A

PROJECT REPORT ON
Quality Control
&
It`s necessities in Plywood Industries



SUBMITTED TO:
H.N.B GARHWAL UNIVERSITY, SRINAGAR (UTTARAKHAND)
IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF THE
DEGREE OF BACHELOR OF SCIENCE IN FORESTRY (2010-2014)

SUBMITTED BY:
SIDDHARTH DAULAGUPHU
B.Sc. Forestry VIII
th
semester

UNDER THE GUIDANCE OF
SARVESH SUYAL
(HEAD OF THE DEPARTMENT IN FORESTRY)
D.C.A.S.T








DEPARTMENT OF FORESTRY
DOON (PG) COLLEGE OF AGRICULTURE SCIENCE AND TECHNOLOGY







CERTIFICATE


This is to certify that the project work entitled
Quality Control and its necessities in Plywood Industries is a
record of bonafied project work carried out by Siddharth
Daulaguphu (ENROLMENT NO. G10661040) a student of B.Sc.
Forestry VIII
th
Semester of Doon (P.G) College of Agriculture
Science & Technology, Camp Road, Selaqui, Dehradun, (Affilated to
H.N.B Garhwal University) submitted in partial fulfillment of the
requirement for the degree of BSc. Forestry.
This project work is carried out under the supervision of
Sarvesh Suyal (Head Of the Depertment in Forestry), Doon (P.G)
College of Agriculture Science & Technology, Camp Road, Selaqui,
Dehradun.



Date :
Place : Sarvesh Suyal
(Lecturer in Forestry)
D.C.A.S.T


ACKNOWLEDGEMENT

I would like to acknowledge all individuals and organisation for their generous
help. This project would not have been successfully completed without their
contribution.
Foremost,I would like to express my heartiest thanks to the directors of
Janardhan Plyboard Industries Ltd. Viz; Shri. Gaurav Singhal, Shri. Sanjay
Taneja, Shri. Bijindra Singh Nirwan for permitting me for the project work and
facilities.
I would also like to express my deep sense of gratitude to Shri. Atul
Singh(Work manager, Janardhan Plyboard Industries Ltd.) for his valuable
time,practical suggestion,support and guidance throughout the completion of
this project.
I owe my gratitude and appreciation to Shri. H.C Joshi (Quality Control
In-Charge,Janardhan Plyboard Industries Ltd.) for his valuable time,fuitful
suggestions and logistic support for project work and report preparation.
I would also like to extend my special thanks to Shri. Sarvesh
Suyal(H.O.D forestry) for his guidance and Mrs. Vishaka Saxena who arranged
the industrial attachment at Janardhan Plyboard Pvt. Ltd. at Langha road. Last
but not least; I would like to thank my family and friends (specially Rishi
Jaiswal) for supporting me morally and spiritually throughout the project
preparation.

Siddharth Daulaguphu





DECLARATION




I hereby declare that this project work entitled Quality
Control and it`s necessities in Plywood Industries is a bonafied and
genuine work carried out by me at Janardhan Plywood Industries Limited
under the guidance of Sarvesh suyal (Head of the Department in
Forestry) Doon (PG) College of Agriculture Science and Technology.

I further affirm that, the contents of this project report shall not be
published in any form whatever without any prior approval of the guide
and the original organisation where the work has been carried out.




Date:
Place: Dehradun Siddharth
Daulaguphu

CONTENTS

I. INTRODUCTION

II. JANARDHAN PLYBOARD INDUSTRIES LIMITED
III. LOGYARD,PEELING AND BOILER

IV. SEASONING CHAMBER

V. FABRICATION

VI. DRYING SECTION AND VENEER

VII. RESIN MANUFACTURING

VIII. HOT PRESS AND DEFECTS

IX. LAB

X. FINISHING,DESPATCHING AND STAMPING

XI. QUALITY CONTROL

XII. CONCLUSION

INTRODUCTION

The use of plywood is an appreciable step in the direction rational utilization of
wood. The plywood including block board, flush doors have certain advantages
over solid wood in addition to some physical and mechanical properties. In
developed countries wood based panels have largely replaced solid wood and
have indispensable for housing.
The development of wood based panels started with manufacture of
plywood at the turn of the 20
th
century. Quality control as an effective system
for integrating the quality development and quality maintenance effort of all
the various groups in an organization so as to enable production of maximum
unit goods of specified quality at the most economic level which allow full
satisfaction(Singh and Das 1998).
In wood based panel industries, especially in a plywood industries for
instance the quality control would commence right from purchase of logs and
involves all the processes from peeling, drying, gluing and assembling of
veneers, pressing, trimming, sanding, finishing operation as well as packing and
shipping.
The main objective of the present study is to inform the necessities of the
quality control management in plywood industries and how to control the
quality at every steps of the production.

