300,000 Sheets per Month High-Tg CCL Plant Proposal

# 300,000 Sheets/Month High-Tg Halogenated CCL Plant Technical Proposal

Chapter 1

1. Production Basis

_All equipment quantity calculations are based on the following core operating schedule settings:_

_1.1, Monthly Production Target:_

_300,000 Sheets_

_1.2, Product Specifications (Spec):_

_$1245mm \times 1093mm$ (49" x 43" Standard Size), Thickness 1.0mm (Typically composed of 5-6 sheets of 7628 Prepreg)_

_1.3, Operating Schedule:_

• Working Days per Month: _25 Days_
• Effective Daily Operating Hours: _22 Hours (2 hours reserved for shift handover, maintenance, and changeovers)_
• Daily Capacity Requirement: _$300,000 / 25 = 12,000$ Sheets/Day_
• Hourly Capacity Requirement: _$12,000 / 22 \approx 546$ Sheets/Hour_

2. Resin Formulation & Mixing

_For Medium High-Tg (Tg 150-170°C) and Halogenated products, formulation stability is the key._

Key Technical Points:

• 2.1, Resin System: _It is suggested to use Low Bromine Epoxy Resin combined with Multi-functional Epoxy Resin to elevate the Tg point._
• 2.2, Hardener: _Traditional FR-4 uses DICY. However, to achieve High-Tg, it is recommended to introduce Phenolic Novolac (PN) or specially modified DICY. The PN curing system offers better heat resistance and superior CAF performance._
• 2.3, Accelerator: _2-MI (2-Methylimidazole) type; precise addition control is required to regulate Gel Time._
• 2.4, Filler: _To control CTE (Coefficient of Thermal Expansion) and reduce costs, Silica powder must be added. For 1mm thickness, the filler ratio can be appropriately increased, provided dispersion is managed._
• 2.5, Equipment Configuration:
• High-Speed Dispersers: _3000L $\times$ 2 Units (Main Resin)_
• Mixing Kettles: _5000L $\times$ 4 Units (Equipped with water bath temperature control to prevent exothermic runaway)_
• Aging Tanks: _Must possess continuous low-speed agitation to prevent filler sedimentation._

3. Impregnation Process (Treater)

_This section impregnates electronic-grade glass cloth with resin to produce Prepreg (PP)._

Capacity & Equipment Calculation:

• PP Demand: _Assuming a 1mm finished product requires 6 sheets of 7628 PP._
• Daily PP Demand: _$12,000 \times 6 = 72,000$ Sheets of PP/Day._
• PP Length Conversion (Assuming 1.25m/sheet): _$72,000 \times 1.25 = 90,000$ Meters/Day._
• Hourly Output Requirement: _$90,000 / 22 \approx 4,090$ Meters/Hour._
• Single Machine Capacity: _Standard vertical treater; for 7628 heavy cloth, speed is approx. $20-25$ m/min._
• Single Machine Hourly Output: _$22 \text{m/min} \times 60 = 1,320$ Meters/Hour._
• _Equipment Quantity Requirement:_

_$$N\_{treater} = \frac{4090}{1320} \approx 3.1$$_

• Suggested Configuration: 4 Vertical Impregnation Lines (3 Active + 1 Standby, or load sharing to reduce speed for higher quality).

Process Characteristics:

• Coating Method: _Suggested combination of Comma Roll + Metering Roll to ensure Resin Content (RC) precision within ±1%._
• Tension Control: _Full-line closed-loop tension control to prevent Weft Distortion, which is critical for PCB drilling accuracy._
• Oven: _At least 8-9 temperature zones, utilizing hot air circulation to ensure Volatiles < 0.5%._

4. Lamination Process (Pressing) - The Core Bottleneck

_This section presses the PP and Copper Foil into shape under high temperature and high pressure._

_Press Cycle Time Calculation:_

_Medium-High Tg resin requires complete curing to guarantee performance._

• Thermal Cycle:
• 4.1 Heat-up: _30 Minutes (Ambient $\rightarrow$ 180°C/190°C)._
• 4.2 Curing (Dwell): _60 - 75 Minutes (Ensuring Tg conversion rate)._
• Cool-down: _30 Minutes (Cool down to below 130°C before opening)._
• 4.3 Total Cycle Time: _Approx. 130 Minutes (2.17 Hours)._

