Detailed Project Report on wooden doors manufacturing unit

WOODEN DOORS MANUFACTURING UNIT

 [CODE NO.3586]  

Wood door is a door made of wood. It is very commonly used in constructions and known for its good machinability, strength and durability along with a lot of other abilities.

Wood doors can be categorized in many ways. By the different manufacturing method due to the structure, the doors can be divided into three categories. Each category of doors has a very different structure from each other.

• Real wooden tenon-joint door

• Wood composite door

• Veneer and wooden frame core door 

Doors are different in design, structure and external finish. 

Wooden door structures may be of different types and different technologies: solid wood, blockboard or double-panel. 

Solid wood: veneered or laminated solid wood for long-lasting stability.

This technology is used to produce Antikè and Rodi.

Blockboard wood: perpendicularly-glued wooden strips for long-lasting stability.

This technology is used to produce Baltimora and Baltimora New.

Double-panel wood: sandwich structure with light interior.

This technology is used to produce Fashion, Natura, Costellazioni, Casa Zen, Venezia.

The external wooden finish is made using fine wood veneer to cover door elements with different materials, colours and finishing.

Carpentry and joinery are common terms used with any class of work with wood. Strictly speaking carpentry deals with all works of carpentry such as roofs, floors, partitions etc. of a building, while joinery deals with the making of doors windows, cupboards, dressers, stairs and all the interior fitments for a building.

Timber is the basic material used for any class of wood working. The term timber is applied to the trees which provide us with wood. Furniture and fixture are essential for a family. Furniture and fixtures proposed to be manufactured in this scheme are made out of wood specially from CP teak, chap, haldu, Jack or similar good quality wood. With the modern life furniture and fixture used in a family are wide and varied in nature starting from plank, almirah, table, chair, rack etc. Apart from this utility furniture is made out of good quality wood and highly finished adds beauty to the room.

Wood with moisture content brought down to the extent that it does not further shrink under normal conditions by way of evaporation of moisture from it is called seasoned wood. Generally timber with moisture content less than 15% does not appreciably shrink and can be called as seasoned timber. It is desirable that in carpentry and joinery work wood does not shrink after it is joined and finished. But if unseasoned wood is used it will give out moisture to further dry and shrink after work is done.

This will obviously weaken the joints and give clauses between the pieces for a bad finish. When seasoned timber is used to joints remain understored and no gap develops between the pieces of timber after finishing. Hence for making door and window shutters, furniture, interior decoration and such other work where strength and finish matter use of seasoned timber is advisable. Since use of seasoned timber is advisable. Since use of seasoned timber gives longer life and better finish. there is growing trend to used seasoned timber in wood industries. Various govt. departments including defense department are now including use of seasoned timber in the specification for various work involving use of timber.

STRUCTURE OF WOOD: The trees are known as growers, due to the fact that each year a new layer of tissue is formed on the outside of previous layers. The layers are termed annual i\rings, because most trees produce one ring each year. Each annual ring is composed of an open porous layer known as springwood, due to the rapid growth in spring and thinner denser layer called autumn wood, due to the outer rings of the tree known as sapwood convey the watery sap from the roots up to the leaves. Here it undergoes certain chemical changes and on its return journey to the roots in autumn, this perfected gap leaves behind various starchy secretions, gums or resins, according to the type of tree. These substances fill up the tissues, feed the tree and help to form a denser wood known as doorman or heartwood. The cambium layer situated between the sapwood and the bark is responsible for the formation of new wood each year. It divides up forming layer of new wood cells on the inside and a soft layer on the outside which becomes bark. Each year the innermost layer of sapwood becomes transformed into heartwood.

It is generally understood that heartwood is the only part of the tree which should be converted for use, as sapwood is more prone to attack from wood-destroying organisms. If sapwood is properly treated with an effective preservative, it is as durable as harrowed, similarly treated, when used under conditions favorable to decay.

The difference in colour between sapwood and heartwood is most important when choosing wood for joinery, the decorative value of which depends on the dark colour and grain of the heartwood. Treating with preservatives is useless and staining is very difficult. as sapwood absorbs stains more readily than heartwood and takes on a much darker shade. Therefore, for all joinery work it is better that sapwood be eliminated altogether.

Wood is generally used to manufacture so many things starting from furniture to industrial products. But mainly used to manufacture wooden doors, windows, shutters etc. Besides these the other uses are to manufacture T.V. cabinets. Wooden TV cabinets are cheap and durable. The rapid expansion of the TV network in India has given a tremendous thrust to the TV manufacturing industries and which in turn has generated a great demand for the various parts and accessories in the manufacture of TV set out of which, cabinet is an important component.

COST ESTIMATION

Plant Capacity                                          100 Doors/Day

Land & Building (1000 sq.mt.)                 Rs. 1.27 Cr

Plant & Machinery                                      Rs. 35 Lac

Working Capital for 2 Months                  Rs. 81 Lac

Total Capital Investment                           Rs. 2.54 Cr

Rate of Return                                             25%

Break Even Point                                        61%

• INTRODUCTION
  
• CLASSIFICATION OF WOOD -
• COMMON VARIETIES OF INDIAN TIMBER
• USES OF SEASONED WOOD
• INSTRUMENT INDUSTRIES
• B.I.S. SPECIFICATION
• SPECIFICATION OF WOODEN DOOR
• TIMBER DOOR, WINDOW AND VENTILATOR FRAMES — SPECIFICATION
• (THIRD REVISION)
• 1 SCOPE
• 2 REFERENCES
• 4 MATERIALS
• 5 CONSTRUCTIONS AND WORKMANSHIP
• 6 DIMENSIONS, SIZES AND TOLERANCES
• EXAMPLE 1
• EXAMPLE 2
• 7 LOCATIONS OF HOLDFASTS
• 8 FINLSH
• NOTES
• 9 SAMPLING
• 10 MARKING
• MARKET SURVEY
• DOOR AND WINDOW FOR RESIDENTIAL BUILDING
• TABLE– RECOMMENDED OPENING SIZES – DOORS
• WOODEN DOOR ELEVATION
• FIG. ELEVATION OF WOODEN DOOR
• TYPICAL DOOR DETAIL – WOOD
• FIG. ELEVATION OF WOODEN DOOR
• BOTTOM RAIL
• KITCHEN DOOR ELEVATION
• FIG. ELEVATION OF KITCHEN DOOR
• DETAILED EXPORT DATA OF WOODEN DOOR SIZE
• MANUFACTURERS OF WOODEN DOORS
• MANUFACTURING PROCESS
• PROCESS FLOW DIAGRAM
• PROCESS IN DETAILS
• PROCESS INVOLVE MAINLY IN FIVE GROUPS-
• SUMMARY OF THE MANUFACTURING PROCESS
• INSPECTION AND QUALITY CONTROL
• PLANT LAYOUT
• SUPPLIER OF RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
• VERTICAL SAW MACHINE
• WOOD CUTTING MACHINE

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)