JANARDHAN PLYBOARD INDUSTRIES
LIMITED (1987-Till Date)


Janardhan Plyboard Industries Limited (JPIL) begin in 1985 with just one
simple idea "A smile on the face of their costumers" which has always been an
obsession. JPIL takes pride in one of the most quality conscious and innovative
team of professionals with rich experience in their respective area of
specialization. The standards house quality system is in excess of the national
standards requirement. Today after years of bard work and dedication in
ensuring the smiling face of the customers, JPIL is now the flagship company of
the business group.
The detail of the factory is as under and the work on panel product was
carried out.
1. Name of factory:

Janardhan plyboard Industries Ltd. Langha
Road Industrial area, Sahaspur, Dehradun.
2. Year of Establishment
:
July 7,1987
3. Production of Factory
:
Wood based panel Products.
4. Constitutional : Companies Limited by Indian Companies
Act.1956

5. Organizational Board of directors -
Structure:

Mr.S.SGoyalM.D
Mr ,Anil Goyal Exe. Director
Mr,N.N Dingahal -Mr.Hikapur,
Mrs S,D,Goyal
Mrs Soumya Goyal
6. Marketing Strategy: By the help of sales staff
7. System of Accounting
:
Under control by C.A.
8. Factory working:
(profit /loss)
Upward Trend in profit, Bonus,
Distribution to Employees


PRODUCTS PREPARED IN JPIL:-


IS: 303 Plywood for general purpose MR and BWR grade (1989)
IS: 1659 Block board (2004)
IS: 2202 Flush door solid core type (1999)
IS: 710 Marine plywood BWR
IS: 4990 Shuttering grade densified
IS: 848 Resin, Glue shear strength(GSS)
IS: 1734 methods of test for plywood



BRAND NAMES :-


GEE Door
GEE Ply
GEE Board
Santro Board
GEE Conplus-Shuttering
GEE Construction-Marine Ply
GEE Dcor
GEE Corner Ply

LOGYARD AND PEELING AND BOILER
DEPARTMENT


BOILER DEPT : The boiler used in the Janardhan Plywood Industries is
limited to only 6 tons, it runs for the whole week except on Sunday. It generates
5 kg/hour steam in a day depending on the amount of steam needed by the
industry. Waste like leaf, fodder, sugarcane waste, husk etc are used in the
boiler department as fuel and also around 9-9.50 quintal of oil / hour is required
to run the machine. Thermea-B is quite expensive but this industry rely only on
it. Safety precaution is a very much needed process to ensure uniform and
steady work for the labourers. Safety valve is attached to the boiler machine for
desperate measures.
A working motor pump of about 25HP is required to
transport the oil(Thermea-B) to every part of the factory. The excess(ash)
products are removed every Sunday and pH and TDS(impurities of water) are
maintained on records.


LOG YARD: Different species used for manufacturing of plywood are
given as follows:
Populus spp
Silver oak
Mango
Toon
Eucalyptus
Gurjan

Logs brought from the forest into the factory premises with
the help of trucks are kept in log yards. Log yard is a place where logs are kept
under direct sunlight for the purpose of natural air drying. They (logs)are
always placed in perpendicular position towards the direction of sunlight or in
other words opposite direction. In doing so, it reduces checks and splits
occuring in wood. For making veneers defect free samples are used which are
without knots. But in this factory veneers are mostly brought from another
larger industries for saving time and labour.
The logs are kept in open in the log yard and so they are prone to
fungi and insects which will result in degrading the quality of the wood to be
used for further veneer manufacturing purpose. For this reason chemicals such
as asphalt pigments, lamp black, coal, resin, paraffin wax are use to overcome
this problem. This retains high moisture content and eliminates checks.