_Daily Batches (Cycles per day):_

_$$\text{Cycles} = \frac{22 \text{ hours}}{2.17 \text{ hours}} \approx 10 \text{ cycles}$$_

Equipment Quantity Calculation:

• Press Specification: _Suggested 24-Opening Vacuum Hydraulic Press._
• Books per Opening: _For 1mm thick laminates, typically 10 Books per opening._
• Single Press Output per Cycle: _$24 \text{ layers} \times 10 \text{ books} = 240$ Sheets/Cycle._
• Single Press Daily Output: _$240 \text{ sheets} \times 10 \text{ cycles} = 2,400$ Sheets/Day._
• Press Quantity Requirement:

_$$N\_{press} = \frac{12,000 \text{ (Total Req)}}{2,400 \text{ (Per Press)}} = 5$$_

Process Technical Points:

• Vacuum System: _Must be equipped with a high vacuum system (< 20 mbar) to remove volatiles and prevent Delamination and Measles._
• Heating Medium: Thermal Oil is recommended over steam. It offers more uniform temperature control ($\pm 1.5^\circ C$), which is vital for High-Tg products.
• Auto Recirculation Line: _Configure fully Auto Lay-up and Auto Break-down systems to reduce copper foil creasing and static dust accumulation caused by manual handling._

5. Finishing (Trimming & Sanding)

• Equipment: _Automatic Trimming & Sanding Line + Automatic Shearing Machine._
• Quantity: _2 Fully Automatic Lines._
• Technology:
• _Must be equipped with Online AOI (Automated Optical Inspection) to detect dents, oxidation, and scratches on the copper surface._
• _The sanding machine requires a dust extraction unit to ensure board edges are free of glass fiber burrs._

6. Summary: Core Equipment List

Chapter 2: Energy Systems

1. Energy System Deep Dive: Thermal Oil Boiler

_For High-Tg products, temperature uniformity and heating rate controllability directly determine the Warpage and Internal Stress of the laminate._

2. Power and Selection Calculation

• Total Heat Load Estimation:
• Press Demand: _5 Units of 24-Opening Presses. High-Tg curing temp needs to reach 180°C - 195°C._
• Treater Demand: _4 Impregnation Lines (Oven heating)._
• Estimation: _Presses typically use Secondary Loop control, with the boiler providing the primary heat source. Peak heat power per press is approx. 400k-500k kcal/h; per treater line is approx. 600k-800k kcal/h._
• Suggested Boiler Capacity: _Recommend configuring a 4 - 5 Million kcal/h Gas-fired Thermal Oil Furnace._
• Configuration Strategy: _Adopt an N+1 Mode (e.g., two 3 Million kcal units in parallel). This handles peak loads and allows for non-stop production during low output periods or single unit maintenance._

3. Key Technical Configuration (For High-Tg Process)

• Secondary Loop Control System:
• Principle: _The boiler outputs constant high-temp oil (e.g., 260°C); each press has its own independent mixing system (pump + 3-way valve)._
• Purpose: _High-Tg resin reaction is vigorous and requires precise control of the Heating Rate, usually controlled at $1.5 - 2.5^\circ C/\text{min}$. Only a secondary loop can achieve this; direct heating cannot be precisely regulated._
• Hot/Cold Oil Switching Design:
• _Configure independent Cold Oil Tanks and Hot Oil Tanks. High-Tg products must be cooled to below $130^\circ C$ (glass transition) within the press before pressure release, otherwise severe board deformation will occur._
• Safety Margin: _Thermal oil piping must use seamless steel pipes. Flange connections should use high-temperature resistant metal wound gaskets to prevent leaks and fire hazards._

4. Environment & Safety Deep Dive: RTO Exhaust System

_In CCL production, the drying process in the Treater evaporates large amounts of organic solvents. Your formulation contains Acetone, MEK, and DMF, which are flammable, explosive, and highly toxic._

5. RTO (Regenerative Thermal Oxidizer) Selection Core

• Treatment Volume: _For 4 Treater lines, total exhaust volume is estimated at $60,000 - 80,000 \text{ m}^3/\text{h}$._
• Type Selection: _Strongly recommend using 3-Tower RTO or Rotary Valve RTO._
• Reason: _2-Tower RTOs have momentary exhaust leakage during valve switching, causing a drop in VOC destruction efficiency, making it hard to pass increasingly strict environmental inspections. 3-Tower or Rotary types ensure continuous $99\%+$ removal rate._
• Special Treatment for Halogens & DMF:
• _Although RTO mainly burns solvents, trace resin dust contains Bromine (Halogen)._
• DMF (Dimethylformamide): _Combustion produces NOx (Nitrogen Oxides)._
• Post-treatment: _A Scrubber (usually alkaline wash tower) must be installed after the RTO to neutralize potential trace acidic gases and reduce exhaust temperature._

