioning of each device may vary based on the production process, plant layout, and actual construction conditions.
Plant location
Loc Son Industrial Park, situated in Loc Son Ward, Bao Loc City, Lam Dong province, boasts excellent infrastructure and convenient transportation access, along with proximity to raw material sources Covering an area of 185 hectares with an occupancy rate of 0.8, the park features a modern design that includes a spacious internal traffic system, extensive green spaces, and water supply and drainage systems that meet international standards.
Loc Son Industrial Park is strategically located just 3 kilometers southeast of Bao Loc City center, with easy access to major transportation routes To the north, it connects to National Highway 20, linking Ho Chi Minh City and Da Lat City, while National Highway 55 to the west provides a route to Phan Thiet City The industrial park is conveniently situated 110 kilometers from Ho Chi Minh City, 70 kilometers from Lien Khuong Airport in Da Lat, and 170 kilometers from Phan Thiet Seaport in Binh Thuan.
Land conditions: Hard soil: 1.5-25 kg/cm 3
Power supply: The power supply to the industrial park is taken from the 110/35/22 kV substation A high voltage electricity network is provided along the internal roads in the industrial park.
Water supply: Clean water is supplied with a capacity of 30000m 3 /day from the clean water plant.
Effluent from the industrial park is directed to a wastewater treatment plant with a daily capacity of 6,000 m³, ensuring proper treatment before release Additionally, waste generated by the plants is transported out of the industrial zone to prevent environmental contamination Exhaust gases are filtered through a state-of-the-art filtration system, adhering to national standards, prior to being released into the natural environment.
Communication: The industrial park is equipped with an underground communication cable system that extends to the fence of the plant
The industrial park features a comprehensive fire fighting and prevention system that adheres to national standards, ensuring safety for all facilities Strategically placed fire hydrants are available at key traffic hubs and throughout each plant, enhancing emergency response capabilities.
- Land rental fee: 20-30 USD/m 2 , land rental period: 50 years
- Industrial park management fee: 0.2 USD/m 2 /year
- Cost of wastewater treatment: 0.22 USD/m
Figure 7.1: Planning of Loc Son industrial park (Source: Bao Lam Dong ).
Plant floor calculation
We chose the area of the raw material warehouse to ensure the supply of raw materials in ten days.
- Area occupied by powdered and granular materials:
Granular and powdered materials are packaged in 25 kg bags, measuring 650x400x200mm To prevent moisture absorption, it is essential to store these bags on pallets.
The area occupied by each stack:0.65 × 0.4 = 0.26m 2
We put on each ballet 6 bags of each layer, arranged into 10 layers.
PF adhesives and UV paint materials are stored in barrels with a weight of 240kg/1barrel of PF adhesive and 200kg/1barrel of UV paint.
The size of the barrel containing PF and UV paint has the following dimensions:H0mm, DX0mm
The area occupied by the barrel is: S=� ×R =0.3m
Table 7.1: Total amount of ingredients needed for 10 days
No Component Material weight (ton)
Our facility has a total occupied area of 2,141.2 m², and to ensure efficient movement and accommodate forklifts for material transportation, it is essential to maintain an empty space that is 50% of the occupied area.
We chose the area for the raw material warehouse to be 3300 m 2
7.3.2 Manufacturing workshop a The main production line
The production line manufacturer specifies a required workshop area of 5,000 m², which accommodates essential spacing such as aisle widths, clearances between machines and walls, and operational space for workers Additionally, a designated UV coating zone is included within this area.
The area occupied by the UV coating machine: 1.82×2.285=4.16 m 3
To facilitate comfortable movement and efficient workflow in the production area, it is essential to maintain specific distances around HDF panels and machinery The required spacing includes a 3-meter distance from the coating machine to the main production line, an additional 3 meters of empty space behind the coating machine, a 3-meter gap to the wall, and a 4-meter width for the main aisle.
We chose the area for coating zone to be 75m 3 c KCS area
In the product quality inspection zone, items that have undergone UV coating are meticulously classified and inspected to guarantee their quality Once verified, standard products are securely wrapped in protective film before being moved to the finished product warehouse.
