COMMERCIAL MANUFACTURING INITIATIVE · Q-323-R.0

High-Speed Ampoule Oven Printing Facility
Sea Melody YZG Line

Turnkey industrial contract printing plant utilizing Sea Melody YZG continuous horizontal screen printing & 580°C solid glaze sintering technology for Popular Group of Companies.

🛰️ Explore 3D Digital Twin 📊 Dynamic Production & ROI Simulator 📄 Download Q-323-R.0 Proposal PDF
18,000BPH
Output Speed per Line (1–2ml)
600,000/Day
Startup Output (5 Phase 1 Lines)
PKR 52.23M
Initial Core Capital Outlay
12.9Mo
Sponsor Equity Payback Period
WEBGL 3D DIGITAL TWIN · EQUIPMENT & PLANT SIMULATION

Interactive YZG Machine & 10-Line Facility

Rotate, zoom, and inspect the continuous horizontal rotary screen printer, 580°C solid glaze sintering tunnel, upright exit station, and 350 kWp rooftop solar PV canopy.

LIVE 3D DIGITAL TWIN Sea Melody YZG Printing Line
10-Line Commercial Ampoule Printing Facility
Turnkey Plant Layout (1,200,000 Units/Day)
5 active startup lines (Phase 1) with self-funded expansion slots for 5 additional lines (Phase 2), integrated rooftop solar, and quality inspection staging.
🖱️ Drag to Orbit · Scroll to Zoom · Right Click to Pan
🏛️US FDA 21 CFR Part 11 Traceability
🛡️EU cGMP Annex 1 Compliance
🌐WHO TRS 961 Sterile Standards
🔥580°C Solid Ceramic Glaze Sintering
🧪100% Autoclave & Chemical Proof
⚙️ISO 9001:2015 Precision Tooling
🏛️US FDA 21 CFR Part 11 Traceability
🛡️EU cGMP Annex 1 Compliance
🌐WHO TRS 961 Sterile Standards
🔥580°C Solid Ceramic Glaze Sintering
🧪100% Autoclave & Chemical Proof
⚙️ISO 9001:2015 Precision Tooling
🏭Surge Laboratories (Installed Reference)
🏭Pharmed Glass (Installed Reference)
🏭Ameer & Adnan (Installed Reference)
🏭ATM Glass (Installed Reference)
🏭Venus Pharma (Installed Reference)
⚡Siemens S7-1500 PLC & Inverter Drives
🏭Surge Laboratories (Installed Reference)
🏭Pharmed Glass (Installed Reference)
🏭Ameer & Adnan (Installed Reference)
🏭ATM Glass (Installed Reference)
🏭Venus Pharma (Installed Reference)
⚡Siemens S7-1500 PLC & Inverter Drives
DYNAMIC SIMULATION & FACILITY PARAMETERS

Operational Modeling & Unit Economics

Interactive economic calculator evaluating contract printing unit revenue, operating costs, solar offset benefits, and sponsor equity payback across 1ml to 20ml formats.

LIVE REVENUE & CASH FLOW CALCULATOR

Contract Printing Payback Simulator

300 WORKING DAYS / YEAR
5 Machine Lines
2ml Ampoule (18,000 BPH)
PKR 0.65 / ampoule
2 Shifts (16h)
Daily Processed Units
1,180,800
Ampoules / Day (Net 82% OEE)
Annual Throughput
354.2M
Million Units / Year
Monthly Gross Revenue
PKR 19.95M
PKR Million / Month
Monthly Operating Costs
PKR 11.04M
Glaze + Power + Labor + Rent
Monthly Operating EBITDA
PKR 8.91M
Net monthly cash surplus after all expenses
Projected Capital Payback
5.9 Mo
Rapid sponsor equity payback horizon
ENGINEERING BENCHMARK

Sea Melody YZG Line Specs

High-precision continuous rotary printing line with integrated glaze sintering tunnel.

1–2ml Ampoule Output 18,000 BPH
3–5ml Ampoule Output 10,000 BPH
20ml Ampoule Output 4,000 BPH
Sintering Oven Temp 580°C Ceramic Fusion
Heating Connected Load 15 kW per Line
Applicable Diameters Ø10 mm to Ø32 mm
STRATEGIC EXPANSION

Phase 1 Startup & Phase 2 Self-Funded Scaling

Zero additional equity required after initial installation. Operating cash flow finances all 5 expansion lines and additional solar.

Phase 1: Initial Core
5 Lines Startup
600,000 units/day · 350 kWp Solar · PKR 52.23M Outlay
Phase 2: Self-Funded
10 Lines Total
1.2M units/day · Expansion funded M12–M24 from profit
Expansion sequence installs 1 machine + 70 kWp solar in Months 12, 15, 18, 21, and 24, fully amortized from operating cash flow while retaining a 1-month liquid cash cushion.
FACILITY LOGISTICS

Shed Siting & 350 kWp Rooftop Solar

Designed for installation in an industrial rented shed (PKR 0.60M/month lease), eliminating expensive civil construction overheads.

☀️
350 kWp On-Grid Solar Array:

Offsets 100% of daytime heating and conveyor drive power, saving ~PKR 2.45M monthly compared to full grid tariffs.