6. Energy Recovery - Key to Cost Reduction

_RTO is not just environmental equipment; it is energy-saving equipment._

• Waste Heat Recovery: _Solvent combustion generates massive heat energy._
• Closed Loop Design: _Send the high-temperature clean air generated by the RTO back to the Treater ovens via heat exchangers or direct air mixing._
• Benefit: _Under normal production (moderate solvent concentration), the RTO can achieve "Self-Heating" or even supply heat to the workshop, drastically reducing natural gas consumption._

7. LEL Safety Interlock (LEL Control)

• Risk: _Acetone and MEK are highly explosive._
• Mandatory Configuration: _Every oven zone and the main duct must have Online LEL Concentration Monitors._
• Logic: _When exhaust concentration exceeds 25% of the Lower Explosive Limit (LEL), the system must automatically open fresh air valves to dilute or emergency stop to prevent flame flashback into the ovens._

8. Scalability & Civil Engineering Deep Dive

_Your reservation for a "6th Press" is very wise. The bottleneck of a CCL plant is always in the Lamination section._

8.1 Why are 5 units not enough? (The Thick Board Trap)

• Capacity Calculation Trap: _300,000 sheets is an ideal calculation based on 1.0mm products._
• Thick Boards (1.2mm / 1.6mm):
• Heat Transfer: _Thicker boards transfer heat to the center layer slower._
• Cycle: _The press cycle for 1.6mm boards may extend from 130 minutes to 150-160 minutes._
• Book Count: _To ensure thermal uniformity, the number of books per opening might reduce from 10 to 8._
• Result: _Once the proportion of 1.6mm orders increases, the capacity of 5 presses will instantly drop below 250,000 sheets/month._
• Role of the 6th Press: _It acts as a buffer pool for "Product Mix Complexity" and a backup unit during equipment overhaul._

8.2 Civil Engineering Reservation Requirements

_Presses cannot just be placed anywhere; Civil Engineering is the biggest irreversible cost._

1. Foundation Pit:

• _24-Opening Vacuum Presses are tall and typically require deep pits to install hydraulic cylinders and lifting tables._
• Suggestion: _Excavate the Foundation Pits for 6 Press Positions during the initial construction. Cover the 6th pit with steel plates as a temporary staging area. Digging a pit after the factory is operational will ruin the quality of CCL in production due to dust and vibration._

2. Oil Volume & Pipe Diameter:

• _When designing the Main Header for thermal oil, the pipe diameter must be calculated for the flow rate of 6 presses (e.g., using DN150 or DN200 pipes) to avoid insufficient flow during future expansion._

3. Clean Room Layout:

• _The Lay-up/Return line area requires a clean environment (Class 100k or 10k)._
• _When reserving the 6th position, ensure the rails of the Auto Circulation Line can be extended, or reserve sufficient AGV aisles._

Chapter 3: Raw Materials & Costs

_"Core Raw Material Monthly Consumption Estimate Table"_

_This calculation is based on your setting of 300,000 sheets/month capacity, with product specs set at 1.0mm thickness (most common FR-4 spec), Copper Foil at 1oz (35$\mu$m) double-sided, and Glass Cloth at 6 sheets of 7628 structure._

_⚠️_ _Note: All calculations include a 5% - 8% Process Loss (trimming, trial runs, scrap), which acts as a safety margin for Working Capital calculations._

1. Monthly Material Consumption

Base Parameters:

• Total Area: _$300,000 \text{ sheets} \times 1.36 \text{ m}^2/\text{sheet} = 408,000 \text{ m}^2$ (Net Area)._
• Input Area: _Approx. $440,000 \text{ m}^2$ (Including trimming loss)._

2. Detailed Cost Structure Analysis

_To help estimate cash flow, here is the typical ratio and procurement strategy:_

3. Copper Foil - The Heavy Cash User

• Consumption: _280 Tons._
• Financial Feature: _Copper foil mills typically offer short payment terms or require Cash/Prepayment. This is the biggest pressure point for Working Capital._
• Tech Point: _For High-Tg boards, using RTF (Reverse Treated Foil) is recommended to increase Peel Strength._

