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VIVA's Plant at a Glance
- Location
- Umbergaon, Gujarat, India
- Capacity
- Over 15 million sq.m a year
- Production lines
- 15+ lines, including 8 ACP lines up to 1670mm wide
- Colour coating
- 5 colour coating lines, a first in India
- Quality testing
- 250+ tests in in-house labs
- Manufacturing since
- 2003, 23+ years
- Certifications
- ISO 9001, ISO 14001, EN 13501-1, Thomas Bell-Wright
- Green ratings
- EPD, IGBC, GRIHA, Green Eco Label
Asia's Largest ACP Manufacturer, Made in India
VIVA Composite Panel Pvt. Ltd. is Asia's largest aluminium composite panel (ACP) manufacturer. Everything is made at our own plant in Umbergaon, Gujarat, which runs 15+ production lines and 5 colour coating lines with a combined capacity of over 15 million sq.m a year. We started in Mumbai in 2003 and have been making ACP for more than 23 years.
Over the years, the plant has brought several firsts to India, including India's first Aluminium Corrugated Core Panels (ACCP), the first A1 fire-rated honeycomb panels, pre-coated ready-to-install solid aluminium panels, and a range of Natural Stone shades.
Because paint mixing, coating and lamination all happen under one roof, we can offer 500+ colour options in solid, metallic, wood, marble and stone finishes, and match custom RAL or Pantone shades for your project.
How VIVA Makes Aluminium Composite Panels
A good panel starts with good raw material. Our aluminium coils come from Hindalco in 1100, 3000 and 5000 series alloys, the core is bonded with DuPont adhesive film, and our paints come from suppliers such as Nippon, AkzoNobel, PPG-Asian Paints, JSW, Berger Becker and Spectrum.
The lines themselves use Korean precision lamination technology. Every stage, from coil cleaning to final packing, is checked in our in-house labs, and each panel type goes through 250+ quality tests before it leaves the plant.
ACP Production Lines
Production Line Overview
01FR and Non-FR Production Lines
Eight dedicated lines make both fire-rated and standard ACP, in widths up to 1670mm.
02FR Class B Production Line
Panels with a core of 70% mineral and 30% polyethylene, classified B-s1,d0 under EN 13501-1.
03FR Class A2 Production Line
Panels with a core of 90% mineral and 10% polyethylene, for projects that need a higher fire rating.
04FR Class A2+ Production Line (ACCP)
VIVA was the first in India to set up A2 core production lines. FR A2+ ACCP (Aluminium Corrugated Core Panel) uses a 100% aluminium corrugated core with no polyethylene, sandwiched between two aluminium skins. It is non-combustible (A2-s1,d0) and certified by Thomas Bell-Wright, Dubai.
Pre-Treatment Line
Aluminium coils are fully cleaned before coating so the paint bonds properly. On our 4-foot line, pre-treatment and coating run in one continuous process.
Colour Coating Lines
VIVA runs 5 colour coating lines, the first ACP brand in India to do so, handling coils from 1000mm to 1670mm wide. The 5-foot line is a three-coat, three-bake line, which gives the panels their depth of colour and finish.
Bonding Line
The core is bonded to the aluminium skins with adhesive applied through high-pressure rollers for even coverage. The sheets then pass through cooling towers to set before cutting.
PVDF and FEVE Coating
Exterior panels are finished in polyvinylidene fluoride (PVDF), a high-performance fluorocarbon resin, using 70% KYNAR 500, or in FEVE (fluoroethylene vinyl ether). Each of the three coats is baked at 240 degrees Celsius for about 45 seconds and checked for proper drying before the next. A protective film is added before the sheets are packed and shipped.
Colour Coating Process
-
Pre-Treatment
The aluminium coil is cleaned so the paint grips well and the finish looks even. -
Chromatizing
A passivation layer is added to protect against oxidation and strengthen paint bonding. -
Coater
Liquid paint is applied with mirror-finished rollers for a smooth, uniform coat. -
Ovens
The paint is dried and baked on the coil. -
Finishes can be glossy, matte or rustic, depending on the look you want.
In-House Paint Mixing and Shade Development
Most of the shades on our coating lines are mixed in-house, using resins, tinters, metallic slurries, micas and additives. A dedicated lab develops new shades to RAL, Pantone, CMYK and other international references, and creates pattern finishes like wood, marble and stone. This is how we keep 500+ shades in the range and can match a custom colour for a project.
VIVA's Firsts in India
- First with pre-coated, ready-to-install solid aluminium panels (Solid X)
- First with A1 fire-rated honeycomb panels
- First with A2 core production lines and Thomas Bell-Wright certified FR A2+ ACCP
- First ACP brand with 5 colour coating lines
- First ACP brand with EPD, IGBC, GRIHA and Green Eco Label certifications
- First ACP brand with 100+ experience centres
Take a 3D Tour of the Plant
Walk through VIVA's factory from your screen. Move between the production floor, coating lines and storage areas in this interactive 3D tour.
Certifications
Frequently Asked Questions
Where is VIVA ACP manufactured?
VIVA ACP is made in India at our own plant in Umbergaon, Gujarat. The head office is in Andheri East, Mumbai.
What is the production capacity of VIVA ACP?
The Umbergaon plant has a capacity of over 15 million sq.m a year, across 15+ production lines and 5 colour coating lines. This makes VIVA the largest ACP manufacturer in Asia.
Does VIVA make its own colours?
Yes. Most shades are mixed in our in-house paint unit and developed in our own lab. We offer 500+ shades and can match custom RAL or Pantone colours.
How is VIVA ACP tested for quality?
Each panel type goes through 250+ quality tests in our in-house labs. Manufacturing is ISO 9001:2015 and ISO 14001:2015 certified, and fire-rated panels are also tested by independent labs.
Can I visit the VIVA factory?
Yes, factory visits can be arranged for architects, developers and project teams. You can also take a 3D tour of the plant on this page, or call 1800-313-3770 to plan a visit.
Plan a Factory Visit or Get a Quote
See how your panels are made, or get samples and a project quote. Call 1800-313-3770 or send us an enquiry.
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