Start a Melamine Tableware Making Plant

(135). Start a Melamine Tableware Making Plant

LONGLITE MM (MELAMINE RESIN MOLDING POWDER) is a high class, cellulose filled melamine formaldehyde material.  It is available in various colors and produces molding with surface hardness unsurpassed by many other plastic.
LONGLITE MM is particularly valuable for the high quality dinnerware and many other applications for domestic and commercial use.  Molded parts with LONGLITE MM comply with the requirements of ASTM D-704-62 Type 1, JIS K6917, JIS S-2029, CNS 2985 and the Food Hygienic Quality Standard established by Japanese Ministry of 
Health and Welfares.


1 Characteristics
Molded articles with LONGLITE MM exhibit the following properties:

• Hard, durable surface with superior luster.  Resist scratching.
• Unlimited colors possibility and stability.
• Excellent hot water durability.  Repeated boiling does not affect appearance.
• Excellent resistance to acid, alkali, detergent and organic solvents.
• Free from taste and odor.
• High resistance to dry heat.
• Excellent electrical properties.

2. Molding
LONGLITE MM is supplied in fine powder form, which is suitable for performing on compression molding. Molding conditions vary with the product shape, thickness.  High quality products can be obtained by using optimum conditions.
Standard Conditions are given below for reference:

Temperature (Mould Surface)	165±10℃ (330±20℉)
Pressure	150-450Kg/㎝2 (2100-6500 PSI)
Curing Time (170℃, preheated)
1.5㎜ thick	30-50 second
3.5㎜ thick	50-80 second
5.0㎜ thick	70-100 second

The recommended test to determine optimum time comprises of boiling a test piece in 0.8% sulfuric acid solution for ten (10) minutes.  A well-cured part will show no chalking.

3. Preheating
LONGLITE MM can be molded without preheating.  However, preheating is strongly recommended, especially when a thick part is molded.  The use of preheating performs will obtain following advantages:

• It can eliminate complicated molding cycle and reduce the curing time.
• It can give the molded parts a good appearance and optimum properties.
• It permits the use of lower pressure to reduce the damage of mould and press.

High frequency heating is preferred.  The optimum preheating temperature is 90-110℃(200-230℉)


4 .Packing
LOGLITE MM is packed in 20 or 25 Kg paper bags

5 .Storage and Handling
LONGLITE MM should be kept in air tight bags at a cold, dry place below 30℃ (85℉), preferably 20℃(70℉) and below 50% of relative humidity.  When stored under such good conditions, LONGLITE MM has excellent storage characteristics for duration of approximate six (6) month after the date of production.In handling LONGLITE MM, good housekeeping is important.  Dust removal in area where powder is handled should be provided for the use of suitable exhaust system.

6. Properties

Specific Gravity	JIS K6911	1.47-1.55
Water Absorption, Normal	JIS K6911	0.8% maximum
Water Absorption, Boiling	JIS K6911	1.0% maximum
Molding Shrinkage	JIS K6911	0.8-1.0%
Heat Resistance (125℃, 2hr)	JIS K6911	No remarkable change
Color Fading Test	JIS S2029	Good
Flexural Strength	JIS K2911	9-13 Kg/mm2
Charpy Impact Strength	JIS K6911	2-3 Kg-cm/cm2
Rockwell Hardness	JIS K6911	115-125 M scale
Insulation, Normal	JIS K6911	1010-1011 Ohm
Insulation, Boiling	JIS K6911	108-1010 Ohm
Arc Resistance	JIS K6911	100 sec, minimum
0.8% H2SO4 boiling Test (10 minutes)	JIS K6911	No change

Overlay Resin LG-110 and LG-220
LONGLITE LG-110 and LG-220 are active synthetic resins, provided to meet end-users requirement in the production of decorated plastics articles.
1 .Characteristics

• Both LG-110 and LG-220 come in white color and exist in fine powder form.
• Excellence in brightness and flow ability
• Strong resistance in heat and boiling water
• Good adhesion with amino-based resins molding powder.
• Apparent Density 0.45~0.50 gm/ml.
• Melting point 95± 5℃

2 .Application
LG-110 can best be used for overlay decorated paper treatment against article made of Urea Resin Molding Powder while LG-220 is best against article made of Melamine Molding Powder.

