Detailed Project Report on Particle Board from Rice Husk

PARTICLE BOARD FROM RICE HUSK

[EIRI/EDPR/1499](J.C.285INR, 288US$)

INTRODUCTION

Rice husk received from the rice mill is winnowed and wind-sifted and then coated with synthetic resin adhesive in specially designed adhesive applicators. The resin coated husk is spread as an even mat on support cauls & consolidated under heat and pressure in a hydraulic hot press. The hot pressed panels are cooled and trimmed to the desired dimension. Unit market price in India: US$ 0.60 per sq.ft.

Application/Uses:

Construction industry, construction materials, furniture industry: wall panelling, furniture, false ceilings, roofing panels, insulation, partitioning flooring & general purpose etc.

Advantages: 

Waste Utilisation: agricultural wastes (rice husk) are used as input. High quality product; termite & fire resistant products; durable product; adequate bond strength, dimensional stability, rodent resistant, decay resistant product.

Rice Husk Particle Board

Rice growing nations all over the world face monumental problems in disposal of rice husk waste, which is a serious environmental hazard, if it is burnt. The technology for manufacture of Rice Husk Particle Board, developed at the Indian Plywood Industries Research Institute, Bangalore has emerged as one of the best solutions to this problem as it helps to maintain the ecobalance and preserves the eco-system. Patents have been filed in India and many other rice growing countries.

This board has emerged as a versatile substitute for wood in a wide range of applications. Moreover, these boards can also be made decorative. The process has been licensed to several firms in India and a turnkey plant has been set up in Malaysia. The firm has also produced floor tile (out of rice husk), fire resistant doors etc. having granite like finish. What is more, the licensee of the technology has helped to build up a large number of low cost houses after the Gujarat earthquake. 

Particle board is as the name suggests a board made of particles of wood obtained mechanically without destroying the inherent character of wood. This new industry initially was started primarily with a view to utilize wood waste. Wood that was left in the forest being unsuitable for lumber industry and wood that was thrown away as waste in various wood industries, (e.g. sawmills, furniture making plywood Industries) could be utilized in making particle board. It may be mentioned here that fiber board also utilizes the same wood waste, the wood is converted into pulp and pressed the bond being obtained mainly from the natural lignin present in wood. In case of particle board, the bond is obtained by using an organic binder-synthetic resin adhesive. The accepted definition of particle 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 first plant to produce particle board commercially was build in Bremen, West Germany in 1941. The first three layer particle board is marketed in Switzerland in 1945, the first particle board plant was based on flax straw. Particle boards find extensive use in the building industry, furniture industry, cabinet and automobile construction. Large size panels can also be manufactured at economic costs.

The wood after debarking 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 the between different stages to make each operation independent of the other. In the flat platen process the mixture is spread on caul plates in forming machine to appropriate thickness. The mat is cold pressed and then loaded onto 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 hammer 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.

Most particle boards produced is in the intermediate density range from 0.40 to 0.80 g/cm3, low density boards in the range from 025 to 0.40 g/cm3 are insulating type whereas high density boards in the range from 0.80 to 1.20 g/cm3 are called hard board type.

COST ESTIMATION

Plant Capacity            2 MT/Day

Land & Building (3000 sq.mt.)    Rs. 3.07 Cr

Plant & Machinery                    Rs. 28.25 Lac

Working Capital for 2 Months    Rs. 1.04 Cr

Total Capital Investment          Rs. 4.51 Cr

Rate of Return                          35%

Break Even Point                      66%

CONTENTS

INTRODUCTION

RAW MATERIAL

LOCATION OF THE PLANT

BIS SPECIFICATIONS FOR WOOD PARTICLE BOARDS DESIGNATION OF PARTICLE BOARDS FOR GENERAL PURPOSES

THE FOLLOWING TOLERANCES ON THE DIMENSIONS OF FINISHED BOARDS SHALL BE PERMISSIBLE

STRENGTH & OTHER CHARACTERISTICS OF VARIOUS TYPES OF WOOD PARTICLE BOARDS

STORAGE AND WORKING OF WOOD PARTICLE BOARDS

MARKET SURVEY

PRESENT STATUS

100% EXPORT ORIENTED UNITS (100% EOU)

PRERSENT MANUFACTURERS/EXPORTERS/SUPPLIERS OF PARTICLE BOARDS

USES & APPLICATIONS

FORMULATION FOR PARTICLE BOARD

MANUFACTURING PROCESS

WOOD REQUIREMENTS:-

CHIP PREPARATION:-

CHIPPING:-

DRYING:-

SECONDARY REDUCTION:-

SCREENING:-

BLENDING:-

A) ADHESIVE PREPARATION:-

ADHESIVE MIXING:-

(A) MAT FORMATION:-

(B) COLE PRESSING:

(C) HOT PRESSING:-

SANDING AND FINISHING:-

FLOW SHEET FOR PARTICLE BOARD MANUFACTURE

SUPPLIERS OF PLANT & MACHINERY FOR PARTICLE BOARD

MANUFACTURERS OF RAW MATERIAL AND CHEMICALS USED

UREA FORMALDEHYDE

FORMALDEHYDE

AMMONIUM SULPHATE

PARAFFIN WAX

MANUFACTURERS OF PENTA-CHLOROPHENOL

PHOSPHATIC CHEMICALS

MANUFACTURERS & SUPPLIERS OF AMMONIUM CHLORIDE     

LIST OF THE IMPORTER

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

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)