PROPOSAL
FOR SETTING UP OF
GREEN WudT ECH
FLUSH D OOR AN D PAN N EL D OOR
And
COM POSI T BOARD
U lt ra w ood K RAFT INDUSTRIES
GREEN WudTECH KRAFT INDUSTRIES
CONTENTS
ABSTRACT OF PROJECT
PART ONE: INTRODUCTION
1.
VENEER Door COMPOST PANEL- at a Glance
4
2.
History of development of board technology
8
2.1
International development efforts
8
2.2
Diversification of manufacturing technologies of bamboo based panels
9
2.3
Development of bamboo mat board: the Indian experience
9
3.
General development attributes and advantages
10
4.
Target groups
11
6.
Applicability
11
7.
Scope for small enterprise development
12
8.
Limitations of the technology
12
9.
Requirements for success
12
10.
Potential improvements and research needs
13
Concluding remarks
1.
The Proposal
2.
Processing Techniques
a. Composit Board
b. Skin Door / Membrane Door
c. Flush Door
3.
Infrastructure and Investment
4.
Marketing Strategy
5.
Process Description & quality control : Appendix A – Suppliers of Raw Material
/ Consumables
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1.0
GREEN WudTECH KRAFT INDUSTRIES
Door Skin COMPOST PANEL AT-A-GLANCE
About COMPOST Malamine & VENEER Door Skin
Door Skin is a MDF/ply -like wooden board made from Wood Dust mats and Mould in 2/4/6 or
Oval panel Designer i.e look like Panel Door. After that Melamine Decorative Paper or
Decorative Veneer is pressed together on Door Skin. It is usually made of 3 mm thick HDF Door
Skin. It can be produced in a range of various pattern and standard sizes.
USE OF COMPOST Malamine & VENEER Door Skin PANEL
Composit (HDF/MDF) Door Skin Panel has similar properties to HDF/ply and is sufficiently
rigid and flexible to substitute for it in a wide range of applications. It can be used for paneling,
ceilings, prefabricated shelters, doors and door panels, furniture and household utensils such as
trays and plates..
Stage of Manufacturing Door Skin
Door Skin is produced by the following stages:
1. MDF cut into Standard Size.
2. Mdf then Soaked in Liquid.
3. Paper is Impregnated through Melamine adhesive resin
4. Mdf are allowed to drain and dry
5. Mdf pressed in Mould platen by HOT Press and later on Melamine Paper /Veneer are pressed
together under required temperature and pressure.
6. Door Skin are trimmed to size and Pack by Overlay Film to Protect from Scratch..
Role in development
The production of mats is labour intensive and difficult to mechanise. Substituting Door Skin
Veneer Composit Panel for plywood also reduces the pressure on timber forests.
Door Skin making enterprise
Establishing Door Skin making enterprise requires a regular supply of MDF Board, electricity,
labour and access to markets.
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Door Skin products have several advantages over solid wood
•
Door Skin products are factory made in uniform standard sizes.
•
They are homogenous with predictable properties.
•
Because of factory processing, panel products are available in a large quantity from a
single source.
•
Most of the operations are already carried out in the factories so no primary processing
necessary at the DOOR Fabrication sites.
•
Finishing of 2/4/6 or Oval panels is made a lot simpler. In most cases, they are available
pre-finished with a whole variety of surfaces from the factory.
However, these new generation panel products could not be processed with the same age-old
tools and techniques. Therefore this material demanded a drastic change in the processing
techniques and consequently in the types of equipments to be used for processing. The other
problem in using particleboard and MDF is that they require special fittings and hardware to join
and assemble them.
Nevertheless, with all the above advantages over solid timber, Door Skin products have lent
themselves to mass production. With the easy availability of materials and processing factories
came up and mass production started in larger scale, hitherto not even thought possible.
2.0 Introduction of Door Skin technology
2.1
International development efforts
Door Skin is produced from MDF that are soaked in water and Decorative Paper are impregnated
in adhesive resin and then pressed firmly together in a hot press.
They were the first of the wide range of different panel Designer Door presently available that use
Door Skin as a raw material, but they are the simplest to produce, involve only Skin raw materials
and have great income generating potential for the Designer Door Manufacturer. The technology
for the manufacture of Door Skin in India has been developed by Toby, Pondichery, who have
developed a technically feasible and commercially viable technology for its manufacture.
Composit Panel is gaining in popularity and there are currently a handful of factories in operation
in India and 16 in China.
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The first recorded production of Door Skin based panels was in Craft Master USA during the mid
1980s where MDF was use the Exterior of Door as an alternative to ply/Flush Door. At about the
initiated in India by Masonite and Lot of Franchisee is given in India
Research has been carried out in several countries and many types of Composites panel products
have been developed - some made of bamboo and others of MDF in combination with
lignocellulosic materials and inorganic materials.
Research and development efforts have been mostly confined to countries of the Asia-Pacific
region i.e. China, India, Indonesia, Japan, Laos, Malaysia, Philippines, Taiwan, Thailand and
Vietnam. Canada and USA.
Although there was some pioneering work in Taiwan and innovative products such as ply
bamboo (bamboo glue-lam) were developed, the bamboo board industry is reported to be facing
extinction there due to the sharp increase in wages and shortages of raw materials. In Thailand,
the only product manufactured is bamboo mat board glued with Urea Formaldehyde (UF) resin
and this is mainly produced for export. In countries such as Laos, the Philippines and Vietnam,
interest in bamboo mat board production is relatively new, and the industries there are presently
in the phase of exploratory studies and experimental or pilot scale production.
2.2 Diversification of manufacturing technologies of MDF based panels
MDF is gaining importance as a replacement for wood in flooring and Door panels and other
housing components (such as windows, doors and partition panels), in furniture and in packing
cases. Some of these products are made of MDF board, some have a core of MDF with thin
veneer facings and others are made of Melamine Decorative Paper on MDF). In some Door Skin,
wood veneer or shavings are used to give a wood-like appearance to the surface.
