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.

1. 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.

1. 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.

2. 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.

1. 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.

1. 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.

1. 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.

3. 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.

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.

1. 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:

1. 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.

1. 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.

1. 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.

1. 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.

3. 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.

4. 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
3. Core Management & Technical Dept

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

1. Production Dept - Two Shifts

Calculated for 25 Days/Month, 22 Hours/Day.

1. Quality Assurance Dept (QA)

High-Tg products demand extremely high standards for testing equipment.

1. Facility & Maintenance Dept

Ensures safety of high-temperature & high-pressure equipment.

1. 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)

1. 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

1. 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.
2. 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".

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.

1. 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).

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.

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".

4. Summary & Analysis

5. 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 1.05 Billion.
• 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.