4. Glass Cloth - The Quality Cornerstone

• Consumption: _560 Tons (Approx. 2.7 Million Meters)._
• Tech Point: _300k monthly output is a mid-sized plant. Recommend selecting 1-2 Core Strategic Suppliers (e.g., Nanya, KB, TGI) to ensure batch stability. Do not switch frequently, otherwise, treater parameters will be hard to stabilize._

5. Chemical System

• Resin Solids: _Approx. 365 Tons/Month._
• Formula Cost:
• High-Tg Difficulty: _To reach Tg 170°C, cheap DICY is insufficient. Expensive Phenolic Novolac (PN) or SMA modification must be introduced._
• Cost Reduction via Filler: _Silica unit price is far lower than resin. Increasing filler loading (e.g., to 25%-30%) without affecting drilling performance is key to cost control._

6. Solvents - The Invisible Cost

• Consumption: _180 Tons._
• Note: _This money is literally "burnt away"._
• Recovery: _If budget permits, a Condensation Recovery Unit can be added before the RTO to reuse some Acetone. However, for High-Tg formulas, moisture control in recovered solvent is difficult, so direct combustion for heat is recommended initially._

7. Energy Monthly Consumption Estimate

_Besides raw materials, energy is a monthly "Cash Out"._

• Electricity: _Approx. 1,200,000 - 1,500,000 kWh / Month._
• _Main consumers: Press hydraulic pumps, Thermal oil pumps, RTO fans, HVAC & Chillers._
• Natural Gas: _Approx. 250,000 - 300,000 $m^3$ / Month._
• _Usage: Thermal oil boiler, RTO pilot (RTO consumes little gas during normal operation)._
• Water: _Approx. 15,000 Tons / Month._
• _Usage: Cooling tower makeup for presses, Boiler, Scrubber._

8. Working Capital Alert

_Based on the data above, assuming current market prices (reference only):_

• Monthly Raw Material Procurement: _Estimated around 25 - 35 Million RMB (Dependent on Copper Price)._
• Cash Conversion Cycle:
• Buying: _Copper (30 days/Cash) + Glass/Resin (60-90 days)._
• Selling: _Customer terms usually 90 - 120 days._
• Gap: _You need to prepare at least 3-4 months of raw material operating funds to cover this time difference._

Chapter 4: Human Resources

_"Personnel Structure & Labor Cost Planning Table"_

_(Includes: Headcount from Plant Manager, Chief Engineer, Lead Operators to General Workers, and qualification suggestions for High-Tg technology)._

_Based on a 25 Days/Month, 22 Hours/Day operating model, to ensure production continuity and personnel alertness, it is recommended to use Two Shifts (12 hours/shift) or Three Shifts (8 hours/shift) for the production line. The following scheme is calculated based on the industry-standard Two Shifts (12-hour system), covering 22 hours of production while utilizing handover time for maintenance._

1. Headcount Summary

• Total Plant Headcount: Approx. 70 - 75 People
• Management & Tech Staff: _12 People_
• Direct Labor: _40 People_
• Indirect Labor (QA/Facility/Warehouse): _20 People_

2. Detailed Organizational Chart

2.1 Core Management & Technical Dept

_Success in High-Tg products lies in formulation and press profiles; this department is the "Brain" of the factory._

2.2 Production Dept - Two Shifts

_Calculated for 25 Days/Month, 22 Hours/Day._

2.3 Quality Assurance Dept (QA)

_High-Tg products demand extremely high standards for testing equipment._

2.4 Facility & Maintenance Dept

_Ensures safety of high-temperature & high-pressure equipment._

2.5 Warehouse

Chapter 5: Human Resource Pain Points & Solutions for High-Tg

_When recruiting and training, pay special attention to these High-Tg specific risks:_

1. Lab Technician Level

_Standard FR-4 only requires Gel Time testing. High-Tg requires operation of DSC and TMA. If the technician cannot analyze the graphs, boards with insufficient Tg (e.g., 140°C instead of 150°C) may be produced, leading to massive batch losses._

• _Suggestion: Recruit Polymer Science graduates or experienced technicians._

2. Press Lead Experience

_High-Tg resin has a narrow Rheology Window (flow time is short, hardens quickly). If the heating rate is uncontrolled, it leads to excessive flow (too thin) or insufficient flow (Measles/Voids)._