The area required for the KCS zone: 65m 2 d Defective product crushing zone
The occupied area of the crushing machine: 1.1×0.86=0.946m 2
In the crushing zone, it is essential to maintain adequate space for workers to operate and move safely, ensuring a sufficient distance between the walls and machinery Therefore, we have designated a crushing zone with an area of 70 square meters.
We have the total area of production workshop: 5000 +75+65+70R10 m 2
The finished product warehouse is designed to hold products for 10 days We stack 100 products on top of each other into 1 stack.
Table 7.2: Area occupied by finished products for 10 days
Model Dimension (mm) Quantity Number of stacks Area (m 2 )
To ensure safe and convenient forklift movement during product transportation, it is essential to maintain adequate distances from walls and provide sufficient free space The selected area for the finished product warehouse measures 2000 square meters.
The office zone features several dedicated spaces, including a leadership room, planning room, technical room, living room, and finance room Strategically positioned at the front of the plant, this office block is distinct from the production factory, ensuring a focused work environment.
Table 7.3: Area of the rooms in the office block
So we chose the office block area: 175 m 2
The auxiliary zone features essential construction items, including a mechanical workshop for the maintenance and repair of plant machinery Additionally, this area encompasses a medical room, canteen, security rooms, parking lot, substation, pumping station, and cooling tower, all contributing to the operational efficiency and safety of the facility.
Table 7.4: Area of auxiliary construction items
No Name of construction item Dimension Area(m 2 )
2 Pumping station and cooling tower
7.3.6 Traffic system and green area in the plant
In addition to the necessary structures, a plant requires designated areas for internal traffic systems and green spaces The internal traffic system is essential for the efficient movement and transportation of goods and materials within the facility Meanwhile, green spaces play a crucial role in controlling pollution and regulating temperature and humidity levels Following construction density regulations, we have allocated 40% of the total plant area for green space, internal roads, and future expansion.
The total ground area for the structures in the plant:
Based on the arrangement of structures in the drawing along with the area for green space and roads We chose to build the plant in an area of 18000m 2
Factory structure
The selected factory structure is a single-story industrial building Based on the current standard (TCVN5547-2012, TCVN4453-1995), some selected features of the factory structure is as follows:
- The height from the floor to the bottom of the roof structure: 7.2m
- The roof of the factory is a corrugated iron roof with a slope of 15%
- The door used is a sliding door with a size of 6m
- Windows are aluminum alloy windows and shutters to ventilate the factory
- Column and beam: Welded or hot rolled H-section steel structural fabrication
Calculation of lighting for the plant
Natural illumination is the technique that efficiently brings natural light into the building using exterior glazing (windows, skylights, etc.), thereby reducing artificial lighting requirements and saving energy.
Natural light offers numerous health benefits, but it also comes with drawbacks, including its inconsistency and reliance on weather conditions To maximize the advantages of natural light, it is essential to implement effective strategies.
Use suitable materials, such as materials that can reflect light or materials that can refract light.
To optimize the flow of light and air, it is essential to arrange structures and devices thoughtfully The design of style, layout, and the number of entry points, including the main door, windows, and roof monitors, should be executed with careful consideration for functionality and aesthetics.
Based on natural lighting standards TCXD 29:1991 The door area calculated as a percentage of the workshop must ensure the natural lighting coefficient as prescribed. a.Calculation of required roof monitor area
K: Reserve factor, check table 1 TCXD 29:1991, we choose K=1
ETc: Standard natural light illuminance value (%)
With the size of the object to be distinguished over 0.5mm, according to natural lighting standards, we choose level b, Etc=2.5
: Light transmission coefficient of the door is determined according to table 14 of TCXD29:1991, We choose =6.9.
: Total light penetration coefficient of the window is determined according to the following formula (TCXD 29:1991).
Where: τ1: Light penetration coefficient of the material, We choose τ1=0.9 (Table 6, TCXD29:1991).
