MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST PRODUCTS

MODERN TECHNOLOGY OF WOOD, VENEER, PLYWOOD, PARTICLE BOARD, FIBREBOARD, BAMBOO & FOREST PRODUCTS
Written By :

EIRI Consultants and Engineers

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Printed and Published by :

4449, Nai Sarak, Main Road, Delhi-110 006 (India) Ph. : 91-11-23918117, 23916431, 45120361, 45626431 Fax : 91-11-23916431, 23918117 E-Mail : eiribooks@yahoo.com Website : www.eiriindia.org & www.eiri.in www.eiribooksandprojectreports.com

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EIRI PROJECT CONSULTANTS & PUBLISHERS

4/54, Roop Nagar, Delhi-110007

Copy Reserved by Sudhir Gupta, Delhi

ISBN : 978-81-89765-36-1
Printed in New Delhi (India)

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Printed and Published by Sudhir Gupta for "Engineers India Research Institute", 4449, Nai Sarak, Main Road, New Delhi-110 006 and Printed at Swastik Offset, Delhi

CONTENTS AND SUBJECT INDEX

Chapter 1 Page No. Chapter 3 Page No.

Wood-The Energy Source 1-25

- Introduction - Energy Needs - Wood Materials Available for Energy - Biomass Consumption Classification - Converting Wood to Energy - Burning/Combustion Method - Wood Fuel Estimation - Other Methods of Converting Wood to Energy - Energy Uses - Firewood - Wood Energy for Forest Based Industries - Wood Energy for Other Industries 1 5 5 9 10 10 13 15 20 21 21 24

Saw Mill

44-50

- Introduction 44 - History of Small-Log 46 Handling and Processing Systems

Types of Saw
Definition The Carpenter's Hand Saw Two-man Ripping Hand Saw The Frame Saw Circular Saw Band Saws

51-61
51 51 52 53 55 57

Timber Terminology
6

62-68

Saw Types 26-43

27 27 27 30 30 31

69-76
7

Wood Carbonisation
-

Definition Carbonisation Stages of Carbonization Charcoal-Composition Charcoal Yield Method of Charcoal Manufacture and Equipment types vis-a-vis Carbonization Processes Continuous Furnaces Operational Procedure of Wood Carbonization Kiln Method Retort Method (The Constantine Portables) Operational Advantages Charcoal Quality

Circular Saw
8

77-93

Sawing Methods
- Introduction

94-99
94

39 39 39

Operations of Saw Mill 100-130

10

42 43

How We do Manage Wood Waste

- Solid wood Waste

131-133
131

Chapter
- Untreated Waste - Treated Waste - Waste from wood derived materials

Page No. Chapter

131 132 133 - Surface Sealing - Design Requirements - Stress Points

Page No.
146 148 149

15

11

"Waste...? The use of 134-139 by products in the forest products industries

- Value added products manufactured from wood waste - Animal bedding and litter - Boiler fuel/Wood Pallets - Chunkrete - Compost amendments/Soil amendments and potting soil - Erosion control - Lanfill cover - Paper and Panel Products - Syngas - Mulch - Packaging Filler - Playground/Handicapped access ground cover - Road Stablization/Pathways - Market Summary 134

Adhesives used for Wood Products

-

150-165
150 150 151 151 152 152 153 154 154 155 157 157

134 135 135 135 136 136 136 137 137 137 137 138 138

Introduction Classification British System of Classification General Classification Glue/Adhesive Terminology Casein Glue Animal Glues Resin Glues Phenol Formaldehyde Adhesives - Urea Formaldehyde Adhesive - Lignin Based Adhesive - Adhesive Testing

16

Lamination and Laminated Wood Products

-

166-173

12

Okoume (Aucoumea Klaineana)

Properties Durability Seasoning Working Properties Uses

140-142
140 141 141 141 142

Introduction Lamination Laminated Wood Manufacture Lumber sorting and re-grading Section-Lumber Preparation - Glue Spreading and Pressing Section - Advantages of Laminated Wood - Wood-Metal Laminates

