Detailed Project Report (DPR) on veneer cum plywood cum mdf plant

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