At present, China has developed the largest number of MDF based panel products and produces
annually approximately 250,000 cubic metres in about 250 manufacturing units. The most
popular panel product is bamboo/MDF (about 100,000 cubic metres)
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2.2
GREEN WudTECH KRAFT INDUSTRIES
Development of MDF board: the Indian experience
In India, research efforts to make panels from MDF were initiated in the mid 1980s by the first
manufacturing process Duratuff and later on other Player come eg. Action Tessa MDF Associates
MDF and Green Industries Ltd.
In this way the potential of the Composite Panel as a wood substitute has been demonstrated, as
well as the techno-economic feasibility of its’ manufacture.
3. General development attributes and advantages
As explained previously, the Door Skin Composite Panel technology is suitable for the
production of “ecofriendly” alternative panel products to substitute for wood and help conserve
forest resources. Moreover, the technology can serve as a basis for economic development. The
main development attributes of the technology are as follows:
• Reduced dependence on timber resources and natural forests due to an increased use of wood
substitutes, leading to environmental protection.
• Creation of employment opportunities, particularly for women, and Labour.
• Improvement of peoples’ skills and enhancement of their earning capacities, leading to
improved welfare of the economically weaker sections of society.
• The production of Door Skin Generate Foreign Exchange by Export.
• MDF material, is highly popular and “environmentally friendly”. The boards posses physical
and mechanical properties on a par with ply/wood and have an excellent internal bond strengths, a
high plane rigidity and hence Finish of Door.
• MDF is durable and resistant to Fire, weather and biological (decay, insects and termite attack)
• MDF have better Look and stain resistance properties than ply/wood.
• They are as fire resistant as fire-retardant treated MDF Board.
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Applicability
A major reason to use Door Skin as an alternative in wood applications such as panels is the
authenticity of the material and the cultural history of its use in Western countries. Plywood still
retains the characteristics of solid wood in terms of structure, density, color and strength. The
advent of materials like MDF changed this scenario completely. This new generation Door Skin
engineered to give desired properties to the finished boards. They are homogeneous and have
equal strength in all directions along the surface.
Scope for small enterprise development
Given the benefits for the many people involved, including consumers, the market conditions for
the production of Door Skin and for the development of related industries and businesses are
favorable. As will be shown in the final sections of this report, the establishment of a small Door
producing enterprise/factory/plant requires a considerable investment, while the Door can be
manufactured in an existing plywood factory with no other facilities and investment of Door Skin
Inventory. In India, the establishment of such a unit would take place in the Small Scale Sector,
and it would thereby become eligible for all incentives provided by the Government for this
sector.
Concluding remarks
The bamboo mat board technology is a commercially and socially effective means of processing
bamboo into quality end products for the construction, packaging and transport sectors. Its
development attributes imply considerable scope for income and welfare improvement for rural
poor people. In addition it enables governments and wood-based industries to cope with the
problem of wood shortages and to reduce environmental degradation due to over harvesting of
timber trees. If properly organised and guided by private enterprises, state agencies and/or NGOs,
the technology as well as its backward and forward linkages can increase the income and welfare
of many people in a sustainable manner.
VISION OF THE PROJECT:“Customer Satisfaction’- by providing high quality in a professional and reliable manner
through merit shop philosophy, allowing it to be competitive, adaptable and creative”
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Advantage for Location :
For manufacturing Door, the Core and wood raw material is available from Importer. The
Company finds the Panel Product industry is growing and to the needs of the demanding and
knowledgeable customer.
Advantage For Rural Employment:
The process includes making fabrication and Carpentry job is required for preparation of
Door. It would provide fulltime employment to the labors and un-skilled workers. This will help
the rural people of this region as they are getting paid for the agriculture waste instead
of burning it and development of both agriculture and industry as well.
VISION OF THE PROJECT:“Customer Satisfaction’- by providing high quality in a professional and reliable manner
through merit shop philosophy, allowing it to be competitive, adaptable and creative”
MISSION OF THE PROJECT:
• To provide jobs to rural skillful unskilled employees.
• To develop the economy of the region.
• To popular eco friendly products.
• To obtain maximum growth with minimum investment.
• To use the modern technology to the DOOR and Particle Board Industries.
SELECTION OF THE PROJECTS:
The main reasons that encourage me to select this project are given as follows as
1.
The main raw materials for the industry, i.e. MDF and Tetra pack recyclable waste.
2.
Government policies beneficial to this project.
3.
We have vast experience in the Door manufacturing industry and Particle Board.
4.
Today Door demand increases day by day.
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GREEN WudTECH KRAFT INDUSTRIES
Bamboo Mat Board - PRODUCTION FLOW CHART
Matured Green
Bamboo
Cross Cutting
Bamboo
Spliting & Silver
Making
Prophylactic
Treatment
Mat Weaving
Prophylactic
Treatment
Asembling &
Hot Pressing
Dimensioning
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Stabilisation &
Drying
Resin Preservative
Application
Packing &
Despatch
GREEN WudTECH KRAFT INDUSTRIES
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Skin Door & Memberan Door
PROCESSING
SAWING /
CUTTING
MDF/HDF Door Skin
PROCESSING
MDF Cut in Req Size
IMPERGANATION &
SEASONING
Suck in Water for Smooth
&
Keep Dry for 24 Hrs.
GLUING
MDF insert in Hot Press
withDesigner Mould
CONSTRUCTION
OF DOOR
Impregnated Melamine Paper
Keep in Moulded Mdf and put in
Hot press for Curring
HOTPRESSING OF
THE DOOR
Packing by PP Film
Inspection/
Despatch
Trimer
Sanding
Routing/ and
Memberane
Pressing
Inspection/
Despatch
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GREEN WudTECH KRAFT INDUSTRIES
3.0
ABOUT COMPANY AND MANAGEMENT:
Ultrawood Kraft. is promoted by the Ultratech Group and Wood Kraft.