PEELING: The logs are first immersed in water pond for few days so that
the barks can be removed easily due to the increase in size. Debarking is done
with the help of axe, man power is needed for this purpose.
After the debarking of logs, they are than put
into the log steaming chamber or tank. The logs are cooked for required time
varying with the type of species. It is to be checked that no unwanted materials
is to be put along with the log in the steaming chamber for it may create
problem while cooking and peeling which may result in production loss.
Steaming imparts plasticity to the wood for easy and smooth cutting. It
improves wood colour, prevents infection in wood and makes uniform
distribution of moisture in the wood. Ultimately it helps in the process of veneer
drying evenly.




The logs are then turned against the sharp blades of
the peeling machine in a tangential direction in archimedial spiral, concentric to
the growth ring with equidistant winding. The distance between the windings
equals to the veneer thickness. In this process the cutting speed and the knife
cutting angle is to be maintained which varies from species to species. The
thickness of veneer peeled from the peeling machine in this factory varies from
1mm to 3.5 mm. The peeling machine in this factory is not in used anymore.
The veneers are brought from other larger industry which saves time and labour.
A machine-operated saw is present in the log yard to separate
the logs into desirable sizes of batons to be used in making of flush door, block
board etc.

Segregation of veneers:
Fibre roughness, death knots, head cracks etc should
not be present on the veneers to be used. In other words; short length to be
resized, rough core should be segregated, hard and soft core should be
segregated, unusable portion such as rough area, rotten portion, death knots,
holes are to be removed. If the length is found to be less than the required size
then they are used as panel lines instead of the glue panel core.
SEASONING CHAMBER


It is a chamber in which batons derived by cutting the logs into desired
sizes are put for klin drying or drying inside enclosed walls. But mostly 25 mm
thickness and 4.5 inches width size having batons are stake over one another
and are put inside the seasoning chamber. Around 1050 batons (2 stakes each
of 525) can be put in the chamber at a time. It nearly takes 4-5 days to complete
the full process of drying or seasoning. During summer it takes 3-4 days
whereas in winter 5-7 days for complete process.
The coils and huge fans are attached to the walls of the chamber which
helps to produce warm air. The coils gets heated by the steam transported from
tube connected to the boiler. There are 6 fans in each of the 7 chamber out of
which only 3 is still working. The temperature required inside the chamber can
vary from 35 degree centigrade to 80 degree centigrade.
A lid is fitted above the chamber which is off outmost importance
because it is the only hole through which the moisture goes out of the chamber
and for this it is kept open for 2 days and then closed again.
The species used are mostly poplar if not then mango. The moisture
present inside the batons should be 105%. Sunday the boiler remains closed so
does this chamber.


PRECAUTION:
There should not be any leakage of steam and the valve should be rotated
to let the moisture go out every 1 hour.
The wheel (motor) should be properly greased and maintained.
Care should be taken so that overheating or less heating does not take
place.
Sometimes fibre arises so it is necessary.
FABRICATION



Fabrication means the process of manufacturing an item by
assembling different raw or semi-finished materials instead of making it from a
readymade parts or components.

1) Rip saw section: Out here the flank are passed through the circular saw
to give out smaller sizes of batons. The sizes maybe of following:


Thickness of the door/board(mm) Width(inches)

19 2,3,4,5
25 3,4,5,6
30 2,3,6
32 2,3,6
35 1,3,4
38 1,3,4
40 5


RIP SAW :- RPM - 2800
Motor - 25 H.P
Motor pulley size - 10
Machine`s pulley size - 5



CIRCULAR SAW:- RPM - 2800
Numbers - 2
Motor - 2 H.P
Circular disc - 12
Motor pulley size - 7
Machine`s pulley size - 3.5






2) Frame section: The batons are joined by finger joints so that it won`t
break easily for frame while making flush door. And the frames are
attached to each other with the help of fastner. The species used maximum
for making the frames are pine, mango.

Length of the flush door frame Width
81 36,39,33,30,27
78 33,30,27
72 30
84 45,48,33,30,27

Pendulum circular saw: It has Tungstan carbide tip(TCT).