166 166 168 169 170

170 171 172

13

17

Chemical Seasoning of Round Bamboo

14

143-144

Technology of Veneer 174-220 and Plywood

Origin and History of Plywood Veneers and Veneering Veneer Logs Species used for Veneering Veneer Types 177 179 182 182 183

Some tips on use of Edge Glued boards

- End Sealing

145-149
145

Chapter
-

Page No. Chapter

183 183 184 185 186 188 189 191 191 192 193 193 195 196 200 200 200 202 202 203 205 208 208 209 209 209 210 210 211 212 213 216 216 216 217 218 218 219

Page No. 18

Rotary-cut-Veneer Sliced Veneer Manufacture of Veneers Veneer Yield Veneer Grades Plywood Balanced Construction Properties of Plywood Advantages of Plywood World Production Plywood Manufacture Pretreatment of Raw Material in the Log Yard Production of Plywood in the Mill Veneer Production Treatment of Veneers against insects and fungi Veneer Drying Preparation and further Treatment of Veneers Patching of Veneers Mixing of Spreading the Glue Lay-up and Pressing Conditioning of Plywood Panels Finishing of Plywood Panels Packing of Storage Sizes and thickness Marketing and Dispatch Moulding of Plywood Special Treatment against Decay and Fire Uses of Plywood Types and Grades of Plywood Based on the Species Used Special Plywood Overload Panels Overlaying of Plywood "Wonder-Woods" of Ply Industry Other forms of Plywood Definition of Kinds Laminated Veneer Lumber

Adhesives for Panel Products

-

221-233
221 221 221 222 222 223 224 224 225 225 226 226 229 229 229 229 229 230 230 231

Classification of Adhesives Adhesives of Natural Origin Synthetic resin Adhesives Phenolic resins Phenol formaldehyde resin Fast/low temperature curing phenol formaldehyde resin Amino Resins Urea Formaldehyde Resins Characteristics of UF Resins Melamine formaldehyde resin Grades of PF and UF Resin Adhesives Isocyanate Resins Constituents of Adhesive Formulations Catalysts Fillers and extenders Fortifiers Buffers Preservations Technical Limitations Adhesives based on Blend of Natural Polyphenols and Synthetic Resins Tannin Adhesives Lignin Adhesives Cashewnut shell liquid Based adhesives Inorganic Cements Prospects for Research

231 231 232 232 232

19

Beech (Fagus Species) 234-236

Properties Durability Seasoning Availability Uses 235 235 235 236 236

Chapter 20

Page No. Chapter

-

Page No.
261 261 261 266 266 267 267 268 270 270 273 279 279 279 280 280 280 281 282 283 283 283 284 284 285

Prevention and Control of Powder Post borer

-

237-241

Lyctid Borers Prophylactic protection of wood Preventive methods Bamboo is very susceptible Eradication of Borers Heat Sterilization Fumigation Economics

237 238 238 239 239 239 240 241

21

Sandwich Boards
Definition Construction Materials Used Structural Properties Uses

242-243
242 242 243 243 243

22

Manufacture of Particleboard and Composite Products

-

244-286

Particle Preparation Debarking Cutting/Flake Preparation Classification Screen Classification Secondary Reduction of Flakes Conveying Drying Re-screening Resin Blending Forming/Matt Spreading Cooling and Conditioning Trimming Additional Manufacturing Operations Storage and dispatch Quality Control Composite Products Wood-Cement Products Bamboo Board Sawdust Board Other Boards Important Characteristics and Uses of Particleboard Strength Properties Dimensional Characteristics Uses

Definition Flavours Basic Materials Particleboard-Classification and Types Flat-Platen Pressed Particleboard Extruded Particleboard Low Density (Insulating Type) Particleboard Medium Density Particleboard High Density (Hardboad type) Particleboard Raw Materials Wood Raw Materials Additives Particleboard Manufacture Raw Material Handling and and Segregation

