Flush Door and WPC Door Frame (200 Numbers per day)

FLUSH DOOR AND WPC DOOR FRAME 

[EIRI/EDPR/4618] J.C.: 2835XL

INTRODUCTION

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.

As per IS: 10013 and IS: 401, timber is chemically treated and vacuum pressured. This process strengthens the timber by making it not only durable but also borer, termite and fungi free. Wood is generally seasoned at the automatic kiln seasoning plant as per IS: 1144, substantially reducing moisture as per standard requirement mentioned in the IS: 287. It is further bonded with phenol formaldehyde synthetic resin, 100% boiling water resistance as per IS: 848 and hot pressed at high temperature under uniform pressure. Decorative veneer or laminated sheet is pressed by melamine or PVAc resin. Flush doors are available in.

1. 9 Ply series

2. 5 Ply series 

Every flush door is processed using our advanced machinery to keep the structure perfect and dimensions accurate and stable. To eliminate telegraphy impressions, it is passed the board through a white belt sander machine which imparts super smooth finishing. Final finishing is done with commercial, natural/recomposed or decorative veneer. This door can be laminated or painted or polished on both 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)