LAMINATED PARTICLE BOARD AND HARD BOARD
[EIRI/EDPR/0795] (J.C.9410)
INTRODUCTION
Particle board and Hard Board is as the name suggests a board made of particles of wood obtained mechanically without destroying the inherent character of wood. Thus chip board or particle board is a board made from crushed wooden material which is bonded by means of a resin under the application of pressure and temperature. This new industry was initially started primary with a view to utilise wood waste. Wood that was left in the forest being unsuitable for plumber industry and wood that was thrown away as waste in various wood industries (e.g. saw mills, furniture making plywood industries) could be utilised in making particle board.
The accepted definition of particle board and hard board is a sheet material manufactured from small pieces of wood on other ligno - cellulosic materials (e.g. chips, flakes, splinters, strands, shives etc.) agglomerated by use of an organic binder together with one or more of the following agents heat, pressure, moisture, a catalyst etc.
The organic binder resin used are normally urea formaldehyde if the particle board is to be used for interior use, or phenol formaldehyde is used if this is used in external exposurer or under severe internal conditions. Melamine formaldehyde is also used.
The first plant to produce particle board and hard board commercially was built in Bremen, West Germany in 1941. The first three layer particle board was marketed in Switzerland in 1945.
Particle boards and hard boards find extensive use in the building industry furniture industry cabinets and automobile construction large size panels can also be manufactured at economic costs.
The wood after deharking is converted into chips of suitable size. The chips are dried to the appropriate moisture content. The dried chips are then mixed with adhesive. Storage silos are placed in between different stages to make each operation independent of the other. In the flat platen process the mixture is spread on casual plates in forming-machine to approximate thickness. The mat is cold pressed and then loaded on the hot press.
In the hot press the mats are subjected to a high pressure and temperature so that the synthetic resin is introduced between two heated plates and hammed at regular intervals to form a board which goes out at the other end continuously. The boards are unloaded and sent through the sanding and sizing machines.
COST ESTIMATION
Plant Capacity 150 MT/Day
Land & Building (2,00,000 sq.mt.) Rs. 93.13 Cr
Plant & Machinery Rs. 269.25 Cr
Working Capital for 2 Months Rs. 20.72 Cr
Total Capital Investment Rs. 87.01 Cr
Rate of Return 45%
Break Even Point 41%
CONTENTS
INTRODUCTION
USE AND APPLICATIONS
PROPERTIES OF HARD BOARD
TYPES OF RAW MATERIALS AND THEIR CHARACTERISTICS
CHARACTERISTICS OF FIBROUS RAW MATERIALS
RAW MATERIALS
PLACE OF LOCATION
ISI SPECIFICATIONS FOR WOOD PARTICLE BOARDS
STRENGTH & OTHER CHARACTERISTICS OF VARIOUS - TYPES OF WOODPARTICLE BOARDS
MANUFACTURING PROCESS
DETAILS OF MANUFACTURING PROCESS OF - LAMINATED PARTICLE BOARD
FLOW SHEET FOR PARTICLE BOARD MANUFACTURE
MANUFACTURING PROCESS FOR HARD BOARD - MAKING PLANT
PROCESS FLOW CHART
PLANT LAY OUT
MARKET SURVEY
PRESENT MANUFACTURERS OF HARD BOARD
PRESENT EXPORTERS OF PARTICLE BOARD
EXPORTERS OF HARD BOARD
OVERSEAS SUPPLIERS OF PLANT & MACHINERY - FOR LAMIATED PARTICLE BOARD
ADDRESSES FOR SUPPLY OF PLANT & MACHINERY - FOR HARD BOARD
MANUFACTURE OF RAW MATERIAL AND CHEMICALS USED
MANUFACTURERS OF FORMALDEHYDE
MANUFACTURE OF AMMONIUM SULPHATE
MANUFACTURERS OF PENTA-CHLOROPHENOL
MANUFACTURERS & SUPPLIERS OF AMMONIUM CHLORIDE
RAW MATERIAL SUPPLIERS FOR HARD BOARD
PROJECT IMPLEMENTATION SCHEDULE
RAW MATERIALS CALCULATIONS
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)
