Detailed Project Report on BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD

BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD
[CODE NO.3315] J.C.: 1396


Bamboo mat boards (BMB) are produced from woven mats of bamboo that are soaked in adhesive resin and then pressed firmly together in a hot press. They were the first of the wide range of different panel boards presently available that use bamboo as a raw material, but they are the simplest to produce, involve only bamboo raw materials and have great income generating potential for the rural poor, who are able to weave the mats from which they are formed. The technology for the manufacture of BMB in India has been developed by the Indian Plywood Industries Research Institute (IPIRTI), Bangalore, who have developed a technically feasible and commercially viable technology for its manufacture. BMB is gaining in popularity and there are currently a handful of BMB factories in operation in India and 16 in China.

Bamboo mat board is very versatile and can be produced up to 6 mm thick by varying the number of mat layers used; boards are usually formed of 2, 3, 5 or 7 mats. For thicker laminated boards, wood veneers are interleaved with the bamboo boards to produce bamboo mat-veneer composite boards (the production of these is not covered in this TOTEM). BMB is at least as durable and stable as wood-based plywood and is very resistant to pest attack, extreme climatic conditions and fire. It can be used for many of the uses to which plywood is now put such as paneling, ceilings, prefabricated shelters, packing cases and storage bins, roofs, doors and door panels, furniture, and household utensils such as trays and plates. BMB is much more flexible than wood-based-plywood and can be used in structural applications such as stressed skin panels, wall bracings and web beams for which plywood is not suitable.

The first recorded production of bamboo based panels was in China during the mid 1940s where bamboo mat board bonded with casein (enamel) glues was used in the interior of aeroplanes as an alternative to aircraft-grade plywood. At about the same time research was initiated in India to develop synthetic resinbonded bamboo mat board, for which the technology became available a decade and a half later. Since then, research has been carried out in several countries and over 30 types of panel products have been developed-some made of bamboo only and others of bamboo in combination with wood, lignocellulosic materials and inorganic materials. Research and development efforts have been mostly confined to countries of the AsiaPacific region i.e. China, India, Indonesia, Japan, Laos, Malaysia, Philippines, Taiwan, Thailand and Vietnam. Canada (in collaboration with Costa Rica) is the only country outside Asia where research on bamboo panels is being carried out.

Although there was some pioneering work in Taiwan and innovative products such as plybamboo (bamboo glue-lam) were developed, the bamboo board industry is reported to be facing extinction there due to the sharp increase in wages and shortages of raw materials. In Thailand, the only product manufactured is bamboo mat board glued with Urea Formaldehyde (UF) resin and this is mainly produced for export. In countries such as Laos, the Philippines and Vietnam, interest in bamboo matboard production is relatively new, and the industries there are presently in the phase of exploratory studies and experimental or pilot scale production.



COST ESTIMATION

Plant  Capacity                                            :       15.00 Cubic Mtr./day
land & Building (3000 Sq.Mtrs)                :    Rs. 1.58   Cr
Plant & Machinery                                       :    Rs. 1.96   Cr
Working Capital for 2 Months                   :    Rs. 2.85   Cr
Total Capital Investment                            :    Rs. 6.55   Cr
Rate of Return                                             :    30%
Break Even Point                                         :    53%