� 2 : Light penetration coefficient taking into account the influence of the door frame,
In accordance with TCXD 29:1991, we select a light penetration coefficient of τ2=0.9 (Table 7) and τ3=1 for side illumination (Table 8), considering the impact of load-bearing structures Additionally, τ4 accounts for the influence of shading structures as outlined in Table 9 of the same standard.
� 5 : Light penetration coefficient taking into account the influence of the protective net placed under the roof monitor, we choose τ5=0.9.
The coefficient K cm for the roof monitor is determined based on table 13 of TCXD29:1991, with a value of K cm = 1.2 for a design featuring two sides with rectangular vertical glazing Additionally, the light gain coefficient due to reflection within the room, r2, is established from table 12 of TCXD29:1991, yielding r2 = 2.5, with the distance from the roof monitor to the conventional working surface measured at H cm = 6m.
From the above data, we can calculate the required roof monitor area:
Table 7.5: The required roof monitor area
No Construction name Ss(m 2 ) Scm(m 2 )
Total 10510 982.6 b.Required door and window area (Scb)
Table 7.6 : Parameters to calculate Scb
Table 7.7: Required door and window area
No Construction name Ss(m 2 ) Scb(m 2 )
The area of the roof monitor, Scm2.6 m 2 , and the area of the doors and windows, Scb8.65 m 2 will ensure natural lighting (TCXD 29:1991).
Electric lighting systems are widely utilized in factories due to their user-friendly nature, affordability, and high lighting efficiency These systems are also easy to repair, making them a practical choice for industrial settings To ensure optimal artificial lighting in factories, the calculation follows the Vietnam construction standards (TCXD 3743-1983).
Artificial lighting for the purpose of increasing the brightness of the factory, where workers can easily work, work with higher productivity, more accurately, and reduce the rate of waste.
Selecting the right type of lighting is crucial for different areas within a factory Common lighting solutions include fluorescent lights, which are typically utilized in offices and auxiliary spaces, while high-pressure lamps are preferred for illuminating production zones.
LED technology encompasses a variety of lighting options, including LED headlights, LED high-bay lights, and solar lights, frequently utilized in industrial settings To determine the appropriate number of bulbs required, we assess the wattage of the bulbs and the power needed for effective illumination per unit area.
Formula for standard power required per unit area:
Z Ratio between average illuminance and minimum illuminance, Z=1 - 1.2 γ:Luminous efficacy of the lamp, Lm/W
Useful illuminance factor of the lamp,
The standard minimum illuminance (E) varies based on the type of work environment As outlined in TCXDVN 3743 - 1983, areas such as offices, production zones, and main gates require an illuminance level of E0 lux, while material warehouses and finished product storage areas may have different lighting standards.
Formula to calculate the number of bulbs needed:
P=Scs x Ptc Lighting power required (W)
Scs: Area to be illuminated (m 2 )
Ptc: Standard capacity per unit area (W/m 2 )
Ptcd: Standard wattage of lamp (W)
Table 7.8: Number of lights needed
P (W) Ptcd Number of bulbs Production workshop
ENERGY CALCULATION
Calculation of electricity
The electrical energy supply to the plant is from the Dai Binh 22kV substation. Besides, to ensure safety of production, it is necessary to equip the backup generator.
Electric power is calculated according to the formula: Pc=Kcx Pđ
The Coefficient of Non-Uniformity of Usage (Kc) varies based on the specific purpose of electricity consumption in different areas For production zones, we assign a Kc value of 0.9, while for other areas, a Kc value of 0.8 is utilized.
Pđ: Lighting power for areas
Total electricity capacity in a year: ΣAcs=Pcx tn tn: Number of hours of electricity use in a year (Hour/year)
Area Pđ(W) Kc Pc(W) tn ΣAcs(Kw)
The total lighting power in a year: 116105.18 Kw.
Table 8.2: Electric power needed for machines
The total electric power for machines in a year: 17805710.784 Kw.
Total electric power consumption in a year: 17921815.964 Kw.
