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    Detailed Project Report on BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD

    Detailed Project Report on BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD
    Detailed Project Report on BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD
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      BAMBOO FIBRE MAT BOARD/BAMBOO MAT BOARD
      [CODE NO.3315] J.C.: 1396



      Bamboo mat boards (BMB) are produced from woven mats of bamboo that are soaked in adhesive resin and then pressed firmly together in a hot press. They were the first of the wide range of different panel boards presently available that use bamboo as a raw material, but they are the simplest to produce, involve only bamboo raw materials and have great income generating potential for the rural poor, who are able to weave the mats from which they are formed. The technology for the manufacture of BMB in India has been developed by the Indian Plywood Industries Research Institute (IPIRTI), Bangalore, who have developed a technically feasible and commercially viable technology for its manufacture. BMB is gaining in popularity and there are currently a handful of BMB factories in operation in India and 16 in China.

      Bamboo mat board is very versatile and can be produced up to 6 mm thick by varying the number of mat layers used; boards are usually formed of 2, 3, 5 or 7 mats. For thicker laminated boards, wood veneers are interleaved with the bamboo boards to produce bamboo mat-veneer composite boards (the production of these is not covered in this TOTEM). BMB is at least as durable and stable as wood-based plywood and is very resistant to pest attack, extreme climatic conditions and fire. It can be used for many of the uses to which plywood is now put such as paneling, ceilings, prefabricated shelters, packing cases and storage bins, roofs, doors and door panels, furniture, and household utensils such as trays and plates. BMB is much more flexible than wood-based-plywood and can be used in structural applications such as stressed skin panels, wall bracings and web beams for which plywood is not suitable.

      The first recorded production of bamboo based panels was in China during the mid 1940s where bamboo mat board bonded with casein (enamel) glues was used in the interior of aeroplanes as an alternative to aircraft-grade plywood. At about the same time research was initiated in India to develop synthetic resinbonded bamboo mat board, for which the technology became available a decade and a half later. Since then, research has been carried out in several countries and over 30 types of panel products have been developed-some made of bamboo only and others of bamboo in combination with wood, lignocellulosic materials and inorganic materials. Research and development efforts have been mostly confined to countries of the AsiaPacific region i.e. China, India, Indonesia, Japan, Laos, Malaysia, Philippines, Taiwan, Thailand and Vietnam. Canada (in collaboration with Costa Rica) is the only country outside Asia where research on bamboo panels is being carried out.

      Although there was some pioneering work in Taiwan and innovative products such as plybamboo (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 matboard production is relatively new, and the industries there are presently in the phase of exploratory studies and experimental or pilot scale production.



      COST ESTIMATION

      Plant  Capacity                                            :       15.00 Cubic Mtr./day
      land & Building (3000 Sq.Mtrs)                :    Rs. 1.58   Cr
      Plant & Machinery                                       :    Rs. 1.96   Cr
      Working Capital for 2 Months                   :    Rs. 2.85   Cr
      Total Capital Investment                            :    Rs. 6.55   Cr
      Rate of Return                                             :    30%
      Break Even Point                                         :    53%