3.Operational Procedures
LG-110220 can be processed in entirely the same molding pressure and temperature as that for Urea/ Melamine Molding Powder. Treatment can be done in accordance with following two methods:
(1) Dispersion

• To mold Urea/ Melamine Molding Powder firsthand under suitable pressure and temperature until 70-80% cured (complete curing shall be avoided).  At this stage, surface of the molded article shows no sign of brightness and is soft in nature.  Open up mould and make the side the overlay decorated paper is to be treated face upward.
• Disperse a little of LG-110/LG-220 on the surface, place decorated paper on the surface of molded article. After this, a small amount of LG shall be re-disperse evenly on decorated paper.
• Re-close mould and return to normal pressure and temperature for 2-3 minutes.  Special attention shall be paid to the procedure of degassing, which is generally performed 5-10 seconds after re-close of mold.
• By dispersion method, the quantity of LG-110/LG-220 to be treated on overlay paper can be decided by the weight of molded articles.  Suggestion is that 1-3% of LG-110/LG-220 be applied against the total weight of molded articles.

(2) Immersion
A. Treatment of overlay papers

• Fixture of LG solution:

LG-110/LG-220	40%
Water	＊ 0~60%	Total 60%
Methanol	＊ 0~60%

＊ Proportion of methanol and water can be adjustable in accordance with the dry time desired for this solution. To shorten dry period, users may increase methanol quantity and reduce water, while maintaining the total portion at 60%.  The following proportion will make it possible for the solution to dry within one and half hour.

LG-110/LG-220	40%
Water	40%
Methanol	20%

• Overlay papers

Place the overlay papers on flat plate, use brush to disperse the LG solution evenly on each side of overlay papers, which shall then be put at good-ventilation places for drying.  (Caution shall be given to prevent the overlay paper from contact with dust or foreign goods).

B. Operational Procedures

• Mould Urea/Melamine Molding Powder under suitable pressure and temperature until molded article is 70-80 cured.  (Avoid complete curing).
• Open mould and attach the LG solution-treated overlay paper on the surface of molded articles.
• Re-close mould and resume to normal temperature and pressure for 2-3 minutes.  Degassing shall be performed 5-10 seconds after close of mould.

Reasons for Defects
1. Bubbles or bad attachment with molding Powders

• Too greasy on the surface of overlay papers.  (Caution: Do not use grease-related paper for overlay use.)
• Improper degassing or under cure.
• Overlay papers shall be attached to molded articles when it is 70-80%cured.  In case the molded articles before attaching overlay papers is completely cured, such defects will arise.

2 Breakage of overlay paper

• Molding pressure too high.  The pressure shall be escalated gradually, or else such defect will arise.
• Uneven disperse of LG-solution on the sides of overlay papers.

3. Deformation of paper designs or inferior brightness

• The overlay paper after treatment with LG solution is not adequately dried.
• Pigment used in printing overlay paper is easily soluble in methanol.

4. White dot on the surface of molded articles

• Molding Pressure is less than adequate.
• Under cure.
• Shortage of LG quantity either in immersion or in dispersion stage.

5. Storage Life
LG-110/LG-220 are active synthetic resins, and will lose its flow ability when time progresses.  It is recommended that it be stored at cool place under 30℃ temperature.  Life will last longer if stored in cooler places.

General Processing Information for Melamine Tableware



Plant Description
High Frequency Preheater

DP-320	MAX. OUT-PUT POWER: 3KW
	POWER SOURCE: 3 PHASE, 380V, 50HZ OSC. FREQUENCY: 62 MHZ OSC. TUBE: 7T85RB RECTIFIER: SILICON RECTIFIER OPERATION: AUTOMATIC OPENING ELECTRODE: PLATE EXECTRODE
DP-520	MAX. OUT-PUT POWER: 5KW
	POWER SOURCE: 3 PHASE, 380V, 50 HZ OSC. FREQUENCY: 62 MHS OSC. TUBE: 7T69RB RECTIFIER: SILICON RECTIFIER COOLING: FORCED AIR COOLIND OPERATION: AUTOMATIC OPENING
DP-1020	MAX. OUT-PUT POWER: 10 KW
	POWER SOURCE: 3 PHASE, 380V, 50 HZ OSC. FREQUENCY: 27MHZ OSC. TUBE: 8T20R RECTIFIER: SILICON RECTIFIER