The power factor, represented as cosφ, indicates the ratio of useful power to apparent power, reflecting the amount of wasted power A higher power factor signifies that equipment efficiently generates useful power, while a lower power factor leads to increased power loss in the grid, reducing transmission capacity and negatively impacting equipment performance.
Therefore, the compensator must be coupled in parallel with the load to improve the power factor.
Compensating capacity: Qb=Ptb(tanφ1- tanφ2)
In a factory operating for 6936 hours per year, the actual power factor (cosφ1) is determined to be 0.7, resulting in a tanφ1 value of 1.020 In contrast, the optimal power factor (cosφ2) is set at 0.9, leading to a tanφ2 value of 0.48.
Based on the calculated power factor, a compensator with parameters:
The number of capacitors required: 1395.3 30 b 50
Qc: Compensating capacity of capacitors:
Q c N q ΔPx: Power loss on capacitors, ΔPx=0.4%× 1500 = 6
With tanφ, we find out: cosφ=0.915
The apparent power of the transformer:
To ensure optimal performance, we selected the transformer's working capacity to be 70% of its rated capacity The rated capacity of the transformer serves as a benchmark for this decision.
Based on Sdm, we choose 4 transformers 500kVA
Figure 8.1: 500 kVA transformer (Source: Sieuthidienmaycongnghiep).
To ensure uninterrupted operation of the plant during sudden power failures, it is essential to equip it with a backup generator The generator must have sufficient capacity to meet the electricity demands of the plant, with an efficiency rating set at H%.
The required power of generator:
We choose 4 generators with a capacity of 800kW.
Figure 8.2: Cummins 800kW generator (Source: Thien Hoa An).
Calculation of water supply
Water supply is crucial in a factory setting, serving essential functions such as cooling production lines and devices, ensuring sanitation, watering plants, and supporting fire fighting and prevention efforts The water used in the factory is sourced from the industrial park.
8.2.1 Water used for life activity purposes
Computing the amount of water needed for workers, technical staff, electromechanical staff, and forklift drivers:
N1: Number of workers working in a shift, N1I n1: Number of shifts in a day, n1=3 q: National standard of water supply for each person, We choose q%L/person/shift for workers.
The amount of water required for production workers in a day:
Calculating the amount of water needed for office workers:
To calculate the daily water requirement for office workers, we consider the number of workers (N2) and the number of shifts (n2), which is set to one We also establish a standard water supply (q2) measured in liters per person per shift By multiplying the number of office workers by the standard water supply per shift, we can determine the total amount of water needed for the workforce throughout the day.
Calculating the amount of water needed for other employees:
To calculate the daily water requirement for employees, first determine the number of employees working in a shift (N3) and the number of shifts in a day (n3), which is set at 3 Next, establish the standard water supply per person (q3), measured in liters per person per shift By multiplying the number of employees (N3) by the number of shifts (n3) and the standard water supply (q3), you can accurately assess the total amount of water needed for all employees throughout the day.
The total amount of water for life activity purposes: V=9.19+0.58+1.35.12 (m 3 /day).
The total amount of water for life activity purposes in a year: 11.12×289213.68 (m 3 ).
8.2.2 The amount of water used for production
The main production line needs some water for cooling This water is recirculated and discharged only when heavily contaminated According to the manufacturer’s catalog, the water consumption is 6 m 3 /hour.
Because this amount of water after passing through the cooling tower will be recirculated about 95% The total amount of water for the main production line in a day:
After 3 months, the amount of water used for cooling will be changed once, the total amount of water needed for the production purpose in a year:
8.2.3 Amount of water use for fire fighting and protection
The factory needs to ensure a continuous supply of water for each hydrant with
3 hours The water flow must be more than 2.5L/sec The factory is arranged with 6 fire fighting hydrants with a flow rate of 5L/sec per hydrant.