• _Suggestion: Press Leads must have 3-5 years of relevant experience; do not use novices._

3. Mixing Environment

_Large amounts of filler (Silica) are used, creating dust._

• _Suggestion: Feeding position wages should be above average, and high-quality PPE must be provided to prevent high turnover._

4. Summary

_At this point, our 300k/Month High-Tg CCL Plant Proposal is complete, covering four core modules:_

1. Process Tech: _Defined Halogenated High-Tg formula & 1mm spec._ 2. Equipment: _Defined 4 Treaters, 5+1 Presses, RTO & Thermal Oil config._ 3. Material Consumption: _Calculated Monthly Tonnage & Cash Flow for Copper, Glass, Resin._ 4. HR Structure: _Planned a lean & efficient team of ~75 people._

Chapter 6: Phased Implementation Strategy

_The Copper Clad Laminate (CCL) industry is a typical "Heavy Asset, Long Cycle" industry. A one-time investment for 300,000 sheets capacity creates immense capital pressure (especially Working Capital for Copper Foil). Adopting a Phased Investment strategy not only lowers initial risk but also leverages cash flow from Phase I to fund Phase II expansion._

_Addressing your target of 300k/Month combined with High-Tg characteristics, we have re-planned a Two-Phase Investment Scheme._

Core Strategy: 1+1 > 2 Modular Expansion

• Overall Concept: Civil Works & Utilities (Water/Power/Gas/Air) One Step 到位 (Done in one go); Core Production Equipment (Treater, Press) Implemented in Steps.
• Phase I (Market Entry): _Target 120k-140k sheets/month (Approx. 40%-45%). Focus on process validation, passing customer certifications (UL, ISO), and achieving break-even._
• Phase II (Scale & Profit): _Target Fill up to 300k sheets/month. Focus on reducing amortization costs and maximizing profit margins._

Phase I: Pilot & Entry

_Target Capacity: 120,000 Sheets/Month_

_Investment Focus: Stability of quality over extreme speed._

1. Equipment Configuration:

• Mixing System: 100% Investment.
• _Reason: Kettles and dispersers are relatively low cost. High-Tg glue requires long aging times. Phase I may have small volume but many varieties (debugging), so it's best to install 2 Dispersers + 4 Kettles at once._
• Treater: Invest 2 Lines (Total Plan 4).
• _Config: 1 Line for 7628 main production; 1 Line for flexible switching (thin cloth or R&D)._
• Press: Invest 2 Units (Total Plan 5+1).
• _Capacity: 2 Units $\times$ 2400 Sheets/Day $\approx$ 4800 Sheets/Day $\times$ 25 Days = 120,000 Sheets/Month._
• _Config: 2 Units of 24-Opening Vacuum Presses._
• Finishing: _Invest 1 Automatic Shearing/Sanding Line._

2. Mandatory "Sunk Costs" (Must be done in Phase I)

_This part cannot be "modularized" and must be completed in Phase I, otherwise Phase II expansion will cause production shutdowns:_

1. Foundation Pits: _Must excavate pits for 6 Presses at once. Cover unused pits with steel plates._

• _Risk: Digging pits during Phase II will create dust that ruins the insulation quality of Phase I production._

2. RTO Exhaust: _Must design for Full Load of 4 Lines._

• _Reason: Environmental approval is usually one-time. Large RTOs run more stably. Use VFD fans to lower energy consumption during low load._

3. Thermal Oil Main Header: _Pipe diameter must be sized for 6 Presses flow rate; leave flange interfaces with blind plates._

Phase II: Expansion

_Start Trigger: When Phase I utilization > 80%, or single customer order > 50k sheets/month._

_Added Capacity: +180,000 Sheets/Month (Totaling 300k)_

3. Equipment Add-ons:

• Treater: _Add 2 High-Speed Lines._
• _Process is mature now; these lines run full speed for large orders._
• Press: _Add 3 Units of 24-Opening Vacuum Presses._
• _Utilizing reserved pits and pipe interfaces, installation takes only 2-3 weeks with minimal impact on Phase I._
• Finishing: _Add 1 Auto Line._
• Boiler: _Dependent on Phase I selection._
• _Strategy: Phase I installs one 3M kcal boiler; Phase II adds another 3M kcal. Parallel operation for redundancy._