Ultrawood Kraft has proposed to set-up an ultra modern energy efficient plant for DOOR and
Flooring is managed by technocrats, who are in Pioneer name in Wood industry in India for
more than 3 decade.
Green Wudtech has proposed to set-up an ultra modern energy efficient plant and which is use
raw material recycle materials and environment friendly addessive to produce Panels Products in
the Name GreenZ Wudtech Flooring. Greenz Wudtech Flooring going to use the raw
material, plantation tree and Import based FSC Certified Product to manufacturing Board, Panel
Door, Flush Door and Flooring.
The Company would propose to start production in Third Quarter, 2015. The plant is of
international standard in the line of FSC control norms.
DIRECTORS AND ITS MANAGEMENT:
Mr. Ashwin Kanodia is a Architect and is own cosultancy PMC firm. He has a vast and varied
experience in the fields of PMC, Consulntancy, finance and PRO of over 5 years; he is a associate
with many Infra Projects.
Mr. Jayendra Kannani is Manager, who is looking after Production & Factory Administration of
proposed Panel Processing plant and implementation of projects.
He has from Industry
Background and having 45 years experience in production, implementation & successful running
of projects
___________________ is a Partner of the Firm. ____________ is Post graduate from _________
University, is looking after admirations of Company.
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Mr. Arun Murarka is a Partner of the Firm., and has a vast and varied experience in the fields of
Manufacture of Wooden Flooring, Kraft Panel Door, Veneer Door and FRD Door, is leader in
Door Segment, looks after implementation of projects. He has from Industrialist family
experience in production, implementation & successful running of projects. His industrial
experience and process knowledge has proved of immense help and it is this knowledge and
experience will give a competitive edge and creating a special niche for itself. He is proprietor of
Wood Kraft, is in pioneer name in wood industry in India for more than 3 decade. He was
Director of Udan Door & Vnneer Pvt Ltd and partner of Kesar Flooring (India) LLP.
The Company finds the Panel Product industry is growing and to the needs of the demanding and
knowledgeable customer.
4.0
THE PROPOSAL
The main objective of this proposal is:
To provide, at the same time advanced mechanized, facilities for producing panel based
furniture thus addressing three main issues i.e. Price, Quality and Delivery which are
very important for the customer.
As we have learnt that the new-age material can not be processed with the traditional
carpenter tools, in a country like India, where 98 % of the wood products are still
produced by traditional carpentry methods, ignoring this large tribe of carpenters and
craftsmen will be a fatal mistake. Mechanization can never come at a pace rapid enough
to replace the traditional craftsmen and carpenters. And even if it does, it would be a
disaster, since it would not take along with it the interests of the traditional craftsmen. It
is therefore necessary in any planning and program to ensure that the traditional
craftsman is not missed out and he is carried along in this stream of development.
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GREEN WudTECH KRAFT INDUSTRIES
The products that could be made from this unit include – Door Skin, Panel Door and
Laminate Door and Flooring.
5.0
Processing Techniques Door for Energy Saving Plant and non emission plant for
Conservation of Energy and Environment friendly Product
a) Door Skin, DOOR and Bamboo Composit Pannel Manufacturing
Although power is a major input in Door manufacturing, it is one of the major focus areas for
cost monitoring and cost cutting. Impact of the measures for reduction of energy consumption
and consequent impact on the cost of production of goods:
Following measures were taken to control the same.
1. Optimization of parameter settings on GREEN WUDTECH Door Skin, Door and
Bamboo composit Panel Hot Press in multi delights Press machines.
2. Hire the Consultant from renowned Suppliers.
3. Change in pre-treatment and Seasoning of wood
- Adoption of environment friendly process.
4. Future plan of action.
- Development of new Product, which is better aesthetics, user friendly and value for
money for the customer.
- Low cost automation and process optimization for continuous improvement in
productivity.
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Green Wudtech has the capacity to produce 33,00,000 Sq. ft various type Bamboo Composit Pannel,
Engineering and Deck Flooring, 1200 Door Skin, 55 Laminates / Venner Door per day.
Such a revolution in manufacturing also demands special techniques for processing and consequently
special equipments to process them on. The panel processing can be broadly divided into three stages of
operation.
DOOR MANUFACTURING PROCESS
The main raw material required for Door manufacturing are Filler (Particle Board) core veneer, face
veneer, urea formaldehyde resin / Phenol formaldehyde (Bonding gum) etc. The Filler core veneer are
required for manufacturing interior core of Door above its core and Face veneer are required for
manufacturing exterior core of Door The both sides of the core veneers are overlapped with face veneers.
Once dried the veneer is graded and stacked. Selected sections of veneer are glued together. A hot press is
used to seal the veneer into one solid piece of Door, which will be trimmed and sanded before being
stamped with its appropriate grade.
 The sections of veneer are then sorted and stacked according to grade. This maybe done manually,
or it may be done automatically using optical scanners.
 The sorted sections are fed into a dryer to reduce their moisture content and allow them to shrink
before they are glued together. Most plywood mills use a mechanical dryer in which the pieces
move continuously through a heated chamber.
 In some dryers, jets of high-velocity, heated air are blown across the surface of the pieces to speed
the drying process.
 Make pieces suitable for use in the interior layers where appearance and strength are
less important.
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 Those sections of veneer that will be installed crossways—the core in three-ply sheets, or the cross
bands in five-ply sheets—are cut into lengths of about 4 ft-3 in(1.3 m).
 When the appropriate sections of veneer are assembled for a particular run of Door, the
process of lying up and gluing the pieces together begins.
 This may be done manually or semi-automatically with machines. In the simplest case of three-ply
sheets, the back veneer is laid flat and is run through a glue spreader, which applies a layer of glue
to the upper surface. The whole sheet is run through the glue spreader a second time.