Amount of water needed for fire fighting and protection purpose:
8.2.4 Amount of water used for irrigation and sanitation
The green area of the plant comprises approximately 12% of the total area, requiring 3.6 liters of water per square meter per day during drought conditions With an average of 175 sunny days annually in Bao Loc, the estimated water requirement for irrigation totals around 130 cubic meters Additionally, a separate water supply of 120 cubic meters per year is necessary for sanitation purposes.
The total amount of water needed in a year (excluding water for fire protection purpose):
8.2.5 Water supply and storage apparatus
A water tank is essential for maintaining a consistent water supply for a plant, as it stores the necessary water to meet daily consumption needs It is crucial for the tank's capacity to accommodate not only the daily water usage but also an additional backup supply sufficient for two days.
To meet the required water tank volume, we selected two 20m³ water tanks Additionally, we will install a 400m³ stainless steel water tank specifically for fire fighting and protection purposes.
Figure 8.3 20000 L water tank (Source: bondaithanh).
The amount of water to be pumped in an hour is about 6.63 m 3 Based on this amount of water, we choose a water pump for the plant.
Table 8.3: Specifications of water pump
Figure 8.4: CHT310 water pump (Source: Pentaxitaly).
To determine the diesel fuel consumption for forklift operation, we calculate that the forklift uses approximately 2.7 liters of diesel fuel per hour With a total of 27,744 operating hours in a year, the annual diesel fuel requirement for the forklift can be accurately assessed.
HUMAN RESOURCES AND ECONOMIC ANALYSIS
Company organization structure
A company's organizational structure consists of various departments and individuals that work interdependently, each with specific responsibilities and authorities This structure is hierarchically arranged to facilitate the achievement of the organization's common goals A flexible organizational framework and adaptable management are essential for the effective functioning of the company.
Figure 9.1: Organization chart of the company.
Responsibilities, roles and authority of positions in the company
The director is a senior executive within the company's organizational structure, tasked with overseeing and directing all activities and personnel This role encompasses the authority to hire and terminate employees, as well as the responsibility of representing the company in signing contracts related to its operations.
The vice director is a key leadership figure within the company's organizational structure, responsible for supporting the director and stepping in during their absence This role involves executing tasks delegated by the director and overseeing various company activities as assigned.
The sales department is responsible for market research and setting sales goals and plans Implement customer care activities, marketing campaigns to promote sales, retain customers, and find new customers.
The accounting department plays a crucial role in overseeing and reporting the company’s revenues and expenses while managing its assets and liabilities It is tasked with analyzing the financial position of the organization and ensuring compliance with legal standards by providing accurate accounting information and data.
The production department plays a crucial role in developing production plans and reporting to management It oversees the entire production process, addresses any issues that arise, and maintains the quality of both input materials and finished products Additionally, the department is responsible for managing and ensuring the safety of workers within the production area.
The administrative department oversees employee-related matters, including timekeeping, salaries, and bonuses It is also responsible for managing administrative procedures and addressing issues related to employee insurance and welfare within the company.
Economic analysis
Fixed capital encompasses assets and capital investments, including expenses related to machinery, equipment, land rental, and construction These investments are classified as fixed because they are not depleted during the production process.
The total area of land to be rented: S000m 2
The cost of renting land in Loc Son industrial park is 25USD/m 2 /year, the current exchange rate is: 1USD"955 VND
The total cost of renting land in 1 year: b Factory construction costs
No The name of construction
We chose to amortize the plant construction cost over 20 years, the depreciation cost per year:
CXD/year=Total construction cost/20128.5/206.425 (million VND) c Investment cost of machinery and device
Table 9.3: Investment cost of machinery and equipment
No Name Quantity Price (million
The total cost of a machine or device includes an additional 15% for transportation, installation, maintenance, and cleaning.
No Name Quantity Price(Million
We have the total fixed capital:
CCD=CĐ+ CXD+ CTB1+ CTB2 329.75 + 19138.5 + 16635.84 + 2554
The total depreciation expense: CKHTB+ CKHXD= 1918.98 + 956.925(75.9 (milion VND)
Raw material Weigh/year (ton) Price (million
Cost of buying raw materials for 10 days:
The formula for computing salaries for company employees is:
Basic salary = (Base salary×Coefficients salary)
The base salary in 2021 as stipulated in decree 38/2019/NĐ-CP is 1.49 million VND/month.