      INTRODUCTION    
      ADVANTAGE OF BAMBOO MAT BOARD    
      THE MAIN DEVELOPMENT ATTRIBUTES OF THE TECHNOLOGY
         ARE AS FOLLOWS    
      USES AND APPLICATION    
      TECHNICAL CHARACTERISTICS    
      CHARACTERISTICS & PROPERTIES    
      OF BAMBOO FLOORING/PANELLING    
      IT HAS VARIOUS IMPORTANT USEFUL PROPERTIES - IN ITS
         CONSTRUCTION FEATURES.    
      SIZES OF BAMBOO FLOORING/BAMBOO PANELING    
      STYLES    
      FOR BAMBOO FLOORING/PANELING ETC    
      BAMBOO MAT BOARD - A REPLACEMENT FOR PLYWOOD    
      OVERVIEW OF BAMBOO IN INDIA    
      TABLE DISTRIBUTION OF BAMBOO IN INDIA    
      TABLE DISTRIBUTION OF SOME IMPORTANT BAMBOO SPECIES IN INDIA    
      BAMBOO MAT CORRUGATED SHEET [BMCS]    
      DEVELOPMENT OF BAMBOO COMPOSITE AND MAT BOARD IN INDIA    
      A. BAMBOO MAT BASED PRODUCTS    
      B BAMBOO STRIP BASED PRODUCTS    
      C. BAMBOO IN ROUND/SPLIT/COMPOSITE FORM    
      FIG 1. A GENERALIZED PROCESS FLOW CHART FOR BAMBOO  
         MAT COMPOSITES IS AS FOLLOWS    
      FIG 2. FLOW CHART FOR THE MANUFACTURE OF BAMBOO WOOD    
      ADHESIVES    
      RESIN APPLICATION    
      HOT PRESS CONDITIONS    
      TEMPERATURE    
      PRESSURE    
      TIME    
      FINISHING OF PRODUCTS    
      BAMBOO MAT BOARD    
      TABLE    
      BAMBOO AND BAMBOO PLYWOOD    
      PROPERTIES OF BAMBOO MAT CORRUGATED SHEET    
      A. BOND QUALITY    
      B. RESISTANCE TO DECAY AND INSECTS    
      C. WATER PERMEABILITY    
      D. LOAD BEARING CAPACITY    
      E. THERMAL CONDUCTIVITY    
      BAMBOO MAT BOARD AND TECHNOLOGIES OF BAMBOO BASED PANELS    
      B.I.S. SPECIFICATION    
      METHODS OF TESTS FOR ROUND BOMBOOS (AS PER IS: 6874 - 1973)    
      MOISTURE CONTENT AND SPECIFIC GRAVITY    
      APPARATUS    
      PROCEDURE    
      MEASUREMENT OF LOAD AND DEFLECTION    
      RECORDING OF DATA AND COMPUTATIONS    
      MARKET SURVEY    
      INDUSTRY STRUCTURE AND DEVELOPMENTS    
      WOOD PANEL PRODUCTS    
      FURNITURE INDUSTRY    
      OPPORTUNITIES AND THREATS    
      OPPORTUNITIES    
      THREATS    
      OUTLOOK AND OPTIMISM    
      DETAILED EXPORT DATA OF BAMBOO MAT    
      MANUFACTURERS/SUPPLIERS/EXPORTERS FOR BAMBOO MAT BOARDS    
      MANUFACTURING PROCESS OF BAMBOO MAT BOARD    
      CUTTING OF BAMBOO    
      REMOVAL OF OUTER    
      BAMBOO SPLITTING & SIZING    
      REMOVAL OF INSIDE BAMBOO KNOTS OF OUTSIDE BAMBOO SKIN    
      PROCESSING OF FOUR SIDES OF BAMBOO STRIP TO SIZE REQUIRED    
      DRYER TREATMENT    
      STICK SIZING    
      BAMBOO STRIP GLUING    
      ADHESIVE PREPARATION    
      GLUE/ADHESIVE MIXING    
      SHAPING THE BAMBOO FLOOR BY HYDRAULIC PRESS    
      PLANING OF BAMBOO FLOOR    
      DOUBLE END CUTTING AND SHAPING    
      SANDING    
      COATING OF BAMBOO FLOOR SURFACE WITH UV PRIMER    
      FEATURES OF ROLLER TYPE COATING MACHINE    
      UV CURING    
      PLANING OF BAMBOO SURFACE BY SANDER 2'    
      STANDARD ACCESSORIES AND FUNCTIONS OF SANDER 2'    
      COATING OF BAMBOO SURFACE WITH UV PRIMER    
      UV CURING & FINISHING    
      GRADING AND INSPECTION    
      PROCESS FLOW CHART    
      SPECIFICATIONS OF PLANT & MACHINERY    
      PROCESSING DETAILS OF BAMBOOS    
      BAMBOO CROSS-CUTTING MACHINE    
      BAMBOO SPLITTING MACHINE WITH KNIVES    
      BAMBOO SPLITTING MACHINE WITH CIRCULAR SAWS    
      BAMBOO WIDTH SIZING, KNOT REMOVING AND PLANING MACHINE    
      BAMBOO FOUR-SIDE PLANING MACHINE    
      BAMBOO ONE-SIDE PLANING MACHINE    
      BAMBOO SLAB MAKING MACHINE    
      BAMBOO TREATMENT    
      DETAILS OF BAMBOO MATS BOARD MANUFACTURE    
      HARVESTING BAMBOO    
      SPLITTING BAMBOO    
      KNOT REMOVAL    
      SLIVER MAKING    
      DRYING AND WEAVING    
      STORAGE OF MATS    
      RESIN APPLICATION    
      RESIN DILUTION WITH WATER FOR DIPPING    
      QUANTITY OF PF RESIN REQUIRED    
      STABILIZATION AND DRYING OF RESIN COATED MATS    
      ASSEMBLY    
      HOT PRESSING    
      TRIMMING AND CHECKING    
      MANUFACTURE OF RESIN    
      DRY-WET PROCESS TO MANUFACTURE    
      SLICED BAMBOO VENEER    
      PRODUCING BAMBOO STRIP AND BOARD    
      PRODUCING LAMINATED BAMBOO LUMBER    
      BAMBOO BOARD MOISTURE CONTENT    
      QUALITY OF SLICED BAMBOO VENEER    
      PRODUCTIVITY    
      CONCLUSIONS    
      PLANT LAYOUT    
      SUPPLIERS OF RAW MATERIALS    
      MELAMINE UREA FORMALDEHYDE RESIN    
      SUPPLIERS OF PLANT AND MACHINERY    
      BAMBOO CROSS CUTTING MACHINE    
      BAMBOO SPLITTING MACHINE    
      BAMBOO KNOT REMOVING MACHINE    

              
      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      

       

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