Financial Comparison: One-off vs. Phased

Technical Notes for Phased Plan

4. Recirculation Line Compatibility:

• _If phasing, design of the Auto Lay-up Line is critical._
• _Option A: Manual Lay-up for Phase I (Cheap), Auto for Phase II. Risk: Phase I quality (static, creases) unstable._
• _Option B (Recommended): Install Auto Line in Phase I, but design rails to cover all 6 pit positions. For Phase II, just modify PLC stops._

5. Personnel Reserve:

• _Skilled workers trained in Phase I (especially Press Leads and Lab Techs) will become Shift Leaders in Phase II. Phased mode builds a talent pipeline, avoiding the chaos of hiring dozens of novices at once._

Revised Proposal Strategy

_Current Strategy Adjustment:_

_"Overall Plan 300k sheets, implemented in two phases. Phase I builds 120k (2 Lines + 2 Presses) for rapid market entry. Reserve all expansion interfaces. Trigger Phase II (180k expansion) after passing Tier 1 Customer High-Tg Certification."_

Chapter 7: Revised Material Consumption & Timeline

1. Raw Material Consumption Comparison: Phase I vs. Full Cap

_(Based on 1.0mm, High-Tg, Halogenated, 25 Days/Month)_

2. Phase I Start-up Capital Advantage

_The biggest risk in CCL is "Buying Copper $\rightarrow$ Making Boards $\rightarrow$ Sitting in Warehouse waiting for Certs"._

2.1 Initial Working Capital Down 60%

• Full Cap Mode: _Requires 3 months full material funds (1mo stock + 1mo transit + 1mo AR gap). Amount could be ~100 Million RMB._
• Phased Mode:
• _Phase I monthly procurement drops to 10-12 Million RMB._
• _Only 30-40 Million RMB working capital needed to spin the wheel._
• _Strategy: Use saved cash to Optimize Civil Standards (better clean room, full pits) or as a risk buffer for Copper Price volatility._

2.2 Inventory Flexibility

• High-Tg Cert Period: _Auto/Server clients take 3-6 months to certify High-Tg._
• Risk Control: _In Phase I, run at low water level (120k). Direct 300k creates massive finished goods inventory risk (CCL degrades after 6 months)._

2.3 Non-Linear Costs in Phase I

_Auxiliary costs do not drop proportionally (Short term price of phasing):_

1. Power/Gas: _Expected at 50%-60% of full cap (not 40%)._

• _Reason: Boiler runs even for 2 presses; RTO fans run full speed for safety negative pressure._

2. Labor: _Expected at 60%-70% of full cap._

• _Reason: Boiler ops, Security, Warehouse, Lab techs must be fully staffed (3 shifts) regardless of volume._

3. Unit Cost:

• _Due to amortization of heavy fixed assets (Civil, Utilities) and shared labor, Phase I Unit Cost will be 5%-8% higher._
• _Countermeasure: Phase I goal is "Process Validation + Customer Entry + Cash Flow Neutral", not high profit._

2.4 Sourcing Strategy for Phase I

• Copper: _No long-term lock. Spot market. Maintain flexibility._
• Glass: _Lock 1 Strategic Supplier. Request tech support for High-Tg wetting issues._
• Resin: _"1+1" Backup. Develop 1 Main (Taiwan/Foreign) + 1 Backup (Domestic Top Tier)._

Chapter 7 (Cont.): Project Implementation Timeline

Project Total Cycle Estimate

• Phase I (120k): _Start to SOP approx. 12 Months._
• Cert & Ramp-up: _3-6 Months post-SOP._
• Phase II (+180k): _Start to SOP only 4-5 Months (Thanks to Phase I provisions)._

Phase I: Greenfield to SOP

Goal: _Complete all Civil (inc. Phase II pits), Install 2 Treaters + 2 Presses._

1. Prep & Design (M1 - M3)

• M1: _Project Approval & Funding. Core Team assembled._
• M2: _Land Survey & Design. Key: Confirm drawings for 6 Pits, RTO Foundation, Boiler Room._
• M3: _EIA/Safety Permit & Contractor Entry. Key: Lock Long Lead Items (Vacuum Press & RTO Valves)._

2. Civil & Utilities (M4 - M9)

• M4 - M6: _Main Structure. Excavate 6 Pits (Waterproof). Steel columns._
• M7 - M8: Clean Room fit-out. Lay-up room (Class 100k/10k). Epoxy flooring.
• M9: _Utility Installation. Boiler install, Piping welding (inc. Phase II interface). RTO hoisting._

