Industry Overview
Plywood is a high-pressure bonded wood product made by laminating successive layers of wood veneer, generally with the grain direction of adjacent plies positioned at approximately 90 degrees to one another. Synthetic resin is commonly used as the laminating agent, producing a strong and stable composite material. Plywood is typically manufactured with an odd number of plies, which helps reduce the tendency to warp or split.
As a manufactured wood panel, plywood is available in a wide range of sizes and thicknesses. Unlike natural wood, engineered boards can be produced in substantially wider dimensions, making plywood particularly useful for construction and other applications requiring large, dimensionally stable panels. The report covers plywood sizes, yields, grades, water-resistant varieties, surface preparation, properties, standards, raw materials, market conditions, manufacturing processes, quality control, and related medium-density fibreboard (MDF) products.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 3000 Sq.ft./day |
| Land & Building (8000 Sq.MT) | Rs. 5.9 Cr |
| Plant & Machinery | Rs. 4.47 Cr |
| Working Capital for 2 Month | Rs. 5.95 Cr |
| Total Capital Investment | Rs. 15.93 Cr |
| Rate of Return | 44% |
| Break Even Point | 38% |
Content Index
- INTRODUCTION
- SIZES OF PLYWOOD
- YIELD
- CURRENT CONVENTIONAL MILL FINISHES
- SURFACE PREPARATION FOR WOOD AND ALLIED MATERIALS
- GRADES
- WATER PROOF PLYWOOD AND GRADES
- MR GRADE PLYWOOD
- BWR GRADE PLYWOOD
- BWP GRADE PLYWOOD
- IN MARKET THE AVAILABLE SIZES ARE AS FOLLOWS:
- PLYWOOD CLASSIFICATION AND GRADES
- SIZES
- PROTECT PLYWOOD FROM WATER DAMAGE
- USES AND APPLICATION
- USES OF PLYWOOD
- MEDIUM DENSITY FIBREBOARD
- BENDY MDF
- ULTRALITE MDF
- FIRE RETARDANT MDF
- MOISTURE RESISTANT MDF
- EXTIRA
- BEADBOARD
- SLATWALL
- GENERAL CHARACTERISTICS OF PLYWOOD
- PROPERTIES OF LAMINATE BOARD
- B.I.S. SPECIFICATION
- SPECIFICATION OF MEDIUM DENSITY FIBREBOARD
- FINISH
- DIMENSIONS & TOLERANCES
- THICKNESS
- WIDTH & LENGTH
- PHYSICAL & MECHANICAL REQUIREMENTS
- PHYSICAL AND MECHANICAL REQUIREMENTS OF MEDIUM DENSITY FIBREBOARDS
- RAW MATERIAL FOR PLYWOOD
- MARKET POSITION 37
- GROWTH DRIVERS AND CHALLENGES
- MAJOR INVESTMENTS CONTINUED IN EUROPE
- AFRICA IS A TRADITIONAL SUPPLIER OF ROUND WOOD
- RUSSIA' ECONOMIC SITUATION SLOWING INVESTMENTS
- GROWTH IN CHINA'S PLYWOOD PRODUCTION LEVELLING OUT
- DECREASED ORDERS IN ASIA-PACIFIC AREA
- GROWTH OPPORTUNITIES IN SOUTH AMERICA
- DECLINE IN NORTH AMERICAN PLYWOOD PRODUCTION
- MEDIUM DENSITY FIBREBOARD
- OVERVIEW OF TIMBER MARKET IN AFRICA
- CENTRAL AND WEST AFRICA
- SAWNWOOD VERSUS LOGS – IS SAWNWOOD GAINING IN CHINA & INDIA?