 Finally, the face veneer is laid on top of the glued core, and the sheet is stacked with other sheets
waiting to go into the press.
 The glued sheets with Door frame loaded into a multiple-opening hot press. It can handle 5 Door
at a time, with each Door Material loaded in a separate slot. When all the sheets are loaded, the
press squeezes them together under a pressure of about 110-200 psi (7.6-13.8 bar), while at the
same time heating them to a temperature of about 230-315° F (109.9-157.2° C).
 The pressure assures good contact between the layers of veneer, and the heat causes the glue to
cure properly for maximum strength. After a period of 2-7 minutes, the press is opened and the
sheets are unloaded.
 The rough sheets then pass through a set of saws, which trim them to their final width and length.
Higher grade sheets pass through a set of 4 ft (1.2 m) wide belt sanders, which sand both the face
and back. Intermediate grade sheets are manually spot sanded to clean up rough areas. Some sheets
are run through a set of circular saw blades, which cut shallow grooves in the face to give the
plywood a textured appearance. After a final inspection, any remaining defects are repaired.
 The finished sheets are stamped with a grade-trademark that gives the buyer information about the
exposure rating, grade, mill number, and other factors. Sheets of the same grade-trademark are
strapped together in stacks and moved to the warehouse to await shipment.
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MANUFACTURING PROCESS AS FOLLOWS:
DRYING IN SEASONING CHAMBERS
Drying and Seasoning is done in seasoning chambers, moisture content from the wooden and veneers are
brought down to approximately 5 to 10%. If there is higher moisture content, the absorption of bonding
glue is affected. Thus for proper manufacturing of Door it is important to bring the moisture content low to
aid absorption of bonding glue.
GLUEING
Composit Bamboo & Bagass Particle Board is glued by Dipping in tray and spinkle method respectively. Finally both
Composit Bamboo & Bagass Particle Board to be use as a face and Filler in Door Manufacturing
respectively.And veneers passed through Glue Spreader which spreads bonding glue (Phenol
phormaldihyde) on both sides over the veneers.
PROCESS OF VARIOUS TYPE OF DOOR
Veeneer Door :The Veneers are stalked, one above the particle Board or Wooden Ribs as per customer
choice, alternatively along and across the grains to the required thickness of Door.
P U PAINT OR Police Door : For making these type of value added Door Face Decorative veneers on
both the top and bottom layer is put into construction and then send for final finished done by Robotic
Painth Bhooth..
Skin Door : The Door Skin is also laid during the construction on top and bottom of the Frame, for
manufacturing Skin Door.
Treatment:
Door Filler and Frame is done treatment for the Borax chemical for decay fungs and done seasoned the
Wood Frame for unblended properties.
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LAMINATION/VENEER BY HOT PRESS:
Now the Door is sent for press Lamination/veneers in press.The constructed Door are sent into the hot
press for pressing. Pressing time and temperature depends on the thickness of glue type and Door. T h e
H yd r a u l i c H o t Press is operated by P o w e r p a c k t e c h n i q u e , and heat transmitted by Tarmac Fluid
Thermo pack.
SIZING:
The pressed sheet of DOOR is then passed
through parallel saw to make Door on required
sizes and right angles at corners.
TESTING:
One sheet on each lot of Door is sent to the lab for testing as per IS codes. Each sheet are marked, checked
and stalked in dispatch godown ready for dispatch.
5.1
Processing Techniques for Bamboo Composite Board Manufacturing
Although power is a major input in Composite Board manufacturing, it is one of the major focus areas
for cost monitoring and cost cutting. Impact of the measures for reduction of energy consumption and
consequent impact on the cost of production of goods:
Following measures were taken to control the same.
1. Optimization of parameter settings on Molding Hot Press in multi delights Press machines.
2. Buy the plant Technique from renowned Suppliers.
Total energy consumption and energy consumption per unit of production: Compared chart from
traditional System enclosed.
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Pr oph yla ct ic Tr e a t m e n t of Ba m boo/ Ba m boo M a t s
Bamboo is easily attacked by insects and fungi due to presence of starch and sugar in abundance.
Prophylactic treatment of either bamboo or bamboo mats is very essential to enhance their life during
storage.
There are two types of prophylactic treatments viz.,
(1) Traditional or Non-Chemical Treatment
(2) Chemical Treatment.
Tr a dit ion a l or N on - Ch e m ica l Tr e a t m e n t
Traditional or non-chemical methods are being widely used by villagers and artisans in several countries
for man centuries and the skill is passed on from generation to generation. Typical traditional methods
include: smoking, white washing, and water storage or pounding.
Sm ok in g:
Smoking is carried out in chambers. This produces toxic agents and heat which destroy starch in bamboo
thus making them immune to insect attack and also blackens the culms.
W h it e w a sh in g
Bamboo culms and mats are often painted with slaked lime, which prolongs their life by delaying/reducing
moisture absorption.
St or a ge in W a t e r :
Freshly cut bamboo is stored either in running water or in water pools for 3-4 weeks to leach out starch.
This process prevents bamboo from insect attack. In case of water pool water has to be changed
frequently to prevent fouling.
Although traditionally treated bamboo show increased resistance to insect and fungal attack compared to
freshly cut culms, these methods do not provide long term durability.
Ch e m ica l Tr e a t m e n t
Chemical treatment is more effective than traditional treatments. Typical chemical treatment methods uses
water soluble preservatives like Gamma BHC 0.5%, Formalin 0.5% , Phenol+ 1 Copper sulphate (1: 2),
sodium penta chlorophenate 0.5% and Borax 1.5%. The chemicals are dissolved in water. Bamboo or
bamboo mats are either sprayed with the solution or dipped in the solution for 10 minutes. After treatment
the bamboo mats are stored in shade till they are processed further.
Bamboo is non-durable in its natural state. Durability can be greatly increased by preservation with safe,
environment-friendly chemicals, such as boron. Several simple and cost-effective treatment methods are
available.
