FLUSH DOOR AND WPC DOOR FRAME
[EIRI/EDPR/4618] J.C.: 2835XL
Flush doors are also a kind of block board which is used to make door panel and differ in sizes according to the size of door. For many years, Flush Doors' style and elegance have been making people an obvious choice for countless homes. While giving an exceptionally long service to your home they accentuate the beauty of your home.
In India few are manufacturing doors as per Indian Standards. A solid core wooden flush door consists of a block board core bounded with cross band and veneer faces constructed on both the sides.
Wood–plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220°C; thus, general-purpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood–plastic composites are boards or lumber used in outdoor decking applications.
COST ESTIMATION
Plant Capacity 200 Nos./Day
Land & Building (4000 sq.mt.) Rs. 6.75 Cr
Plant & Machinery Rs. 2.37 Cr
Working Capital for 2 Months Rs. 4.63 Cr
Total Capital Investment Rs. 14.06 Cr
Rate of Return 16%
Break Even Point 71%
CONTENTS
INTRODUCTION
USES AND APPLICATION OF FLUSH DOOR
FLUSH DOORS CAN BE CATEGORIZED AS FOLLOWS
COMPONENTS OF A FLUSH DOOR
1. WOODEN OUTER/INNER FRAME.
2. TOP & BOTTOM FACE - MDF/PLYWOOD/SKIN
3. FILLER MATERIAL:
A) MAIN ENTRANCE FLUSH DOORS:
B) INTERNAL PARTITION DOORS:
ADVANTAGE OF PVC/WPC DOOR FRAME
USES & APPLICATIONS OF WPC
FIGURE: EXAMPLES OF WOOD-PLASTIC COMPOSITES (WPCS)
OUTDOOR APPLICATION OF WPC
RAW MATERIALS
WOOD
PARTICLE GEOMETRY
MOISTURE CONTENT:
ADDITIVES
POLYMERS
FIGURE: TRENDS IN THE POLYMER PROPERTIES OF THERMOPLASTICS AS A FUNCTION OF TEMPERATURE, T.
FIGURE: TYPICAL ROOM TEMPERATURE PROPERTIES OF COMMON POLYMERS
WOOD
B.I.S. SPECIFICATION
ADVANTAGE AND DISADVANTAGE OF WPC
PROPERTIES OF WPC
MECHANICAL PROPERTIES OF TYPICAL WOOD PLASTIC COMPOSITE
ADVANCE MATERIALS FOR WPC
WOOD MODIFICATION
ADDITIVES
PROFILES
ASPECT OF WPC DURABILITY
STRUCTURAL
WEATHERING STUDIES
TECHNOLOGY FOR MAKING FLUSH DOOR
TECHNICAL DETAILS:
CUSTOMERS' CHOICE:
CORE:
FRAMES:
ASSEMBLY:
CUSTOMERS' CHOICE:
VISON PANELS AND LOUVERS:
PLASTIC COATING:
SPECIAL SHAPES:
ARCHITECTURAL DOOR SPECIFICATIONS
FLUSH DOORS
MATERIALS:
CONSTRUCTION:
FACTORY FINISHING:
MANUFACTURING PROCESS OF FLUSH DOOR
PROCESS FLOW DIAGRAM FOR FLUSH DOOR
MANUFACTURING PROCESS OF WOODEN PANEL DOOR
PROCESS FLOW DIAGRAM FOR WOODEN PANEL DOOR
PROCESS OUTLINE OF FLUSH DOOR MAKING
FLOW PROCESS
PROCESSING DETAILS OF DOOR MANUFACTURING
COMPONENTS IN A DOOR
CORE
STILE AND RAIL
CROSS BAND
VENEER
WORKFLOW OF MANUFACTURING A DOOR
FIGURE: WORKFLOW OF DOOR MANUFACTURING
INCOMING OF MATERIALS
MATERIAL QUALITY CHECKING
MANUFACTURING OF DOOR FRAME
CORE BOARD MANUFACTURING AND ASSEMBLING TO THE FRAME
TUBULAR BOARD SIDE VIEW AND TUBULAR BOARD
FIGURE: THERMO COMPRESSOR
CUTTING AND CURVING
FIGURE: HOMAG MACHINING CENTER FOR WOODWORKING EQUIPPED WITH VACUUMING SYSTEM
SANDING AND CLEANING
FIGURE:. THREE BELT SANDER WITH VACUUMING SYSTEM.
LAMINATION OF FACE VENEER
LIPPING
FIGURE: EDGE BANDING.