One in number
Motor 25 H.P
RPM - 640
Teeth/inch of blade - 3

Finger shaping machine: It is use for chipping the batons into the finger
shape like which makes it able to be joint together, it helps the frame to remain
strong and unbreakable.

Motor - 3H.P
RPM - 2800


1) Board fabrication : All the small batons collected from rip saw
section are again run through the cutter to be put in the block board and
flush door in smaller sizes.
While running the batons through the cutter we are to cut thin
gaps on it so that if some batons are curve , could be bend and adjust to fit in the
block board and flushdoor.
No. 1 Vertical band saw No. 2 vertical band saw
Wheel size 36 Wheel size 36
Blade size 3 Blade size 3
Motor 10 H.P. Motor 15 H.P.
Motors pulley size 5 Motor pulley size 12
R.P.M. of motor 1440 R.P.M. of motor 1440

The red paper : The paper used for covering the waterproof quality of
plyboard is red in colour. The width of this paper is measured in GSM girth per
square meter. The cost of this paper roll is Rs. 105/kg . At a time about 400/500
kg of paper roll is used. This paper is run through the Paper impregnated drier
machine. Before running into the 1
st
chamber, densified resin is put all over the
paper which is responsible for the waterproof quality. Next it is pass through the
steam chamber. The inlet steam temperature is 116C whereas the outlet steam
temperature is 185C,the average or required temperature is 120C. Lastly, the
fan cools down the paper when it passess from second chamber to the last one
before it comes out of the machine. The paper that is already out of the machine
are then cut with the help of digital caliper.


DRYING SECTION AND VENEER

Veneer:- A thin layer of finely grained wood glued together in numbers to
make a base for plywood manufacture can be called as Veneer.
Moisture content:- For developing satisfactory glue bond, optimum
moisture content in the timbers and veneers is required. As such the material
should be dried to a moisture content not exceeding 12 %.
Sizes of veneer:- Length(feet) Width(inches)
3 8
4 6
Species used:- 1) Eucalyptus : In this veneer moist brown, black patches is
visible.
2) Poplar : In this veneer no patches is seen, in other words.
It is a clean sheet or white in colour.
Moisture content of the green veneer:
Eucalyptus: 60-65%
Poplar : 80-85%
Moisture content of dry veneer: 6-8%
Freshly peeled veneer or the veneers brought from another
industry is are passed through the dryer for drying at 134 degree centigrade
approx.
Care should be taken not to overlap any veneer while placing them in the inlet
of veneer. For this a suitable gap is maintained between the veneers while
passing them though the dryer.
The wet veneer is fed into the dryer inside which hot air
(steam) in blown . As wet veneer becomes dry it moves out of the tight and
compressed dryer to the discharge point of the machine becoming flat in shape.
The veneers are than cut with the help of Hydraulic jointer
so to make all the veneers of same sizes.

Face veneer: The very thin layer extracted from the heartwood of raw timber
or log which is used for putting at the topmost portion of the plyboard for
decorative purpose and not for strength can be called as face veneer.
Face thickness 30 mm
Face veneer species which are brought into this industry from their respective
places are as follows :
Species Native
Hollong - Arunachal Pradesh
Gurjan - Burma
Keruing - Malaysia
Burma Teak - Burma
(decorative veneer)

Size square feet square metre
8*4 32 * 2.9768 (2.44 * 1.22)
7*4 28 * 2.6108 (2.14 * 1.22)
6*4 24 * 2.2448 (1.84 * 1.22)
8*3 24 * 2.2448 (2.44 * 0.92)
7*3 21 * 1.9688 (2.14 * 0.92)
6*3 18 * 1.6928 (1.84 * 0.92)

Ammonia treatment of veneer:

For this purpose the veneers are stack over one
upon the other and put inside the chamber where steam is passed from the
boiler. The liquid ammonia is used for this treatment. The veneers are kept
inside the closed chamber for about 12 hours. When the veneers are taken out
we can notice that the colour of the veneer has turned into reddish brown in
colour.
RESIN MANUFACTURING


P.F Phenol formaldehyde: This resin is made for applying on the core
plyboard of exterior grade.