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Cutting – Matured bamboo culms with a diameter of over 90 mm should be harvested following the
prescribed silvicultural practices Cross cutting – The culms are cut into required lengths using cross
cutting machine up to the length of the bamboo where the outer diameter is 90 mm.
Bamboo with a diameter less than 90 mm poses problem in the splitting operation.
Splitting and sizing - Bamboo culms cut into required lengths are split into strips of 19-20 mm in splitting
and shaping machines. Four-side planning – Bamboo strips are shaped in a 4 side planning machine to
the correct dimensions.
This helps in producing laminates
without much gap between strips.
Boiling – Boiling strips is a key procedure in the manufacture of laminates. Boiling removes starch and
thereby improve the resistance to borer attack. Preservative and bleaching chemicals can also be added
in desired quantities during the boiling process to further improve durability and appearance. Boiling is
Carbonization (Steaming) – For
done in vats for about 2 hours.
carbonization, an optional step or darkening the color of strips to brownish, strips are steamed in a
pressure vessel for about 2 hours. Steaming also removes starch from the strips and in addition to
imparting a brownish color to the strips.
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Drying – Bamboo strips which are boiled/steamed are dried in a kiln to a moisture content of 8-10 per
0
cent. Drying is done at a temperature of 70 – 80 C.
Sorting and Gluing – Dried strips
are sorted to reduce the colour differences among the strips so that finished laminate has even colour.
Urea formaldehyde resin is applied to the strips using adhesive applicator.
0
Hot pressing – Hot pressing is done in a special press at 105 C and
2
with a specific pressure of 10 kg/cm vertical pressure and 2.5 kg side pressure for horizontal laminates;
2
and 10 kg/cm side pressure and 2.5 kg vertical pressure for vertical laminates. Pressing time depends
upon the thickness of the laminates to be manufactured.
Board and floor shaping – These are done using four side grinding machine and double end cutting and
shaping machine.
Sanding – Boards are sanded in a sanding machine to smoothen the surface for further finishing the
surface.
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GREEN WudTECH KRAFT INDUSTRIES
Phase II Implement to start Particle Board Plant at Tamilnadu
Particle Board MANUFACTURING PROCESS
Chipping:
Chipper is first and starting process of raw materials for producing perfect chips,
For making process of Particle board it can Bamboo and Bagass are cut into high quality with even length
and uniform chip thickness.
It is also suitable for the chipping of branches and twigs, and planks.
Machine is composed by a seat Knife roll, up and down feeding roller, Conveyor belt, and hydraulic
system and so on.
This series chipper structure is advanced, the cutting quality is high, raw material compatibility is broad,
easy of operation.
Dryer of Chips:
Roller Drier is the main equipment for drying the chips in the Particle board production line. It is mainly
use for put out the water from the chips from the flakers, so that the moisture of the chips can come to the
request of the production technical.
Market Share:
It is roughly presumed that the total size of Indian Panel and Door Market is around Rs.5000 cores.. The
market is divided between two categories i.e. (1) branded products and (2) non-branded products. Until
1970 the share of branded products was 90% in comparison to 10% of non-branded products but now the
situation has been almost reversed and the branded products have only 10 per cent market share. Most of
these SSI units generally are not fully integrated ones. They buy semi-processed raw material and do the
pressing and finishing jobs in their factories.
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Skin Door & Memberan Door
PROCESSING
Bagasses Composit Board
PROCESSING
Chipping
SAWING /
CUTTING
Knife Mill
IMPERGANATION &
SEASONING
Dryer
Seive
GLUING
Glue Blending
CONSTRUCTION
OF DOOR
HOTPRESSING OF
THE DOOR
Forming
Hotpress
Trimer
Trimer
Sanding
Sanding
Routing/ and
Memberane
Pressing
Inspection/
Despatch
Inspection/
Despatch
Project Report
GREEN WudTECH KRAFT INDUSTRIES
Marketing Strategy
Market Potential And Competition
Green Wudtech Kraft Value added Door made by using Solid Wud and HDF Skin is always have ready
demand in the market, because it has more life and appearance better then traditional Door.
The product is eco friendly and cheap as compared to traditional Door. The different Door products have different
categories of customers.
The “Green Wudtech Kraft” - Door products like ready made Door and furniture component for Kitchen Door
generally popular among the middle class of people of the regions.
Potential Customers
•
Developer and Contractor
•
Retailers of the Plywood and Hardware Shop
•
Government organization like MAHADA
•
Direct Consumer by Various e-Commerce Platform
MARKETING CHANNELS:
The marketing channels plays important role in the distribution of the products to reach the potential
customers. The selection of the marketing channels is also important .so choose my marketing channels as
follows as :
Wholesaler & Distributor: These People working as a company partner because they are giving place our
product.
Industrial Merchants: The registration with the trading companies like India mart will also be the
marketing channel.
The Initial sales will be made to only Selective buyers in India and abroad who are ready to make a
buying Agreement with us. They are ready to buy entire total Production.
Total sale generated through e-commerce and Direct to consumer by our Marketing Team.
The market is ready for our product and the technology is accepted by the buyers.Since the buyers are
aware about the technology used by us they are ready to buy the total production from us from the day
one.
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
Market Share:
It is roughly presumed that the total size of Indian Panel and Door Market is around Rs.5000 cores.. The
market is divided between two categories i.e. (1) branded products and (2) non-branded products. Until
1970 the share of branded products was 90% in comparison to 10% of non-branded products but now the
situation has been almost reversed and the branded products have only 10 per cent market share. Most of
these SSI units generally are not fully integrated ones. They buy semi-processed raw material and do the
pressing and finishing jobs in their factories. So our DOOR SKIN have no Market Tread.
Pricing
The Pricing of our Product will be very competitive along Quality, since the technology used by us is
certified by World Leader.
The main feature of this technology is
A.
