Detailed Project Report on plywood and mdf including water proof plywood and mdf

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PLYWOOD AND MDF INCLUDING WATER PROOF PLYWOOD AND MDF

[CODE NO.3941]

The term `Plywood' covers a form of laminated wood in which successive layers of veneer are ordinarily cross laminated, the care of which may be veneer or sawn lumber in are piece several pieces. It is a high pressure bonded wood product composed of layers of waves with resin as the laminating agent.

Plywood is a composite material, although we often consider it as a traditional working material. It is composed of individual plies / veneers of wood. It is very strong due to the way the plies are put together. The grain of each ply is positioned at ninety degrees to the pieces of ply above and below it. The plies are glued together with synthetic resin, making a very strong composite material. Furthermore, plywood is usually constructed so that an odd number of plies are used. Plywood is less likely to warp or split, due to this construction.

Manmade boards of this type are supplied in a range of sizes and thicknesses. This is an advantage compared to natural woods, as manmade boards can be manufactured so that they are extremely wide. This makes plywood a popular material in the construction industry.

COST ESTIMATION

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%

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:

(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 – 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

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