3. Equipment Install (M10 - M11)

• M10: _Core Equipment Move-in. Press assembly in pits. Treater ovens assembly._
• M11: _Commissioning. High Risk: Thermal Oil Boil-out. Requires 1-2 weeks slow heating to remove water. DO NOT RUSH._

4. Trial & Cert (M12 - M15)

• M12: _Internal Trial. Produce dummy/low-end boards to debug RC & Temp uniformity._
• M13: SOP & Sampling. Ramp to 30%-50%. Submit to UL & Clients (Thermal Shock Test).
• M15: _ISO/IATF Certification._

Phase II: Plug & Play

Trigger: _Phase I > 80% Util. & High-Tg Cert passed._

• T: _Order Equipment (3 Presses + 2 Treaters)._
• T+3: _Equipment Move-in. Use reserved pits. Dust Isolation required._
• T+4: _Install & Debug._
• T+5: Full Capacity (300k).

Gantt Chart Visualization

Executive Note

_"The core risk control points are M11 (Oil Boil-out) and M13 (Certification)._

1. _We front-load Civil/Utilities, increasing Phase I CAPEX slightly, but compressing Phase II expansion to 4 months, maximizing market response speed._ 2. _We start High-Tg Cert at M13, utilizing the ramp-up window for reliability testing, ensuring orders are ready when capacity hits full."_

Chapter 7 (Cont.): CAPEX Budget Estimate

_Basis: "Two-Phase Strategy" (120k $\rightarrow$ +180k)._

_Config: Mid-High End (Domestic Tier 1 or Taiwan Brand for High-Tg precision)._

_Currency: RMB. Excludes Land/Civil Construction/Working Capital._

Part 1: Main Production Equipment

Part 2: Utilities & Facility (Sunk Costs)

Note: _Most must be done in Phase I._

Part 3: Lab & QC

_High-Tg relies on "Accurate Testing"._

1. Summary & Analysis

2. Proposal Writing Suggestions (Key Takeaways)

_In this chapter, we highlight three key financial takeaways for investors:_

• _Phase I "Ticket to Entry" Attribute:_

_The Phase I investment is approximately RMB 60 Million. Although this yields only 40% of the total capacity, it establishes 100% of the infrastructure, environmental compliance, and R&D capabilities. This represents the necessary "admission ticket" to enter the industry._

• _Phase II "High Profit" Attribute:_

_Phase II requires only an additional investment of RMB 45 Million to generate 60% (180,000 sheets) of new capacity._

• Phase I Investment Cost per 10k Sheets: _RMB 59.5 Million / 12 ≈ RMB 4.95 Million._
• Phase II Investment Cost per 10k Sheets: _RMB 45.8 Million / 18 ≈ RMB 2.54 Million._
• Conclusion: _The true profit explosion point lies in Phase II, as the unit depreciation cost is nearly halved._
• _Key Risk Point — Stainless Steel (SUS) Carrier Plates:_

_"Stainless Steel Carrier Plates" are explicitly listed in the budget table. Many initial factory proposals overlook this item, leading to passive budget overruns later. High-Tg processing requires high lamination temperatures, resulting in high plate wear. This RMB 7.5 Million expense is a mandatory hard cost that must be reserved._

Chapter 8: Conclusion

_Project Name: Annual Output of 3.6 Million Sheets High-Performance High-Tg CCL Manufacturing Base Project_

_—— Phased Construction Proposal_

Section 1: Executive Summary

1.1 Project Background and Objectives

• Construction Objective: _Monthly production of 300,000 sheets of FR-4 Copper Clad Laminates._
• Core Product Positioning: _1.0mm thickness, Medium-High Tg (150-170°C), Halogenated standard laminates._
• Target Applications: _Automotive electronics, Servers, Industrial control power supplies._

1.2 Construction Strategy: The Two-Phase Strategy

• Core Strategy: _Overall planning with phased implementation to mitigate capital risk._
• Phase I (Market Entry): 120,000 sheets/month (40%) — Focus on market entry and technical certification.
• Phase II (Scale & Profit): +180,000 sheets/month (60%) — Focus on economies of scale and profit maximization.