Following steps is carried out while making P.F resin :-

1) 800 litre of phenol and 1400 litre of formaldehyde is taken to be mixed in
1 solution together in the ratio of 1:1.8 ( C6H5OH : HCHO ).
2) A 40 kg solid form of caustic soda is then mixed with 100 litre of water to
form a solution.
3) The caustic soda solution is put into the mixed solution of phenol and
formaldehyde.
4) The solution is cooked or heated in a double jacketed tank or cylinder for
1 hour.
5) Exothermic Reaction starts and slowly the temperature will rise from 40
degree to 60C.
6) When the reaction reaches 60C, the machine running the double jacketed
cylinder should be stopped to cool down the reaction.
7) Even though the machine is switched off at 60C reaction, it rises up to
90C automatically.
8) The machine should not be switched on at least for 4 hours. The
temperature then cools down.
9) The resin is then put out in a small beaker to check its viscosity with the
help of B4 cup:

Water tolerance 5

Water flow - 18

Colour - Dark red


The resin is now ready to be used.

* Double jacketed Cylinder tank - 3 ton capac2500 kg glue making
capacity.



U.F Urea formaldehyde : This resin is used in the manufacturing of the
least quality or the interior grade ply board. The ply board made from these
resin are sensitive to all the external forces like heat, water etc.
Following steps is carried out while making U.F resin :-
1) In a double jacketed cylinder tank 1200 litre of formalene and 500 kg
urea are mixed in the ratio 1: 2.4 (NH2CONH2 : HCHO) to get a
solution.
2) 2 to 3 litre of caustic soda solution is then mixed into the double jacketed
cylinder.
3) It is to be noted that the PH of formalene should be 8.
4) The steam or heating is started. The solution is to be cooked atleast for 1
hour.
5) Due to the exothermic reaction the temperature will rise from 40C to
90C.
6) Heating or cooking is done for again 2 more hours and the PH is
checked, it should be 7 or 7.5.
7) According to the PH, Acetic acid of about 2-3 litre is mixed.
8) Should note the time, and the tank should be heated for the next 15-20
minutes. PH here will be 5.5 6 .
9) A sample of resin is taken out to check the bonding:
Water tolerant : 5
Flow or viscosity : 17
PH : Atleast 8 8.5
10) Stop the machine and let it cool down for 2 and half hour.
The resin is now ready to be used. The colour is abit
whitish as compared to the P.F resin.

Densified resin : This resin is best of all the quality. It is used for the
manufacturing of the waterproof plywood. This resin is used for applying over
the red paper which passes through the Paper impregnated dryer machine
which is later pasted over the ply board.
For the manufacture of this resin, the following process is to
be carried out :-

1) 200 litre of phenol,240 litre of formaldehyde and 10 litre of liquid
ammonia is put and mixed together in the double jacketed cylinder tank.
2) The machine is started to let the steam flow in unless the temperature
rises till 60 degree centigrade to 70 degree centigrade.
3) The steam flow is stopped but the temperature will rise till 80 85
degree centigrade.
4) Time is noted down.
5) The steam is again flowed in for 25 30 minutes into the cylinder.
6) Next, we are to take out sample of the resin in a glass beaker. We will
notice that the sample is divided into 2 parts ; a solid type matter which
is Densified resin and liquid which is water.
7) We should always check, that the sample taken out is in the ratio of 2 : 1
(Densified resin : Water).
8) We closed the machine after the temperature drops to 40 degree
centigrade for atleast 1 and half hour.
9) We then extract the densified resin from the tank and then later remove
the water which gets stock inside the tank.

The resin is now ready to be used. The colour is dark red.