INTRODUCTION    
ADVANTAGE OF BAMBOO MAT BOARD    
THE MAIN DEVELOPMENT ATTRIBUTES OF THE TECHNOLOGY
   ARE AS FOLLOWS    
USES AND APPLICATION    
TECHNICAL CHARACTERISTICS    
CHARACTERISTICS & PROPERTIES    
OF BAMBOO FLOORING/PANELLING    
IT HAS VARIOUS IMPORTANT USEFUL PROPERTIES - IN ITS
   CONSTRUCTION FEATURES.    
SIZES OF BAMBOO FLOORING/BAMBOO PANELING    
STYLES    
FOR BAMBOO FLOORING/PANELING ETC    
BAMBOO MAT BOARD - A REPLACEMENT FOR PLYWOOD    
OVERVIEW OF BAMBOO IN INDIA    
TABLE DISTRIBUTION OF BAMBOO IN INDIA    
TABLE DISTRIBUTION OF SOME IMPORTANT BAMBOO SPECIES IN INDIA    
BAMBOO MAT CORRUGATED SHEET [BMCS]    
DEVELOPMENT OF BAMBOO COMPOSITE AND MAT BOARD IN INDIA    
A. BAMBOO MAT BASED PRODUCTS    
B BAMBOO STRIP BASED PRODUCTS    
C. BAMBOO IN ROUND/SPLIT/COMPOSITE FORM    
FIG 1. A GENERALIZED PROCESS FLOW CHART FOR BAMBOO  
   MAT COMPOSITES IS AS FOLLOWS    
FIG 2. FLOW CHART FOR THE MANUFACTURE OF BAMBOO WOOD    
ADHESIVES    
RESIN APPLICATION    
HOT PRESS CONDITIONS    
TEMPERATURE    
PRESSURE    
TIME    
FINISHING OF PRODUCTS    
BAMBOO MAT BOARD    
TABLE    
BAMBOO AND BAMBOO PLYWOOD    
PROPERTIES OF BAMBOO MAT CORRUGATED SHEET    
A. BOND QUALITY    
B. RESISTANCE TO DECAY AND INSECTS    
C. WATER PERMEABILITY    
D. LOAD BEARING CAPACITY    
E. THERMAL CONDUCTIVITY    
BAMBOO MAT BOARD AND TECHNOLOGIES OF BAMBOO BASED PANELS    
B.I.S. SPECIFICATION    
METHODS OF TESTS FOR ROUND BOMBOOS (AS PER IS: 6874 - 1973)    
MOISTURE CONTENT AND SPECIFIC GRAVITY    
APPARATUS    
PROCEDURE    
MEASUREMENT OF LOAD AND DEFLECTION    
RECORDING OF DATA AND COMPUTATIONS    
MARKET SURVEY    
INDUSTRY STRUCTURE AND DEVELOPMENTS    
WOOD PANEL PRODUCTS    
FURNITURE INDUSTRY    
OPPORTUNITIES AND THREATS    
OPPORTUNITIES    
THREATS    
OUTLOOK AND OPTIMISM    
DETAILED EXPORT DATA OF BAMBOO MAT    
MANUFACTURERS/SUPPLIERS/EXPORTERS FOR BAMBOO MAT BOARDS    
MANUFACTURING PROCESS OF BAMBOO MAT BOARD    
CUTTING OF BAMBOO    
REMOVAL OF OUTER    
BAMBOO SPLITTING & SIZING    
REMOVAL OF INSIDE BAMBOO KNOTS OF OUTSIDE BAMBOO SKIN    
PROCESSING OF FOUR SIDES OF BAMBOO STRIP TO SIZE REQUIRED    
DRYER TREATMENT    
STICK SIZING    
BAMBOO STRIP GLUING    
ADHESIVE PREPARATION    
GLUE/ADHESIVE MIXING    
SHAPING THE BAMBOO FLOOR BY HYDRAULIC PRESS    
PLANING OF BAMBOO FLOOR    
DOUBLE END CUTTING AND SHAPING    
SANDING    
COATING OF BAMBOO FLOOR SURFACE WITH UV PRIMER    
FEATURES OF ROLLER TYPE COATING MACHINE    
UV CURING    
PLANING OF BAMBOO SURFACE BY SANDER 2'    
STANDARD ACCESSORIES AND FUNCTIONS OF SANDER 2'    
COATING OF BAMBOO SURFACE WITH UV PRIMER    
UV CURING & FINISHING    
GRADING AND INSPECTION    
PROCESS FLOW CHART    
SPECIFICATIONS OF PLANT & MACHINERY    
PROCESSING DETAILS OF BAMBOOS    
BAMBOO CROSS-CUTTING MACHINE    
BAMBOO SPLITTING MACHINE WITH KNIVES    
BAMBOO SPLITTING MACHINE WITH CIRCULAR SAWS    
BAMBOO WIDTH SIZING, KNOT REMOVING AND PLANING MACHINE    
BAMBOO FOUR-SIDE PLANING MACHINE    
BAMBOO ONE-SIDE PLANING MACHINE    
BAMBOO SLAB MAKING MACHINE    
BAMBOO TREATMENT    
DETAILS OF BAMBOO MATS BOARD MANUFACTURE    
HARVESTING BAMBOO    
SPLITTING BAMBOO    
KNOT REMOVAL    
SLIVER MAKING    
DRYING AND WEAVING    
STORAGE OF MATS    
RESIN APPLICATION    
RESIN DILUTION WITH WATER FOR DIPPING    
QUANTITY OF PF RESIN REQUIRED    
STABILIZATION AND DRYING OF RESIN COATED MATS    
ASSEMBLY    
HOT PRESSING    
TRIMMING AND CHECKING    
MANUFACTURE OF RESIN    
DRY-WET PROCESS TO MANUFACTURE    
SLICED BAMBOO VENEER    
PRODUCING BAMBOO STRIP AND BOARD    
PRODUCING LAMINATED BAMBOO LUMBER    
BAMBOO BOARD MOISTURE CONTENT    
QUALITY OF SLICED BAMBOO VENEER    
PRODUCTIVITY    
CONCLUSIONS    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
MELAMINE UREA FORMALDEHYDE RESIN    
SUPPLIERS OF PLANT AND MACHINERY    
BAMBOO CROSS CUTTING MACHINE    
BAMBOO SPLITTING MACHINE    
BAMBOO KNOT REMOVING MACHINE    

        
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