⚡
Night & Backup Power Strategy:

Second shift runs on industrial WAPDA connection (PKR 70/kWh) backed by dual diesel generators ensuring continuous uptime.

OFFICIAL QUOTATION Q-323-R.0

Equipment Bill of Quantities (EXW China)

Direct OEM factory pricing for the Sea Melody YZG continuous horizontal screen printing line including format tooling and feeding stations.

Item / Component Specification & Performance Qty Unit Cost (USD) Total Value (USD)
YZG Main Machine Continuous horizontal rotary screen printer with 1× 2ml chain guide & 580°C high-temp sintering tunnel 1 Pc $16,500 $16,500
Standing Exit Station Automated upright ampoule discharge starwheel collector & accumulator tray 1 Pc $1,200 $1,200
Standing Feeding Station Motorized upright infeed hopper with continuous orientation bucket elevator 1 Pc $1,200 $1,200
Feeding Tray (1ml) Precision quick-change format tray for 1ml glass ampoules 1 Pc $150 $150
Extra Conveyor Chain (1ml) High-tensile heat-resistant conveyor chain for 1ml ampoules 1 Pc $1,400 $1,400
TOTAL CORE EQUIPMENT EXW CHINA (Q-323-R.0) USD 20,450
Optional: Dual Ring Printers In-line double identification ring marking applicator for ampoule neck coding 1 Pc $2,500 $2,500
AUTOCAD VECTOR LAYOUTS

Machine Elevation & 10-Line Plant Floor Plan

Mechanical side elevation for the Sea Melody YZG printer and validated industrial shed floor plan housing all 10 machine lines.

YZG Machine Mechanical Elevation

Vector SVG · NTS

Side view showing infeed hopper, printing screen carriage, heating tunnel, and exit collector.

10-Line Facility Floor Plan

Phase 1 & Phase 2 Layout

Optimized linear floor plan in industrial rented shed with raw glass infeed, packing, and solar routing.

TECHNICAL DIMENSIONAL SUITE

Standardized Glass Ampoule Formats

Engineering drawings and constriction profiles for 1ml, 2ml, 3ml, and 5ml pharmaceutical glass ampoules supported on the YZG line.

1ml Glass Ampoule Drawing

1ml Glass Ampoule

Overall height, stem diameter, and neck constriction profile for high-speed automated feeding.

2ml Glass Ampoule Drawing

2ml Glass Ampoule

Standard pharmaceutical high-volume format with 18,000 bottles/hr continuous printing chain.

3ml Glass Ampoule Drawing

3ml Glass Ampoule

Precision glaze transfer profile with single and double identification color bands.

5ml Glass Ampoule Drawing

5ml Glass Ampoule

Large-format ampoule specifications with 10,000 bottles/hr continuous sintering cycle.

FINANCIAL MODEL & BANKABILITY

Commercial Feasibility & Bank Financing Structure

Validated 48-month cash flow and 60-month bank financing analysis. Evaluates contract printing unit economics (PKR 0.50 vs PKR 0.65 per ampoule) and self-funded expansion capability.

Commercial & Financial Metric Scenario 1 (PKR 0.65 / ampoule) Scenario 2 (PKR 0.50 / ampoule) Bank Financing Case (PKR 0.55 / ampoule)
Client Payment Tariff PKR 0.65 per accepted ampoule PKR 0.50 per accepted ampoule PKR 0.55 per accepted ampoule
Annual Processed Volume 180.0 Million units 180.0 Million units 180.0 Million units
Annual Gross Revenue PKR 113.49 Million PKR 90.00 Million PKR 98.01 Million
Annual Operating Costs PKR 64.98 Million PKR 64.98 Million PKR 65.04 Million
Annual Operating Profit PKR 48.51 Million (42.7%) PKR 25.02 Million (27.8%) PKR 32.97 Million (33.6%)
Initial Core Capital Outlay PKR 52.23 Million (100% Equity) PKR 52.23 Million (100% Equity) PKR 52.23M (Bank: 35M / Equity: 17.23M)
Monthly Loan Instalment (60 Mo @ 14%) — — PKR 0.814 Million / month
Debt Service Coverage Ratio (DSCR) — — 3.38x (Expanding to 7.75x)
Sponsor Equity Payback Period 12.9 Months 25.1 Months 20 Months
EXECUTIVE VAULT

Official Proposals & Financial Models

Download the complete BTI quotation Q-323-R.0, verified 48-month & 60-month cash flow models, and bank financing summary packages.

Official Proposal Q-323-R.0

YZG Ampoules Oven Printing Machine budget proposal for Popular Group.

📄 Download Q-323-R.0 PDF

Bank Financing Summary

60-month loan structure, debt service coverage, and equity payback.

📄 Bank Summary PDF

60-Month Bank Cash Flow

Month-by-month financial projection including loan amortization waterfall.

📄 60-Month Cash Flow PDF

Financial Model (Excel)

Validated workbook with dynamic tariff sensitivities and expansion formulas.

📊 Download Excel Model
Sea Melody YZG Printing Line
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