 Melamine Tableware Mold for Reference

ITEM	SPECIFICATION	SIZE (CM)	MOLD (Cav./Mold)	MACHINE (HCB-)	Q’TY (SET)
1.	Small Bowl	9.5×5	4	80	1
2.	Medium Bowl	11.1×5.6	4	100	1
3.	Large Bowl	15.4×7.5	1	100	1
4.	Small round Bowl	17.8×1.8	1	100	1
5.	Round Plate	25.5×2	1	100	1
6.	Round Plate	35.9×2.9	1	150	1
7.	Saucer	8.5×1.9	4	100	1
8.	Oval Plate	20.2×14.1×1.9	1	100	1
9.	Oval Plate	50.1×22.1×2.4	1	150	1
10.	Oval Plate	40.7×30.6×3.3	1	150	1
11.	Soup Bowl	12.1×4.2	1	150	1
12.	Soup Bowl	19.7×6.6	1	150	1
13.	Soup Bowl	28×9.6	1	150	1
14.	Noodle Bowl Cover	28×9.6	1	150	1
15.	Spoon	1.3×11×1.6	8	100	1
16.	Cup For Children	8×5.5	2	100	1
17.	Bowl For Kids	13.5×4	4	150	1
18.	Round Plate	26.6×2.3	1	100	1
19.	Round Plate	36.7×2.8	1	150	1
20.	Ashtray	9.5×9.5	1	150	1

 Machines and Equipments（Economic Production For Melamine Ware）
A. Machines:

1.	100 M/T HYDRAULTIC MOLDING MACHINE	3 SETS
2.	150 M/T HYDRAULTIC MOLDING MACHINE	2 SETS
3.	200 M/T HYDRAULTIC MOLDING MACHINE	1 SET
4.	3 KW PREHEATER	3 SETS
5.	5 KW PREHEATER	3 SETS
6.	TRIMMING MACHINE	5 SETS

B. Equipments:

1.	2HP AIR COMPRESSOR	2 SETS
2.	SCALER 0-2 KG	7 SETS
3.	4 KW HEATER	1 SET
4.	CHILLER TOWER（5 TON）	1 SET

Production Capacity
Following information is based on the above-mentioned machines and working hour for 8 hours, 25 days / month. Good Products Rate 80 %.
Products:（Plain Plate）

DIA.	Thickness	Weight	Monthly Output	Raw Material
7”	2.5MM	110G	32,000PCS	4.95 MT/Month
8”	2.5MM	150G	32,000PCS	6.7
9”	2.5MM	180G	32,000PCS	8
10”	3.0MM	270G	24,000PCS	9
12”	3.0MM	370G	16,000PCS	8.3
14”	3.0MM	520GT	16,000PCS	11.6

Raw Material
MELAMINE RESIN MOLDING COMPOUNDS

Manpower Requirement

Section	Manpower （person）
Plant Manager	1
Production Technician	1
Foreman	2
Operator	10
General Worker	1
Total	15

 Utilities

Water Consumption	5 TON/DAY (OIL COOLER)
Elec. Power	60KW

 Plant Layout
Factory Building: 400M2
Main Production Area: 20M× 15M
Warehouse: 60 M2

Office: 40 M2






Total Budget
The total budget for purchasing the Melamine tableware manufacturing machines and equipments is about US$ 300,000 to 500,000, depending on the production capacity and the size of the tableware products.

Suppliers Information
Company Name: Han Chang Machinery Co., Ltd.
Address: 5F, No.45, Chung Shan N. RD. SEC.3, Taipei, Taiwan, R.O.C.
TEL:             886-2-25975301      
FAX: 886-2-25930672
E-mail: paitechf@ms5.hinet.net
http//: www.plasticscommerce.com/paitech/