1.3 Key Financial Indicators Summary

• Total Investment Estimate (CAPEX): _Approx. RMB 105 Million._
• Phase I Start-up Capital: _Approx. RMB 60 Million (Equipment) + RMB 30 Million (Working Capital)._
• Construction Cycle: _Phase I to reach production in 12 months._

Section 2: Technical Proposal

2.1 Product Specifications

• Standard Size: _1245mm x 1093mm (49" x 43")._
• Layer Buildup: _1.0mm = 6 sheets of 7628 Glass Cloth + 2 sheets of 1oz Copper Foil._

2.2 Core Process Flow and Technical Key Points

• Resin Formulation: _Low Bromine Epoxy Resin + Linear Phenolic Novolac (PN) hardener system; Silica filler dispersion technology._
• Impregnation Process: _Comma Roll coating, high-precision tension control._
• Lamination Process: _High-Tg specific curing profile (Heating Rate control), Vacuum < 20 mbar._

Section 3: Production Capacity Planning & Equipment Selection

3.1 Operating Schedule and Capacity Calculation

• Work Schedule: _25 days/month, 22 effective operating hours/day._
• Efficiency Targets: _Impregnation speed 22-25m/min; Press Cycle 130 minutes._

3.2 Core Equipment Configuration (Phased Implementation)

• Mixing System: _2 Dispersers + 4 Kettles (Phase I Full Config)._
• Impregnation System: _Total Plan 4 Lines (Phase I: 2 Lines + Phase II: 2 Lines)._
• Lamination System (Bottleneck): _Total Plan 5 units of 24-Opening Vacuum Presses (Phase I: 2 Units + Phase II: 3 Units)._
• Finishing System: _2 Automatic Trimming & Sanding Lines._

3.3 Utilities and Environmental Facilities

• Thermal Energy Center: _Thermal Oil Boiler (4M kcal), Secondary Loop Temp Control._
• Environmental Center (RTO): _80,000 CMH 3-Tower RTO, Halogen Scrubber._
• Civil Provisions: _6 Press Foundation Pits, Clean Room standards._

Section 4: Raw Material Consumption & Supply Chain

4.1 Monthly Core Material Consumption

• Copper Foil: _Phase I: 112 Tons → Full Cap: 280 Tons (Key Working Capital focus)._
• Glass Cloth: _Phase I: 225 Tons → Full Cap: 560 Tons (7628 Electronic Grade)._
• Resin/Solvents: _Consumption calculation and storage requirements._

4.2 Supply Chain Strategy

• Copper Foil: _Spot market strategy, no long-term lock._
• Glass Cloth: _Lock 1-2 strategic suppliers._

Section 5: Implementation Timeline

5.1 Project Cycle Planning

• Total Duration: _12 Months (T+1 to T+12)._
• Key Milestones: _M4 Civil Start → M10 Equipment Move-in → M11 Thermal Oil Boil-out → M13 Trial Run._

5.2 Certification & Expansion Plan

• _High-Tg Product Certification Cycle (3-6 Months)._
• _Phase II Trigger Condition (Capacity Utilization > 80%)._

Section 6: Organizational Structure & Human Resources

6.1 Organizational Chart

• Total Headcount: _Approx. 75 employees._
• Shift Structure: _Two shifts, 12-hour system._

6.2 Key Positions & Skills

• Core Tech Roles: _Chief Engineer (Formulation), Press Lead (Temp Control), Lab Tech (DSC/TMA testing)._

Section 7: Investment Estimate & Financial Plan

7.1 Fixed Asset Investment Estimate (CAPEX)

• _Production Equipment Breakdown (RMB 81.20 Million)._
• _Utilities Breakdown (RMB 14.40 Million)._
• _Laboratory Investment._

7.2 Working Capital Calculation

• _Optimization analysis via Phased Construction (saving approx. 60% initial Working Capital)._
• _Raw material turnover and AR/AP gap analysis._

Section 8: Risk Analysis & Countermeasures

8.1 Technical Risk

• _Incomplete curing of High-Tg leading to exploded boards → Countermeasure: Equip DSC Thermal Analyzer, strictly control Gel Time._

8.2 Market Risk

• _Copper price volatility → Countermeasure: Copper/Laminate price linkage mechanism._

8.3 Safety & Environmental Risk

• _Solvent explosion → Countermeasure: Online LEL Monitoring Interlock._

Section 9: Conclusion & Recommendations

• Conclusion: _This project adopts a mature High-Tg manufacturing process combined with a robust Phased Investment Strategy. It is technically feasible, risks are controllable, and it demonstrates strong market competitiveness._
• Recommendation: _Immediately initiate procurement for Long Lead Time Items (LLTI), specifically the Vacuum Presses and RTO System._