Recycle and FCS raw Material to be used in production
B.
Environment Friendly- Since there is no wastage of any material while processing Bamboo
Composite Panel the technology being used is completely Environment friendly. Hence there is
no danger to the Environment as well as to the human beings.
Quality
Door Skin is procured by us is Water proof and pressed with D3 Glue which is having property of
Marine grade adhesive. Other manufacture are using Urea formaldehyde and Malamine resin for
veneer bonding, high density plywood making press etc
This will result in the first Door will be water proof, and unique as not a single door player are making
these quality.
Indoor Air Quality
A No-Added-Formaldehyde (NAF) option is available for all molded door designs.
This means that we do not add formaldehyde in the process of making the molded door.
Formaldehyde is a chemical that is a natural part of our world, emitted from wood and other natural
substances and part of the air we breathe. However, high emissions of added formaldehyde have been
found to be risk to health.
Project Report
GREEN WudTECH KRAFT INDUSTRIES
The (NAF) option will not have any form of formaldehyde added. This may help earn points for green
building programs that request NAUF or NAF products.
Solid Particleboard Core with NAF
Combination Wood/MDF or All-Wood Frame in 1-3/8" and 1-3/4" Doors
20-minute fire rating available for 1-3/4" up to 3'0" x 8'0"
The No Added Formaldehyde (NAF) option is available for all molded door designs. This means that we
do not add formaldehyde in the process of making the molded door. (NAF) option assures that
formaldehyde was not added at any point in the manufacturing process.
This core option is available in ProCore The option which reduces the transmission of sound by up to 50
percent (compared to a hollow flush door)
Hollow Core with NAF
MDF Frame with blocking behind panels for support
The No Added Formaldehyde No Added Formaldehyde (NAF) option is available for all molded door
designs. This means that we do not add formaldehyde in the process of making the molded door. (NAF)
option assures that formaldehyde was not added at any point in the manufacturing process.
Solid Mineral Core
All-Wood Frame in 1-3/4" Door
Doors available in 45 or 60 minute fire ratings up to 4'0" x 8'0"
We manufacture and supply the most widely specified and diversified product offering for the health care,
education, hospitality, public/government, military, office and mixed use/ multi-family markets.
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
At GREEN WUDTECH being easy, fast, on-time, complete and correct is our corporate mantra. Our
commitment, to environmental leadership, our focus on customer service and our relationships with
architects, designers, contractors, end-use customers and distributors helps us navigate and serve the
complexities of our industry.
Bringing together two strong brands GREEN Wudtech (a leading residential door manufacturer in the
world map)
MicroPro termo technology is a revolutionary way to pressure treat wood for decks, fences, landscaping
and general construction uses. MicroPro pressure treated wood is treated with micronized copper
preservatives, which help protect against termite damage and fungal decay. MicroPro offers many benefits
including significantly improved corrosion performance. MicroPro treated wood products are US building
code compliant.
MicroPro termo pressure treated wood is lighter in color compared to current copper based treated wood
products. The unique appearenace of MicroPro termo allow Contractors the ability to build Zero
Emission and Green Building projects using treated wood that is lighter, fresher and more natural in
appearance.
•
•
•
•
•
First wood treatment process to complete Life Cycle Assessment Studies.
And Effective protection against fungal decay and termite attack.
Lighter, more natural wood appearance
Improve painting and staining qualities.
Better corrosion resistance for code approved fasteners and hardware
combines Green Wudtech Kraft - Door Systems (an architectural class door and Frame manufacturer)
with
Green Wudtech Kraft Deck and Flooring (a architectural class Interior Product) forming one of the
most complete Exterior Flooring product also offering in the building industry.
Marketing Strategy
Market Potential and Competition
Green Wudtech Kraft Flooring and Value added Door and Flooring are made by using Composite wood, real
wood and HDF Skin is always having ready demand in the market.
Project Report
GREEN WudTECH KRAFT INDUSTRIES
Green Wudtech Kraft is eco friendly and value added as compared to traditional Door , Frame and Flooring..
The different Door and Flooring products have different categories of customers.
The Green Wudtech Kraft - Door products like ready made Door and furniture component for Kitchen Door
generally popular among the middle class people of the regions.
MARKETING CHANNELS:The marketing channels plays important role in the distribution of the products to reach the potential
customers. The selection of the marketing channels is also important .so choose my marketing channels as
follows as
Wholesaler & Distributor: These People working as a company partner because they are giving place our
product.
Industrial Merchants: The registration with the trading companies like India mart will also be the
marketing channel.
The total sales will be made to only Selective buyers in India and abroad who are ready to make a buying
Agreement with us. They are ready to Sale our Brand only.
The market is ready for our product and the technology is accepted by the buyers.
Since the buyers are aware about the technology used by us they are ready to buy the total production
from us from the day one.
8.0
Process Description & quality control:
The company is planning to import methanol directly from foreign countries such as Saudi Arabia,
Malaysia, Singapore, Iran, Iraq etc. and convert this methanol into formalin and then urea and phenol; is
added. The above cost saving is derived by the bulk import of methanol and minimizing transporting
overhead.
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Project Report
8.1
GREEN WudTECH KRAFT INDUSTRIES
Technical
The company will appoint necessary technical experts and skilled workers for running the smooth
operation.
SECTION - II
RAW MATERIALS & TECHNICAL ASPECTS
FORMALIN : The process of manufacturing Formalin consist of mixing Methanol, water and air and then
reacting over silver granule catalyst bed in a particular method. The reaction starts when the temperature
reaches at 75O C and then the temperature is gradually increased to 600 to 700OC. The exit gas from
reactor outlet containing formaldehyde and un-reacted methanol are lead to absorption tower where
formaldehyde and methanol are dissolved in water forming a solution of Formaldehyde which is known as
Formalin. The formalin is taken to final storage tank.
