Detailed Project Report (DPR) on plywood and plyboards

PLYWOOD AND PLYBOARDS

[EIRI/EDPR/1210] J.C.: 9861

INTRODUCTION

Plywood is made of three or more thin layers of wood bonded together with an adhesive. Each layer of wood, or ply, is usually oriented with its grain running at right angles to the adjacent layer in order to reduce the shrinkage and improve the strength of the finished piece. Most plywood is pressed into large, flat sheets used in building construction. Other plywood pieces may be formed into simple or compound curves for use in furniture, boats, and aircraft.

The use of thin layers of wood as a means of construction dates to approximately 1500 B.C. when Egyptian craftsmen bonded thin pieces of dark ebony wood to the exterior of a cedar casket found in the tomb of King Tut-Ankh-Amon. This technique was later used by the Greeks and Romans to produce fine furniture and other decorative objects. In the 1600s, the art of decorating furniture with thin pieces of wood became known as veneering, and the pieces themselves became known as veneers.

Until the late 1700s, the pieces of veneer were cut entirely by hand. In 1797, Englishman Sir Samuel Bentham applied for patents covering several machines to produce veneers. In his patent applications, he described the concept of laminating several layers of veneer with glue to form a thicker piece—the first description of what we now call plywood.

Despite this development, it took almost another hundred years before laminated veneers found any commercial uses outside of the furniture industry. In about 1890, laminated woods were first used to build doors. As the demand grew, several companies began producing sheets of multiple-ply laminated wood, not only for doors, but also for use in railroad cars, busses, and airplanes. Despite this increased usage, the concept of using "pasted woods," as some craftsmen sarcastically called them, generated a negative image for the product. To counter this image, the laminated wood manufacturers met and finally settled on the term "plywood" to describe the new material.

COST ESTIMATION

Plant Capacity            145 sq.ft./Day  

Land & Building (6000 sq.mt.)    Rs. 3.60 Cr    

Plant & Machinery                    Rs. 1.33 Cr 

Working Capital for 1 Month    Rs. 49.68 Lac 

Total Capital Investment          Rs. 5.57 Cr 

Rate of Return                          20%

Break Even Point                      63%

CONTENTS

INTRODUCTION

STRUCTURAL BOARDS

SIZES OF PLYWOOD

USES AND APPLICATION

GENERAL CHARACTERISTICS OF PLYWOOD

SURFACE TREATMENTS

PROPERTIES & CHARACTERISTIES

PHENOL BOARD

B I S SPECIFICATION

MARKET SURVEY

PRODUCTION OF PLYWOOD

DIRECTION OF EXPORT

DEMAND OF PLYWOOD

FACTORS RESPONSIBLE FOR DEMAND OF PLYWOOD

APPARENT CONSUMPTION OF PLYWOOD

BOILING WATER RESISTANT (BWR SEMI-EXTERIOR GRADE PLYWOOD):

EXCISE REVENUE

OTHER MAJOR PROBLEMS THE INDUSTRY IS FACING AT PRESENT ARE:

EXPORTS OF PLYWOOD AND PLYWOOD PRODUCTS

PRESENT MANUFACTURERS

AFFILIATED MEMBERS

ASSOCIATE MEMBER

ADHESIVE FOR PLYWOOD INDUSTRY

INTRODUCTION:

1. MELAMINE-FORMALDEHYDE:

2. UREA-FORMALDEHYDE:

3. PHENOL FORMALDEHYDE (HOT SETTING)

ADHESIVES IN PLYWOOD LAMINATORS:

LAMINATING RESINS:

BONDING AGENTS FOR PLYWOOD:

PHENOL-RESIN ADHESIVES:

SOME MORE SALIENT FEATURES OF PHENOL-RESIN GLUES:

PHENOL - FORMALDEHYDE RESIN

PHENOL FORMALDEHYDE EMULSIONS

RESORCINOL-FORMALDEHYDE ADHESIVES:

UREA-FORMALDEHYDE RESIN ADHESIVE

MISCELLANEOUS FORMULATIONS FOR ADHESIVES FOR VARIOUS PLYWOOD BOARDS:

COLD PRESS UREA FORMALDEHYDE ADHESIVES

MELAMINE RESIN FORMULATIONS

PHENOLIC RESIN ADHESIVE

TYPE:

PHYSICAL FORM

CONDENSATION POLYMERISATION WITH ELIMINATION OF WATER

SETTING PROCESS

PROCESSING CONDITIONS

COVERAGE

PERMANENCE

RAW MATERIALS

PLYWOOD CLASSIFICATION AND GRADING

SIZES

PLANT AND EQUIPMENT

BASIC METHOD OF MANUFACTURE FOR DIFFERENT TYPES OF PLYWOOD

FIBREBOARDS

QUALITY AND SPECIFICATION

FLOW SHEET OF PROCESS OF MANUFACTURE

MANUFACTURING PROCESS

THE MANUFACTURING PROCESS

FELLING THE TREES

PREPARING THE LOGS

MAKING THE VENEER

FORMING THE PLYWOOD SHEETS

PROCESS FLOW DIAGRAM

PHENOL BOARD

(1) MANUFACTURE LIQUID RESOLES

(2)  PHENOL BOARD PREPARATION

FLOW DIAGRAM FOR PHENOL BOARD

MANUFACTURING PROCESS OF PRELAMINATED BOARD

(1)  PARTICULAR CONSTRUCTION PLYWOOD

(2)  SPECIALLY TREATED FACE PLYWOOD

I)   MECHANICALLY TREATED PLYWOOD

II)  PRINTED PLYWOOD

III) OBJECTIVES OF PREFINISHED PLYWOOD

PREFINISHING OF RECENT DEVELOPMENT FEATURES :

IV)  OVER-LAY PLYWOOD

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

SUPPLIERS OF PLANT & MACHINERY

PLYWOOD MACHINERY

PLYWOOD PRESSES

DRYERS

BOILER

SAWS: CIRCULAR

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)