VENEER CUM PLYWOOD CUM MDF PLANT
[CODE NO.3393]
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 : VENEER CUM PLYWOOD CUM MDF PLANT
land & Building (10000)Sq.Mtr) : Rs. 9.82 Cr
Plant & Machinery : Rs. 10.00 Cr
Working Capital for 1 Month : Rs. 6.12 cr
Total Capital Investment : Rs. 26.82 Cr
Rate of Return : 30%
Break Even Point : 49%
INTRODUCTION
SIZES OF PLYWOOD
YIELD
CURRENT CONVENTIONAL MILL FINISHES
SURFACE PREPARATION FOR WOOD AND ALLIED MATERIALS
GRADES
USES AND APPLICATION
USES OF PLYWOOD
MEDIUM DENSITY FIBREBOARD
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
MARKET SURVEY
MARKET SEGMENTATION
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
GLOBAL MDF CAPACITY
MEDIUM DENSITY FIBREBOARD
MEDIUM DENSITY FIBREBOARD
OVERVIEW OF TIMBER MARKET IN AFRICA
CENTRAL AND WEST AFRICA
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
TURBULENT MONTHS AHEAD FOR THE RAND
RESIDENTIAL ACTIVITY SURVEY DELIVERS HINT OF GROWTH
MANUFACTURERS/EXPORTERS
RAW MATERIALS
PLYWOOD CLASSIFICATION AND GRADING
SIZES
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:
(C) QUARTER SLICING:
(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
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
SEQUENCES IN PLYWOOD MANUFACTURE
FELLING THE TREES
PREPARING THE LOGS
MAKING THE VENEER
FORMING THE PLYWOOD SHEETS
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”:
PROCESS FLOW DIAGRAM OF PLYWOOD
MANUFACTURING PROCESS OF MDF
PROCESS FLOW DIAGRAM OF MDF MANUFACTURE 101
PROCESS DETAILS OF MEDIUM DENSITY FIBRE BOARD
PREPARATION OF RAW MATERIALS
FLAKES
GRANULE
SHAVING
FIBRE PREPARATION (DEFIBRATION)
MAT FORMING
PRESSING
HEAT TREATMENT & HUMIDIFYING
TRIMMING
FINISHING
PLANT LAYOUT
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
3. LOG PEELING LATHE MACHINE
4. VENEER DRYER
5. GUILLOTINE JOINTER
6. WET VENEER CLIPPER
7. GLUE SPREADER MACHINE
8. VENEER / HORIZONTAL SLICER
9. HYDRAULIC COLD PRESS
10. SCISSOR LIFT
11. VENEER EDGE GRINDER AND SCARFING MACHINE
IMPLEMENTATION SCHEDULE
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