Urea/Phenol FORMALDEHYDE SYNTHETIC RESIN : Formalin is mixed with Phenol in the reaction
vessel and heated in presence of catalysts. Excess water in the vessel is distilled over by external heating as
a result of which the final product of 50% solids is obtained.
The resin formation is the result of two different chemical reactions. formalin with urea to form a polymer.
These reactions are carried out under the catalytic influence of a number of chemicals, suitably added to
the reaction mixture. The main catalysts are Citric acid and Caustic soda.
Green Wudtech Kraft MDF and Decorative Veneer :
MDF and Decorative Veneer were procured from International Market and other local supplier.
Decorative Veneer also of thickness approximately 0.6 mm and MDF app 3mm. The species of
MDF made from Pine Wood, Which Is Due To the Best Properties like Density,
Aesthetical Appearance, ConsistentAvailability and Better Nail Holding Capacity
Furniture, Packaging And Construction Activity.
Project Report
GREEN WudTECH KRAFT INDUSTRIES
Woven bamboo mat:
Woven bamboo mats were procured from M/s. Kerala Bamboo Corporation and other local
supplier. Mats are tightly woven in herringbone type with bamboo sliver of thickness
approximately 0.6 mm. The species of bamboo used ochlandra travancoria.
Resin:
Since corrugated roofing sheets are meant to use under exterior condition, the bonding material
must be water and weather resistant. Two types of resin were attempted to make coir based
corrugated sheets.
i. Phenol Formaldehyde resin (conventional).
ii. Phenol cardanol formaldehyde resin (PCF).
Although initial trials were carried out with both the resins, the final pilot scale trials were done
with PCF resin keeping in view of the eco friendly nature of the final product.
The main constituents of PCF resol resins are phenol, cardanol, formaldehyde and a catalyst.
Properties of resins depend upon the proportion of chemical ingredients used and method applied
to synthesize the same
Raw materials for resin manufacture:
Phenol: is available either in crystal form or in liquid form. If crystalline phenol is used it has to
be melted either by keeping the drum in a steam pit or by heating electrically to around 65 c and
then loaded into kettle. Another way of melting phenol is to add water or formaldehyde (10%) on
the wt. of phenol and allow for 3-4 days in the drum, slowly the phenol gets liquefied Phenol is
highly corrosive and will cause injury to the skin on contact. Handling of phenol must be done
carefully.
Workers should be provided with rubber gloves, rubber shoes and goggles while handling phenol.
In case if it comes in contact with skin, it should be thoroughly washed with water followed by
washing with sodium bicarbonate.
Formaldehyde: Is a gas dissolved in water to form formaldehyde solution. Formaldehyde
solution is commercially available as Formalin of 37% HCHO concentration (w/w). Percentage
purity of formaldehyde is very important in order to use optimum proportion of formalin for resin
manufacture. Formaldehyde is highly irritating to eyes and has pungent odour. If too much
formaldehyde is inhaled, it affects the lungs and long contact with skin leads to dermatitis.
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
Workers should be provided with gloves, rubber shoes, goggles and nose guard.
If formalin comes with contact with skin or any part of the body, it should be washed
thoroughly in running water.
Cardanol: Cashewnut Shell Liquid (CNSL) is one of the few economic sources of naturally occurring
phenols. The main constituents of CNSL are anacardic acid and cardol in the approximate ratio of 90:10.
When commercial CNSL is distilled, the main decarboxylated product is cardanol which is a
monohydroxy phenol with a linear side chain in the meta position. The side chain contains on an average
two double bonds.
General properties of cardanol and the test methods to find out its suitability as a partial substitute for
phenol in PF resin adhesives are given below.
Bamboo Pannel require HIGH DENSITY PLYWOOD PRESSING:
The core veneer of the required thicknesses is first glued by phenol formaldehyde resins with the help of
the glue spreader. Over the core veneers, on either side a face veneer is also glued on.
A margin of about half an inch on all sides is allowed for sawing off after pressing to obtain smooth edges.
This is considered normal waste and has been provided for.
This glued and wet Bamboo mate, now between the aluminum sheets is then transferred to the hydraulic
hot press with the help of the scissor lift and placed inside the daylights (that is between the platens). The
pressure in the press is then raised to 1000 tones by the oil operated hydraulic press and the temperature
maintained around 110 Degree Centigrade by the boiler. After this treatment - 10 minutes for 4 mm, 15
minutes for 6 mm plywood, 20 minutes for 8 mm, 30 minutes for 12 mm, 45 minutes for 18mm Bamboo
composite Panel - the temperature and pressure are reduced to normal and the platens lowered and the
Bamboo composite Panel with the aluminum sheets taken out of the press. These are then allowed to cool,
sanded to make the surface smooth, the serrated edges, if any, cut out and all sheets are cut to the required
size, the standard size being 8’ x 4’ and 7 Ft x3Ft.
Project Report
8.2
GREEN WudTECH KRAFT INDUSTRIES
Manpower:
Number of Labour is as per following
Skilled
-6
Unskilled - 9
8.3
Training:
Trained 2 no. of people will be send by Consultant and they will train to local person.
Phase I :
In 1st phase Wood Kraft do Collection of all information, data, preparation of drawings and inviting
quotations etc.
A detailed schedule in terms of bar charts is prepared for implementing the project. This will be carried out
within a period of 2 months.
Phase II :
In 2nd phase the actual implementation of the project will be in 3rd Quarter of Next year.
This will take at least 2 months as the supply period of the machines and install will take 2 months.
Besides it will take around 1 to 3 months for land development and building construction. The tentative
date of trial production will be September 2014 and operation of CFC will be carried out within 30 days
from the date of trial production.
HIGHLIGHT of Project
Our project is technically feasible and our product is useful in green building for nation.