- CRACKDOWN ON ILLEGAL ACTIVITIES IN CAMEROON
- MERANTI HEAD-TO-HEAD WITH SAPELE IN NETHERLANDS
- GHANA
- WOOD TRACKING SYSTEM FIELD TESTED
- PRESIDENT - BUSINESSES WILL BE REVIVED
- NEW MINISTER ANNOUNCED
- BUSINESS LEADS EXPRESS OPTIMISM
- SOUTH AFRICA
- BUSINESSES BACK TO WORK MID-JANUARY
- WARNING ON STRUCTURAL TIMBER USAGE
- MANUFACTURERS/EXPORTERS
- PROCESSING OF PLYWOOD
- FELLING THE TREES
- PREPARING THE LOGS
- MAKING THE VENEER
- FORMING THE PLYWOOD SHEETS
- PROCESSING STEP IN VENEER MANUFACTURE
- THE STEPS INVOLVED IN VENEER MANUFACTURING ARE AS FOLLOWS:
- STEP 1 – LOG YARD:
- STEP 2 – DEBARKING:
- STEP 3 – SOAKING OF LOGS:
- STEP 4 – CUTTING THE LOGS:
- STEP 5 – PEELING:
- LET’S TAKE A LOOK AT EACH METHOD:
- (A) FLAT SLICING:
- (B) ROTARY CUT:
- (C) QUARTER SLICING:
- (D) RIFT SLICING:
- (E) HALF ROUND SLICING:
- STEP 6 – DRYING:
- STEP 7 – QUALITY CHECK:
- STEP 8 – CLIPPING:
- STEP 9 – SPLICING:
- STEP 10 – PACKING:
- STAGES IN VENEER BASED PRODUCT MANUFACTURING
- STAGE 1: VENEER MANUFACTURE
- GRADING, SORTING AND HANDLING LOGS
- DEBARKING, PRE-CONDITIONING AND ROUND-UP
- PEELING 74
- FIGURE: THE THREE STAGES OF PANEL MANUFACTURE. SOURCE: WALKER (2006), P.399.
- STAGE 2: VENEER CLIPPING, DRYING AND UPGRADING
- CLIPPING AND SORTING
- DRYING
- GRADING, PATCHING, JOINING, SORTING
- STAGE 3: PRODUCT LAY-UP, PRESSING AND FINISHING
- PRODUCT MANUFACTURE
- STORAGE
- PRESERVATION
- QUALITY CONTROL
- PROCESS FLOW SHEET OF VENEER
- THESE ARE
- A) PREPARATION OF LOGS
- B) VENEER MANUFACTURING
- PLYWOOD MANUFACTURING
- PREPARATION OF FACES
- PRESSING PLYWOOD
- SANDING
- TRIMMING
- STORAGE
- OUTLINE OF PLYWOOD MANUFACTURING PROCESS
- RAW MATERIAL:
- LOG YARD STOCK:
- LOG STORAGE:
- LOG CONDITIONING:
- LATHE:
- DRYERS:
- LAY- UP:
- PRE-PRESS:
- HOT PRESSING:
- TRIMMING PLYWOOD:
- SANDING, GRADING, AND REPAIRING PLYWOOD:
- TRADEMARKING:
- WAREHOUSE AND SHIPPING:
- “INSPECTOR IN THE MILL”:
- METHOD TO MAKE WATER PROOF PLYWOOD
- WATER ABSORPTION TEST FOR PLYWOOD
- PROCESS FLOW DIAGRAM OF PLYWOOD
- SEQUENCES IN MDF MANUFACTURING
- DEBARKING AND CHIPPING
- MAT FORMATION
- STORAGE
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF MDF
- PROCESS FLOW DIAGRAM OF MDF MANUFACTURE
- PROCESS DETAILS OF MEDIUM DENSITY FIBRE BOARD
- PREPARATION OF RAW MATERIALS
- FLAKES
- GRANULE
- SHAVING
- SPLINTER & SILVER
- FIBRE PREPARATION (DEFIBRATION) 103
- MAT FORMING
- PRESSING
- HEAT TREATMENT & HUMIDIFYING
- TRIMMING
- FINISHING
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF RAW MATERIALS
- ADDRESSES FOR CONSULTANT
- LIST OF MACHINERY
- 1. ROTARY PEELING LATHE MACHINE
- 2. SPINDLE LESS ROTARY PEELING LATHE
Appendix
- APPENDIX – A:
- 1. COST OF PLANT ECONOMICS
- 2. LAND & BUILDING
- 3. PLANT AND MACHINERY
- 4. FIXED CAPITAL INVESTMENT
- 5. RAW MATERIAL
- 6. SALARY AND WAGES
- 7. UTILITIES AND OVERHEADS
- 8. TOTAL WORKING CAPITAL
- 9. COST OF PRODUCTION
- 10. PROFITABILITY ANALYSIS
- 11. BREAK EVEN POINT
- 12. RESOURCES OF FINANCE
- 13. INTEREST CHART
- 14. DEPRECIATION CHART
- 15. CASH FLOW STATEMENT
- 16. PROJECTED BALANCE SHEET
Frequently Asked Questions
Plywood is a laminated wood panel made by bonding multiple wood veneers together with their grain directions arranged in alternating orientations. The manufacturing process generally involves log preparation, debarking, conditioning, peeling or slicing into veneers, drying, grading, clipping, splicing where required, adhesive application, lay-up, pressing, trimming, sanding, grading and finishing. Cross-lamination improves dimensional stability and helps reduce warping and splitting compared with individual pieces of natural wood.