HOT PRESS AND DEFECTS
Plywood is the term applied to glued wood construction built of veneers
in such a way that the grain of each veneer is at right angle to that of the
adjacent veneer. This method is called the cross band construction. The outer
plies in a plywood panel are called face veneer and the inner core. Core may
consist of veneer of different combinations of species of which poplar and
Eucalyptus are usually used.
After the application of glue on the veneers these thin sheets are then
assembled at the assembly table in odd numbers of 3, 5, 7 etc; depending on
thickness which is to be required for the final product. The grain in the adjacent
layers lies at right angle to one another.
Applied pressure = Face area of the door/Total ramp area * specific
pressure
Ramp area :-
Dial pressure = Specific pressure * Plywood area / Ramp
area
Ramp area = 3.14 x d
2
x number of ram / 4
D = G / 3.14 ( G girth)
Normal length of core - 50 mm x 23.05
Normal weight of core 780 gram ( dry)
Weight of the core after P.F resin is applied 960 gram
23 gram is needed per square foot normally
TEMPERATURE MAINTAINED FOR UF IS 115C-1200C
TEMPERATURE MAINTAINED FOR PF IS 140C-150C
TEMPERATURE MAINTAINED FOR PF IS 140C-150C

PRESSURE
SIZE UF PF
2.44 x1.22 75 100
2.44 x1.22 65 90
1.84 x1.22 60 75
1.54 x1.22 50 65
2.44 x0.92 60 75
2.44 x0.92 50 65
2.44 x0.92 45 60
1.84 x0.92 35 50
1.54 x0.77 50 65
2.44 x0.77 45 55
2.44 x0.77 40 50
2.44x0.77 30 40


Normally Time and Pressure required for following sizes:-

P.F Block board 19 mm 20 minutes 12 kg pressure

P.F Flush door 30mm,32mm,35mm 20 minutes 14 kg pressure

U.F Block board - 19 mm 15 minutes 10 kg pressure



Thickness P.F Core Core Core Panel Pressure
Poplar B`GR-
poplar
Eucalyptus Eucalyptus kg

6 mm 5 ply 2.1 x 2 - - 1.4 x 1 12 kg
9 mm 7 ply 2.1 x 2 - 2.1 x 1 1.4 x 2 12 kg
12 mm 9 ply 2.1 x 2 - 2.1 x 2 1.4 x 3 12 kg
16 mm 13 ply 2.1 x 2 - 2.1 x 3 1.4 x 4 12 kg
19 mm 15 ply 1.4 x 2 - 2.1 x 4 1.4x4+2.1x2 14 kg
25 mm 19 ply 2.1 x 2 - 2.1 x 5 1.4 x 8 14 kg



P.F Block board 19 mm double core full thickness = 14 kg


Thicknes U.F Core Core Core Panel Pressure
Poplar B`GR-
poplar
Eucalyptus Eucalyptus kg
6mm 5 ply 2.1 x 2 - 1.4 x 1 10 kg
8 mm 7 ply 2.1 x 2 1.5 x 1 - 1.4 x 2 10 kg
12 mm 9 ply 1.5 x 2 2.1 x 2 - 1.4x2,2.1x1 10 kg
16 mm 11 ply 2.1 x 2 2.1 x 3 - 1.4x4
19 mm 13 ply 1.5 x 2 2.1 x 4 - 1.4x5 10 kg
25 mm 17 ply 1.5 x 2 2.1 x 6 - 1.4x7


U.F Block board core full thickness = 12 kg

Hot press - It is necessary for making the veneers flat and smooth. There are
3 hot press in the industry where pressing of panel products which includes
plywood, block board, flush door etc.
Flow chart for a water proof ply board is as follows:-
Red paper (After passing through the Paper impregnated dryer)

Face veneer

Glued veneer Ready ply board

Dry non glued veneer Hot Pressing

Glued veneer Red Paper

Dry non glued veneer Face veneer

Resin or glue applied Glued veneer
dry veneer freshly

Glued veneer Dry veneer


Dry veneer Glued veneer

Hot press 1:- Capacity ( in tons ) - 650 tons
Brand - AMBIKA ( Gujarat )
Delight - 10 ( 10 ,12 ,15 ,30 variety also available )
Ramp area - 1815 cm
2

No. of piston - 8
Temperature - 115C - 120C (U.F)
140C - 150C (P.F)
Compression loss U.F 1 mm
P.F 1.5 2 mm
Specific pressure - U.F 11kg/ cm
2

P.F 14 16kg/ cm
2

Block board ( 15 minutes P.F ) 19 mm
(12 minutes U.F ) 19 mm
Flush door ( 20 minutes P.F) 19 mm