List of the machine to be used in the manufacturing process and their cost of purchase:High Technical Panel Processing Machine
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
1. HYDRAULIC PRESS MACHINE:
3 nos Hydraulically Press will be installed operated steam/oil heated Five daylight Press in up closing
frame. The main body is fabricated from M.S. and Platens are also fabricated from solid plate as well as
complete with Automatic Power pack, steam connection pipes and other necessary parts and components.
PLANT AND MACHINERY
A plant is a place where men, material, money, equipment, machineries etc. are brought together for
manufacturing products. Today in modern industry equipment and machineries are very important part of
the total production effort than the case years ago.
The following machineries are required.
The Company will arrange necessary technical experts and skilled operators for running this plant. The
continuity of professionals and skilled workers are ensured by the consultant.
General Manager will be in charge of functions of the unit. He looks after the overall management of plant.
There will be one supervisor, 2 machine operators, 2 skilled workers, 6 unskilled workers 5 women
workers 2 mechanics cum electrician reporting to General Manager.
There will be 1 accountant in helping Managers in matters like accounting, book keeping, banking and
other finance related affairs. There will be 2 more office staffs in charge of office matters.
In total there will be 21persons including Manager employed in the unit.
OTHER PROJECT DETAILS
A. Power:
The total connected load for plant is 200 H.P and Now for 1 st Phase we require 110 Kw HT conection
which is already Section.
The annual electric charge is Rs. __________ lakhs at full capacity utilization. Details are given in
Annexure - V.
Project Report
GREEN WudTECH KRAFT INDUSTRIES
B. MISCELLANEOUS EXPENSES:
These items includes repair and maintenance of building, plant and machineries, postage charges, cost of
printing and stationary items, insurance charges. An amount of Rs.______ lakhs per annum has to be
incurred towards the smooth operation of the Plant. The details of estimation are given in Annexure - VIII.
C. PRELIMINARY AND PRE-OPERATIVE EXPENSES:
These items include company registration, project report preparation, building design and drawing,
technical consultancy fee etc. Thus the preliminary and pre operative expense required for implementing
the proposed project is Rs. _____lakhs. The details of estimation are given in Annexure - IV.
D. PLANT CAPACITY AND CAPACITY UTILISATION
The Plant have an annual installed 400 Door and Bamboo Composite Panel etc..
Because of down time and other various reasons, the capacity may not be releasable and it is assumed that
60% of the capacity utilization will be achieved during first year and 75% during second year and 85%
capacity utilization will be achieved, third year onwards.
E. FINANCIAL ASPECTS
The estimated capital outlay of the project is Rs. ______ lakhs as shown in Annexure - XI.
The capital expenditure is proposed to be raised as the contribution of Promoters to the extent of Rs. 33%)
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
I. Feasibility Report of the Project:
Assumption to Revenue Estimates:
The projected revenue estimate of the unit is shown in Annexure XIV and is based upon the following
assumptions.
1. The Plant will have an installed capacity of 300 Door and 100 Board total 400 Board and Door
processing per day.
2. The capacity utilization is at 60% first year, 75% during second year, 85% third year onwards.
3. The main utilities are power. The total power requirement is 110 K.V.A. The power charge is calculated
considering the tariff.
4. Repairs & Maintenance is provided @ 2% on building and 3% on Plant & Machinery.
Details of computation of depreciation is attached as Annexure-XII & XIII. Straight line method of
depreciation is applied for project purpose. However, for income tax purpose, written down value method
is applied for.
6. Administrative expenses is provided in the net revenue estimate. It includes rates & taxes traveling
expenses, postage telephone & telegram, printing & stationery, other office expenses etc.
7. Income tax is provided considering the rates applicable to private limited company. Computation of
income tax is attached as Annexure - XVI.
8. A corpus fund is raised from the surplus derived from the operation of the common facility centre.
Net Revenue estimates are furnished in Annexure - XIV According to this statement there is a cash surplus
of Rs. ___________ lakhs in the first year of operation. The projected cash flow statement is appended
as Annexure - XVI. As per cash flow statement there is cash surplus adequate to meet all the day to day
expenses and making corpus fund for periodic maintenance and up gradation of CFC.
The internal rate of return of the project is 5% after tax which is computed in Annexure - XVIII.
Break even level of operation is computed in Annexure -XIX. Operating BEP works out to 41.84% of the
installed capacity and the cash BEP works out to 16.94% of installed capacity.
Project Report
GREEN WudTECH KRAFT INDUSTRIES
BREIF
U lt ra t e c h K ra ft is planning to set up a Composit Bamboo Pannel pressing etc.
The capacity of the 400 sheets Panel Pressing etc. pressing per day.
The required technical know how for production is indigenously available.
This common facility centre will not create any atmospheric pollution.
The estimated capital outlay of the project is Rs. _______
lakhs and as is proposed to be financed as
follows :
(Rs. in Lakhs)
Contribution from Promoters (30%)
50.00
Bank Term loan and Working Capital
236.16
286.16
The projected net revenue estimate for first 7 years is satisfactory.
The project is technically feasible and provide a key role in the total development of Bamboo Composite
panel manufacturing etc..
Ultrawood Kraft took lease from Ultratech India Ltd, Add. MIDC, Ambernath Dist. with 110 HP Ht
Electricity connection.
U;trawood Kraft had planned to start production by 3rd Quarter of this year.
Our Location of Factory is perfects, as it is a very important factor in the success of such ventures. Our
Factory in located at MIDC, where already a considerable amount of necessities like power, transport, etc
are available. In brief, the location of the unit should be such that the unit can cater to both domestic as
well as Inter-state market.
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Project Report
GREEN WudTECH KRAFT INDUSTRIES
The phase II Wood Kraft plan to put Back ward Integration Plant of 900 Door Skin per day for Job work
for Exporter and very highly valued Customer and making bamboo composite pannel etc. is proposed to
set up in _______ Cents of land in survey number ______________in ___________ Village, _________
Taluk, _____________ District. The lease Land for above facility is Rs. ---------- Lakhs including land
developments.
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