245 246 246 247 250 251 252 253 253 254 254 257 259 261

23

Fibreboard Technology
-

287-322
287 288 288 289 289 289 290 290 290 291 291 293

Introduction Definition Classification Non-Compressed Fibreboard (Insulation Board) Semi-Rigid Insulation Board Rigid Insulation Board Compressed Fibreboard (hardboard) Intermediate density of medium density fibreboard Hardboard Special Densified Hardboards Terminology Raw Materials

Chapter
-

Page No. Chapter

294 294 296 297 300 301 301 302 304 305 306 306 308 310 311 312 312 315 316 319 320 320 321 321 322 -

Page No.
337 338 338 340 342 343 343 343 343 344 346 347 348 349 350 350 352 353 353 354 355 355 357 357 357 358 358 358 359 359 362

Wood Raw Material Additives Water History of Hardboard Manufacture Raw Material Handling Pulp Preparation Mechanical Pulping Thermal Plus Mechanical Pulping Chemical Plus Mechanical Pulping Explosion Process Sizing Formation Drying Additional Manufacturing Operations Hardboard Sizing Formation Pressing Tempering Humidification and Conditioning Trimming Additional Manufacturing Operations Combined Insulation Board and Hardboard Operation Testing of Sheet Materials Uses/Applications

24

Manufacturing Technology of Pulp and Paper

-

323-362

Wood Preparation Mechanical Pulping Stone Groundwood Pulping Refiner Mechanical Pulping Thennomechanical Pulping Uses of Mechanical Pulps Merits and Demerits of Mechanical Pulping Chemical Pulping Sulphite Process Sulphate Process Semichemical Pulping Chemimechanical Pulping Washing and Bleaching Qualities and Uses of Pulp Other Operations before paper manufacture Beating and Refining of Pulp Introduction of Additives Blending Forming the Paper/ Sheet Formation Fourdrinier Type Machine The Wet End or the Wire The Press Section The Dryer Section The Calender Section Sizing Reeling and Final Cutting Cylinder Paperboard Machine Recycling Wastepaper Rayon or Artificial Silk Manuracture Manufacture Techniques Uses

25
323 324 324 331 333 333 333 334 336

Introduction Background Historical Development The Manufacturing Process Pulp Definition Pulp Production Pulp Types Pulping Processes

Types of Flooring
- Solid hardwood flooring - Engineered or Multilayer flooring - Laminate Flooring - India : The Possible future course

363-368
364 364 364 367

Chapter 26

Page No. Chapter

- Bamboo mat corrugated sheets (BMCS) - Moulded articles - Uses of Bamboo Mat Composites - Results and Discussion - Conclusions

Page No.
384 387 388 388 389

Wenge (Millettia laurentii)

- Workability - Availability - Uses

369-372
371 371 372

27

30

Kiln drying : Manual Versus Automatic

- What is manual or Automatic Control ? - What are the advantages of Automatic kilns? - Cycle Time - Cost effectiveness

373-376

Shake and Shingle Industry- Roofing Material

- Introduction - Hand Split Shakes - Tools for Manufacture of Hand Split Shakes - Timber Selection - Splitability - Treatability - Splitting - Problems - Shingles - Timber Selection - Building Practices - Roof Farming - Installation - Flashing - Vent Pipes - Hips and Ridges - Valleys - Materials

391-403

373 374 374 374

391 392 392 392 393 393 394 394 395 396 397 398 399 401 401 401 402 402

28

Phenol-Formaldehyde 377-382 Resin Emulsions as Wood Adhesives

- Phenolic Resins - Emulsion Preparation - Similarities of Phenolic Emulsions to Traditional Resoles - Differences between Phenolic Emulsions and Traditional Resoles 377 378 379

380

31

29

Bamboo mat composites and moulded products

383-390

Processed Wood and Wood Products

404-411
404 405 406 406 407 408

- Manufacturing ProcessBamboo Mat Composites and Moulded Products - Bamboo Mat Board (BMB) - Bamboo Mat Veneer Composites (BMVC)