The report covers MR grade, BWR grade and BWP grade plywood. These classifications are associated with different levels of resistance to moisture and water exposure and are selected according to the intended application. The report also discusses water-proof plywood, plywood classification and grades, sizes, surface preparation, properties and relevant specifications. Actual suitability should be determined from the applicable product specification and the environmental conditions in which the plywood will be used.
The principal raw material for plywood manufacturing is suitable timber from which veneers are produced. The process also requires an appropriate resin or adhesive system for bonding the veneer layers. Depending on the product and finishing requirements, additional materials may be required for repairs, surface treatment, finishing and packaging. Raw material selection directly influences veneer quality, panel properties, yield and the suitability of the finished plywood for its intended application.
The major veneer manufacturing steps include log yard handling, debarking, soaking or conditioning, cutting, peeling or slicing, drying, quality checking, clipping, splicing and packing. Different cutting methods such as flat slicing, rotary cutting, quarter slicing, rift slicing and half-round slicing can produce veneers with different grain patterns and characteristics. Proper conditioning and drying are important for obtaining veneers with suitable moisture content, dimensions and quality for subsequent plywood manufacture.
Plywood manufacturing requires machinery for log preparation, veneer production, drying, lay-up, pressing, trimming, sanding and finishing. The report specifically includes a rotary peeling lathe machine and a spindle less rotary peeling lathe in its machinery list. Other process equipment supports operations such as log conditioning, veneer drying, adhesive application, pre-pressing, hot pressing, panel trimming, sanding, grading and repair. Equipment selection depends on production requirements, veneer dimensions, product specifications and the desired level of automation.
Quality control ensures that plywood consistently meets the required physical, mechanical, dimensional and moisture-resistance characteristics. Inspection can be carried out at several stages, including log selection, veneer production, drying, grading, lay-up, pressing, trimming and finishing. The report also includes a water absorption test for plywood and discusses quality control within veneer-based product manufacturing. Consistent process control helps reduce defects, improve product reliability and maintain conformity with applicable specifications.
MDF manufacturing uses wood fibres rather than cross-laminated veneers to form a homogeneous fibreboard panel. The report describes MDF operations including debarking and chipping, raw material preparation, fibre preparation or defibration, mat formation, pressing, heat treatment and humidifying, trimming and finishing. Plywood, in contrast, is produced by assembling and bonding individual veneers in successive layers. The two engineered wood products therefore differ in raw material form, panel structure and manufacturing sequence while both provide alternatives to solid wood for a range of applications.
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