PLYWOOD AND PLYBOARDS
[EIRI/EDPR/1210] J.C.: 9861
INTRODUCTION
Plywood is made of three or more thin layers of wood bonded together with an adhesive. Each layer of wood, or ply, is usually oriented with its grain running at right angles to the adjacent layer in order to reduce the shrinkage and improve the strength of the finished piece. Most plywood is pressed into large, flat sheets used in building construction. Other plywood pieces may be formed into simple or compound curves for use in furniture, boats, and aircraft.
The use of thin layers of wood as a means of construction dates to approximately 1500 B.C. when Egyptian craftsmen bonded thin pieces of dark ebony wood to the exterior of a cedar casket found in the tomb of King Tut-Ankh-Amon. This technique was later used by the Greeks and Romans to produce fine furniture and other decorative objects. In the 1600s, the art of decorating furniture with thin pieces of wood became known as veneering, and the pieces themselves became known as veneers.
Until the late 1700s, the pieces of veneer were cut entirely by hand. In 1797, Englishman Sir Samuel Bentham applied for patents covering several machines to produce veneers. In his patent applications, he described the concept of laminating several layers of veneer with glue to form a thicker piece—the first description of what we now call plywood.
Despite this development, it took almost another hundred years before laminated veneers found any commercial uses outside of the furniture industry. In about 1890, laminated woods were first used to build doors. As the demand grew, several companies began producing sheets of multiple-ply laminated wood, not only for doors, but also for use in railroad cars, busses, and airplanes. Despite this increased usage, the concept of using "pasted woods," as some craftsmen sarcastically called them, generated a negative image for the product. To counter this image, the laminated wood manufacturers met and finally settled on the term "plywood" to describe the new material.
COST ESTIMATION
Plant Capacity 145 sq.ft./Day
Land & Building (6000 sq.mt.) Rs. 3.60 Cr
Plant & Machinery Rs. 1.33 Cr
Working Capital for 1 Month Rs. 49.68 Lac
Total Capital Investment Rs. 5.57 Cr
Rate of Return 20%
Break Even Point 63%
CONTENTS
INTRODUCTION
STRUCTURAL BOARDS
SIZES OF PLYWOOD
USES AND APPLICATION
GENERAL CHARACTERISTICS OF PLYWOOD
SURFACE TREATMENTS
PROPERTIES & CHARACTERISTIES
PHENOL BOARD
B I S SPECIFICATION
MARKET SURVEY
PRODUCTION OF PLYWOOD
DIRECTION OF EXPORT
DEMAND OF PLYWOOD
FACTORS RESPONSIBLE FOR DEMAND OF PLYWOOD
APPARENT CONSUMPTION OF PLYWOOD
BOILING WATER RESISTANT (BWR SEMI-EXTERIOR GRADE PLYWOOD):
EXCISE REVENUE
OTHER MAJOR PROBLEMS THE INDUSTRY IS FACING AT PRESENT ARE:
EXPORTS OF PLYWOOD AND PLYWOOD PRODUCTS
PRESENT MANUFACTURERS
AFFILIATED MEMBERS
ASSOCIATE MEMBER
ADHESIVE FOR PLYWOOD INDUSTRY
INTRODUCTION:
1. MELAMINE-FORMALDEHYDE:
2. UREA-FORMALDEHYDE:
3. PHENOL FORMALDEHYDE (HOT SETTING)
ADHESIVES IN PLYWOOD LAMINATORS:
LAMINATING RESINS:
BONDING AGENTS FOR PLYWOOD:
PHENOL-RESIN ADHESIVES:
SOME MORE SALIENT FEATURES OF PHENOL-RESIN GLUES:
PHENOL - FORMALDEHYDE RESIN
PHENOL FORMALDEHYDE EMULSIONS
RESORCINOL-FORMALDEHYDE ADHESIVES:
UREA-FORMALDEHYDE RESIN ADHESIVE
MISCELLANEOUS FORMULATIONS FOR ADHESIVES FOR VARIOUS PLYWOOD BOARDS:
COLD PRESS UREA FORMALDEHYDE ADHESIVES
MELAMINE RESIN FORMULATIONS
PHENOLIC RESIN ADHESIVE
TYPE:
PHYSICAL FORM
CONDENSATION POLYMERISATION WITH ELIMINATION OF WATER
SETTING PROCESS
PROCESSING CONDITIONS
COVERAGE
PERMANENCE
RAW MATERIALS
PLYWOOD CLASSIFICATION AND GRADING
SIZES
PLANT AND EQUIPMENT
BASIC METHOD OF MANUFACTURE FOR DIFFERENT TYPES OF PLYWOOD
FIBREBOARDS
QUALITY AND SPECIFICATION
FLOW SHEET OF PROCESS OF MANUFACTURE
MANUFACTURING PROCESS
THE MANUFACTURING PROCESS
FELLING THE TREES
PREPARING THE LOGS
MAKING THE VENEER
FORMING THE PLYWOOD SHEETS
PROCESS FLOW DIAGRAM
PHENOL BOARD
(1) MANUFACTURE LIQUID RESOLES
(2) PHENOL BOARD PREPARATION
FLOW DIAGRAM FOR PHENOL BOARD
MANUFACTURING PROCESS OF PRELAMINATED BOARD
(1) PARTICULAR CONSTRUCTION PLYWOOD
(2) SPECIALLY TREATED FACE PLYWOOD
I) MECHANICALLY TREATED PLYWOOD
II) PRINTED PLYWOOD
III) OBJECTIVES OF PREFINISHED PLYWOOD
PREFINISHING OF RECENT DEVELOPMENT FEATURES :
IV) OVER-LAY PLYWOOD
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
SUPPLIERS OF PLANT & MACHINERY
PLYWOOD MACHINERY
PLYWOOD PRESSES
DRYERS
BOILER
SAWS: CIRCULAR
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)