384

384 384

- Furniture Industry - Selection of Timber Species - Sawing and Subsequent Treatment - The Indian Wooden Furniture Industry - Chinese Furniture Industry - United States Furniture

Chapter

Page No. Chapter

409 433 434 436 438 439 441 442 445 445 445 447 448

Page No.
448 461 463 463 464 468 468 469 470 473 476 477 479 480 482 482 483 484 485 485 485 486 489 489 490 490 491 492

Industry - Downstream Processing of Further processed Wood Products-World Scenario - Raw Materials, Smaller Logs and Smarter Technology - Sustainable Forest Management Implications

410 410

32

Wood and Biomass Utilization

- Changing Nature of Timber Resources - Timber from World Forests - Complete Utilization of Raw Materials

412-418
414 414 415

33

Forest Products
-

419-493
423 424 426 426 427 427 427 428 429 430

Nomenclature and Definition Classification Fibres, Flosses and Coir Fibres from Leaves Flosses Coir Grasses, Bamboo and Canes Bamboo Canes Distilation and Extraction Products including Oil Yielding Grasses The Distillation Process Oil Seeds Tans and Dyes Dyes Dyes from Leguminous Plants Exudes-Gums, Resins, Oleoresins, Rubber, Latex etc Resins Rubber Latex Lac Silk Medicinal Plants, Drugs, Poisons

Traditional Medicines Pharmaceutical Drugs Poisons Edible Products Fruits, Nuts and Seeds Flowers Palms Bamboo and Rattans Spices, Condiments and Herbal Teas Fungi Honey Animal Protein Fodder and Feed Miscellneous Pesticides Orchid Terrestrial Orchids Epiphytic Orchids growing on trees, or on rocks Insect Ranching Wildlife and Ecotourism Wildlife Eco-tourism Role of NTFP in the National Economy Needs of Rural People The National Needs Demand-Supply Position Policy and Future Management International Cooperation

34

Bamboo Mat Board, Bamboo Mat Corrugated Sheets & Bamboo Floor Board
- Introduction - Why bamboo mat/ ply board - Technology - Application of Bamboo Mat Board (BMB) - In house Construction

494-505

494 495 496 496 496

Chapter
-

Page No. Chapter

496 496 496 496 497 498 498 498 498 498 498 500 501 501 501 502 503 503 503 503 503 504 504 504 504 -

Page No.
508 509 510 511 511 512 512 512 512 513 513 513 513 514 515 516

& House-hold In Transportation In Concrete form work Shuttering The properties of BMB are comparable to plyboard The Properties of Bamboo mat corrugated sheet Comparative properties Properties of Bamboo Floor Board Size Colour Process Bamboo Mat Board Bamboo Mat Corrugated Sheets Bamboo Floor Board Proposed Capacity Raw Material Plant and Equipment Building and civil Work Power Requirement Water Requirement Direct Employment Indirect contract employment Financial analysis Break Even Point Pay Back Period Internal Rate of Return

Proposed Capacity Dried Bamboo Shoots Canning of Bamboo Shoots Plant and Equipment Packaging Section Building and Civil Work Power Requirement Water Requirement Employment Estimated Project Cost Break Even Point Pay Back Period Internal Rate of Return Projected Profitability Statement Name of the Machine Manufacturer - Consultants

36

Cane & Bamboo Products

Products and Uses Market Quality Process Production Target Basis and Presumption Infrastructure required Cost of shed Machinery and Tools Total Capital Cost Manpower Other Administrative Overheads (per month) Total Working Capital Working Capital Estimation Capital Cost of Project Total Investment Sales Realization

517-523
517 517 519 519 519 519 520 520 520 520 521 521 521 522 522 522 522

35

Bamboo Shoot
-

506-516
506 506 506 506 507

Indian Governmental Policy Facts Possibility Action Plan Introduction of Bamboo Shoots