MAIN PRODUCTION STEPS IN WPC MANUFACTURE
EXTRUSION MANUFACTURING PROCESS OF WOOD PLASTIC COMPOSITE
DIFFERENT TYPES OF WOOD COMPOSITE PRODUCTS
APPLICATION OF WOOD PLASTIC COMPOSITES AS DECKING
A TYPICAL PRODUCTION FLOWCHART OF WOOD PLASTIC COMPOSITE
COMPOUNDED FORMULATION OF WPC DOOR FRAME
FORMULATION OF WPC
FIGURE POLYETHYLENE (PE) – BASED COMPOSITE
MANUFACTURING TECHNIQUE FOR WPC
COMPOUNDING:
FORMING:
DIFFERENT PROCESSES FOR PLASTIC COMPOSITES
EXTRUSION PROCESSING
SINGLE-SCREW EXTRUDER
COUNTER-ROTATING TWIN-SCREW EXTRUSION
COMPOSITE SYSTEM
MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS
MARKET OVERVIEW OF WPC
INDIA WOOD PLASTIC COMPOSITES MARKET TRENDS:
GLOBAL MARKET OF WPC
WPC PLASTIC COMPOSITE MARKET 2020-2027
FUTURE TRENDS IN WOOD PLASTIC COMPOSITE
PRESENT MANUFACTURERS OF WOOD PLASTIC COMPOSITE
MARKET OF FLUSH DOOR
MARKET SEGMENTATION:
KEY INSIGHTS
FURNITURE MARKET IN INDIA
INDIA VERSUS THE WORLD
MAJOR COMPETITORS AND SCOPE OF GROWTH
CHALLENGES THAT INDIA FACES IN THE GLOBAL MARKET
FINAL WORD
ANALYSIS OF WOOD FURNITURE MARKET
PRESENT MANUFACTURERS OF FLUSH DOORS
RICE HUSKS PLASTICS COMPOSITE AND IT’S ADVANTAGE
WORKING WITH RH-PVC COMPOSITE MATERIALS
HOW RH-PVC PRODUCTS CAN BE CUSTOMIZED FOR VALUE ADDITION?
THE ABOVE PROCESSES ARE EXPLAINED IN BRIEF BELOW
A) FORMULATING RH-PVCS FOR SPECIFIC PERFORMANCE REQUIREMENTS
(I) FOAMING TO PRODUCE A CELLULAR MATERIAL
FOAMING OF RH-PVC PROVIDES OTHER ADVANTAGES BESIDES WEIGHT REDUCTION
(II) COUPLING FOR STRENGTH
(III) COLORANTS FOR WOOD-LIKE APPEARANCE
(IV) LUBRICANTS FOR HIGH THROUGHPUT
(V) COMBATING WEATHERING, COLOR FADING, MOLD & AMP; MILDEW
(VI) FLAME RETARDANT & MINERAL FILLERS
B) PHYSICAL PROCESSES FOR SURFACE MODIFICATIONS
C) CO-EXTRUDING A CAP LAYER
D) SURFACE LAMINATION, COATING AND PRINTING
ADVANTAGE OF FOAMED RH PVC PRODUCTS OVER SOLID RH PVC
FIGURE 1
FIGURE 2
PROCESS FLOW DIAGRAM FOR PLASTIC COMPOSITE
THE WPC (PLASTIC COMPOSITE) MANUFACTURING PROCESS WITH EXTRUSION FORMING
TABLE 2.0: FUNCTIONS OF ADDITIVES USED IN THERMOPLASTIC COMPOSITES
PROCESS DESCRIPTION OF WPC USING RICE HUSK
A PRE-PROCESSING
B EXTRUSION AND FORMING THE END PRODUCT
C POST PROCESSING
PRODUCTION PROCESS FLOWCHART
TYPICAL RH-PVC DOOR FRAME PRODUCTION PROCESS
FIGURE 01
TYPICAL TWO STEP MANUFACTURING PROCESS
FIGURE 02
TYPICAL IN-LINE MANUFACTURING PROCESS
TYPICAL RICE-HUSK PLASTIC COMPOSITE PRODUCTION EQUIPMENT
TYPES OF EXTRUDERS USED IN RH-PVC PRODUCTION
FIGURE 03
FIGURE 04
ADVANTAGES OF TWIN-SCREW EXTRUDER VERSUS SINGLE SCREW EXTRUDER
ADVANTAGES OF CONICAL TWIN SCREW EXTRUDER
DETAILS OF ADDITIVE
POLLUTION CONTROL NORMS AND ENVIRONMENTAL IMPACT
MANUFACTURING PROCESS OF WPC
EXTRUSION PROCESSING
SINGLE-SCREW EXTRUDER
COUNTER-ROTATING TWIN-SCREW EXTRUSION
CO-ROTATING TWIN-SCREW AND HOT MELT SINGLE-SCREW WOOD COMPOSITE SYSTEM
WOOD TRUDER
MISCELLANEOUS POST-EXTRUDER UNIT OPERATIONS
INJECTION MOLDING
COMPRESSION MOLDING OR THERMOFORMING
CODES AND STANDARD
INDICATIVE PROPERTIES OF GENERIC RH-PVC COMPOSITE
TECHNICAL/TURNKEY CONSULTANT FOR SETTING UP WPC PLANT
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS FOR FLUSH DOOR
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS FOR WPC
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)
SUPPLIERS OF BOILER
SUPPLIERS OF GENERATOR SET (D.G. SET)
SUPPLIERS OF EXTRUDERS
SUPPLIERS OF PRESSING MACHINE
SUPPLIERS OF COOLING TOWERS
SUPPLIERS OF GENERATOR SET (D.G. SET)
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF RICE HUSK
SUPPLIERS OF PLASTIC POLYMERS
SUPPLIERS OF COUPLING AGENT
SUPPLIERS OF ADDITIVES
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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