The coefficient salary depends on the position of the employee Each position has a different coefficient salary.
The salary for the employee is equal to the basic salary plus allowances In which, allowances are insurance costs and environmental allowances for employees.
Table 9.6: Salary cost for company employees
Quantity Total salary(million VND)
The total cost of the employee’s salary for a year:
The cost of the lunar new year bonus for our workers is equal to one month’s salary We have a total bonus spending of: 1500.659 million VND.
The cost of social insurance, health insurance and accident insurance is equal to 21.5% of the total basis salary of employees for a year:
The total cost for company personal per year:
Cost of reserve salary for employees for 1 month:
The average price of electricity for industrial production: 1500 VND/kWh. The water price provided by the industrial park: 9000 VND/m 3
Table 9.7: Energy cost for a year
Consumption Price (VND) Cost (million
The energy cost for 1 month: CE= 2336.585 (Million VND)
Other costs include food support costs, waste water and trash treatment costs, costs for advertising and marketing products.
Estimated cost of food support for employees is 25000/1 person The total cost of food support in a year: 25000×185×28936.63 (Million VND)
The remaining cost are estimated to be: 1036.1 million VND/year
The other costs in a year : CNSX/year72.75 + 1036.1#72.75 (Million VND) The other costs in a month: CNSX/month#72.75/127.7(Million VND)
Total working capital: CLD=CNL+ CDTL + CE+ CNSX780.385(Million VND)
Total invested capital is the sum of fixed capital and working capital:
We choose to borrow from Vietinbank The loan amount is 100% invested capital, the loan interest rate is 7.7%/year, and the loan period is 7 years.
The loan amount is 68438.485 million VND.
We choose to borrow according to the method of an amortized loan, the principal debt and interest are paid every quarter.
Interest paid quarterly = Principal paid×7.7%
Payment quarterly = Principal paid + Interest paid
Table 9.8: Loan amortization schedule in 7 years (Unit: Million VND)
Quarter Beginning balance Principal paid Interest paid Payment Ending balance
The amount to be paid for the loan for invested capital with both principal debt and interest after 7 years is 87964.849 million VND.
Investment summary
Table 9.10: Summary of annual production costs
Cost name Cost (million VND)
Cost of producing a product: C=(Production cost× productivity ratio)/The number of products.
Table 9.11: Productivity ratios of each model
The number of products/year
We have the cost of producing a model:
Table 9.12 Production costs each model
No Model Production cost/model (VND)
We chose the price of the WPC12 model, which is 15% higher than the cost, WPC15 is 14% higher than the cost, WPC20 is 13% higher than the cost.
Assume that all products produced by the plant are sold out, we have the total revenue per year of the plant:
DT=Quantity of products×Price
Table 9.14: Plant revenue per year
Model Quantity of products Price of 1 product
The total annual revenue of the plant is: 585061.1 million VND
Value-added tax (VAT)=Revenue×10%X506.11 (Million VND)
Net revenue =Revenue - VATX5061.1-58506.11R6555 (Million VND)
Earnings before taxes (EBIT) = Net revenue - Total operating expenses
We have, EBITR6555 - 513565.3989.7 (Million VND)
Taxable profit = EBIT - Total depreciation
We have, Taxable profit= 12989.7 - 2875.9= 10113.8 (million VND)
Profit tax = 20%Taxable profit = 20%×10113.8 22.76(million VND)
Net income= Taxable profit - profit tax
Enterprises implementing new investment projects in industrial parks will be entitled to corporate income tax incentives as follow: Tax exemption for 2 years and
50 percent reduction of payable tax amount for 4 subsequent years.
Income tax incentives: (2022.76×2)+(2022.76×4×50%)91.04(Million VND)
Payback period = (Fixed capital - Income tax incentives) /(Net income+ amortization)