It really depends on how many kinds of metal ceiling you wanna to do.
Usually, the very normal and popular metal ceiling (aluminum ceiling) as below:
- Clip in 600*600
- Lay in 585*585
- Linear (84R, 100C, 150C, 200G, 300S)
- Baffle (B20, B25, B30, U20-200)
- Open cell (10, 15, 20, 30mm width)
- Channel for above ceiling tiles
At the beginning, considering about budget, you really no need to purchase all the related machine lines for above mentioned metal ceiling (aluminum ceiling). It’s better go to check your market to see which one is hot selling, you can shoot it firstly. After biting the first sweet cake, then consider exploding different machines step by step. If you want to be a successful business man but with limited resources and support, then you should read the following info carefully, there will bring you much benefits from it since I am writing you the business secret for metal ceiling industry but not too much people will to talk.
For starting up a metal ceiling factory, you need to think about a right place, i.e.: workshop +office +warehouse
Workshop area
About 200m2 (2152sq.ft) as the most of each machine line size is around 1m (width) by 12m (length) or 1.5m (width) by 3m (length)
Office area
About 30m2 (322sq.ft) for 2-3 desk sitting
Warehouse area
Two sections in the warehouse, one is for material storing, the other one is for finished goods like ceiling tile storing. The total area need about 300m2 (3229sq.ft).
If your business is mainly working with local dealer, the bigger warehouse is better for you, like 200m2 to 500m2 or more; If your business is build to order (produce after getting the order), the warehouse area requires not too much, but you need to take care of the delivery time.
Speaking to the material, there will be the aluminum coil (pre-painted aluminum coil or GI), or square size aluminum sheet which is for clip in and lay in sheet production stored at your warehouse.
In conclusion, for the space cost, it’s about US$:1200 per month, and if you wanna do some construction or decoration, that will be extra charge surely.
For starting up a metal ceiling factory, you need to think about a team to start working.
What you need is at least 4-5 operators, one engineer for running the machine and solving the basic problem. 2 persons for packaging and delivery, 1 worker for the daily order processing, also you need 2 salesmen surely. So the total at least 10 workers to start running your factory.
As for the salary, it depends on your local economic status. Generally, the average cost is at: US$450 *10=US$4500/month, for your reference.
After running factory, your other management cost also need to be calculated, such as water, electricity, office supplies: computer, telephone, catalogue, website, etc. The general cost is at: UD$800/month.
For starting up a metal ceiling factory, the main cost you need to think about is for purchasing machines.
1. Machine for Clip in /Lay in.
As clip in and lay in ceiling tiles can be produced by the same machine. So you just need to change the mold (clip in or lay in), that would be fine. What you need is one 40T hydraulic + one 120T hydraulic +four mold.
Cost for below:
40T hydraulic is for cutting the four corner, cost: US$7500
120T hydraulic is for forming shape, cost: US$15000
Four mold:
Mold for cutting corner- clip in, cost: US$3200
Mold for forming shape- clip in, cost: US$6500
Mold for cutting corner- Lay in, cost: US$3200
Mold for forming shape- Lay in, cost: US$6500
Machine for triangle channel and T bar would be extra.
2. Machine for Linear.
Machine for linear is roll forming machine line. It includes one decoiler + one roll form machine + collection parts, cost is vary based on the width of your ceiling tile.
Below cost is for common one, for your reference.
84R: US$11300
100C: US$14500
150C: US$16200
200G: US$17800
300S: US$28000 (with end bending)
3. Machine for Baffle
Machine for baffle ceiling is higher cost compared with linear. But this machine can do much more kinds of width and height to meet different requirement. The new tech can achieve: width 20-200mm, height 20-200mm for various combinations. That’s why we combine the B20,25,30 and U 20,30, 200 together.
Baffle ceiling machine cost: US$48500
4. Machine for Open cell
Machine for open cell ceiling is also a roll forming machine line. This line is made up of one decoiler+punching machine+straightener +feeder+transport +roll forming machine +collection (mold extra)
We also supply the newest tech machine which can vary width and height automatically .
Width spec: 10 15 20 25 30mm height spec: from 30 to 80mm
Open cell machine line: US$48500 auto change width and height
Open cell machine line: US$21000 manually
5. Machine for channel line
If all your channel is same width say 200mm, then you can use one roll forming machine line for producing several kinds of channel, like U channel, C channel, 84R channel, G channel, 300S channel, etc. The only you need to do is to change the mold.
Roll forming machine line: US$25000usd
Mold cost: US$650/set
84R mold: US$1300/set
That’s most of ceiling machines I have mentioned, based on above cost, I think you can choose the right machine which is most suitable for you.
For your starting factory, the total purchasing machine cost can be set budget at: US$120000.
Similar projects in other countries:
June, 2015, India
Factory scale: one 40T hydraulic + one 120T hydraulic + four mold + one 84R linear + one baffle ceiling +one channel line
June, 2016, Pakistan
Factory scale: one 40T hydraulic + one 120T hydraulic +four mold +one 84R linear + one baffle ceiling +one channel line
Mar, 2017, Vietnam
Factory scale: one 40T hydraulic + one 120T hydraulic +two mold ( clip in only) +one 84R linear + one baffle ceiling +one channel line + one 100C linear +one 150C linear )
For starting up a metal ceiling factory, don’t forget to think about the material stock
At the beginning, suggest to prepare 5 ton aluminum coil stock for manufacturing baffle or linear ceiling, 2000m2 aluminum sheets and some GI coil.
Total material cost about: US$35000
For starting up a metal ceiling factory, if possible, it’s better to make a showroom for showing your products to clients, and it’s helpful to do marketing there.
For the showroom cost, also depending on the size and design effect to achieve, but average cost can be at about: US$6500.
So based on above we talked, it’s easy to calculate out your start up budget for setting up a factory: $1200+$4500+$800+$120000+$35000+$6500=$168000
And plus 5 month capital turnover: $100000
Your total amount would be $268000 to start up this new factory.
OK, there the most important question you may ask is when I can get my $268000 invest money back or when my factory start to make profit. Following is the basic info for your reference.
Metal ceiling cost: $5.35/m2
Market price : $6.35/m2
You can get $1/m2 profit
For your invested money, 200000/1=200000m2
Assume one day can produce 2000m2
Need 200000/2000=100days to make it.
Generally, one building material shop every month can sell 6000-8000m2
So if your market is good, your invest cycle would be 4-5 month. If market slow, let us say 1 year, should be fine.
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