Hot press 2:-
Capacity 1600 ton
Ram area 528 cm
2
( d = 91 or 92 cm)
Brand - INTERCON (Shri chakra equipment
Engineering Bangaluru)
Delight - 12
Weight of a normal board 32 kg
(Without cutting)
Pressure maximum - 320 kg (280 kg average)
No. of piston - 8
Temperature - P.F :- 140 - 160C
U.F :- 125- 135C
Time required to keep the - 30 minutes
Flush door, block board
Under pressure

Time for cooling those - 10 minutes
Flush door, block board

Causes of failure in adhesion :- It is dangerous to jump to conclusion on
inspection of one or two defective sample. If all is not well with gluing, a
thorough check on the process be made. It may well be found that a fault is
due to the combination of circumstances, all of which must be considered
before corrective measure be put in hand.
A) Open glue joint maybe caused by:-
1) Imperfect machining, preventing complete contact in the whole
length or breadth of the joint.
2) Poorly fitted joints.
3) Pieces of warped stocked forced together under pressure.
4) Excessive moisture content in wood or excessive drying.
5) Uneven glue spread
6) Glue dried or jellied before pressing.

B) Close,but-week joints maybe caused by :-
1) Poor quality adhesive.
2) Use of thick or thin mixture.
3) Insufficient adhesive being used.
4) Adhesive partially dissolved.
5) Animal glue overcooked at high temperature.
6) The adhesive being allowed to troth in the mixing.

C) Blisters under veneers may be caused by:-
1) Poor quality core containing knots.
2) Uneven thickness of core.
3) Uneven cutting of veneer.
4) Steam pocket (hot press).
5) Overlapping joints of veneers.
6) Insufficient conditioning and flattening of veneer.

D) Warping maybe caused due to:-

1) Gluing pieces of wood of varying or incorrect moisture content.
2) Gluing pieces of wood of varying species, strength and porosity.
3) Adding too much moisture in gluing.
4) Bending in the clamp or press.
5) Using poorly constructed plywood as base for veneering.
6) Improper construction such as:-
a) Veneering the face, not the back of the panel.
b) Veneering both side, but not equalizing the build as a result of using
veneering entirely different strength and thickness.
c) Finishing, painting or varnishing a panel face without seating the
back.

E) Various surface defects and their causes :-

a) Shrunken joints due to machine before adhesive has dried out of finished
contracting.

b) Check due to:-
1) Wood being glued at too high moisture content.
2) Adding too much moisture in gluing.
3) Finishing before wood or veneer has dried out of correct moisture
content.
4) Improper construction.

c) Wavy or corrugated veneered surface due to:-
1) Use of core of varying species.
2) Hard and soft grain core.
3) Cores having planer marks surfaces.
4) Cores having varying thickness.
5) Cores having varying moisture content.
6) The commencement of delamination as a result of exposure non-
moisture resistant adhesive to moisture condition.

F) Staining due to:-
1) Alkaline adhesives.
2) Veneers left under pressure for too long.
3) Veneers glued when too wet.
4) Veneers placed under excessive pressure.
5) Thin veneers under dark glue.
6) Use of porous or exceptionally thin veneer without sizing before
gluing.

Defects:- The change in appearance on the ply wood which reduces
the strength and economic aspect of the ply wood maybe defined as ply
wood defect. It can due to many reasons like uneven drying, low quality
adhesive, uneven thickness of the core etc.


Some of the defects are given below:-
1) Core delamination:- This defect may arise due to uneven thickness,
low temperature, highly adhesive spreads etc.
2) Core over :- This defect may occur due overlapping of veneers,
labours carelessness etc.
3) Core gap :- This occurs due to separation of veneer, low quality
veneer etc.
4) Core blister:- This defect may occur due to the low quality of face
veneer, uneven thickness of core etc.
5) Panel over:- This occur due to overlapping of panel while
assembling.
6) Panel gap :- This occurs due to the uneven thickness of the panel.
7) Face crack :- This occurs due to high moisture content U.F- 12%,
P.F-10%, low quality face, separation of fibres etc.
8) Face short :- This occurs when during plywood preparation, the
face veneer remains shorter than the core veneer and after the
final plywood is prepared the core veneer appears on the surface
where face veneer is absent.
9) Face chip off :- It occurs due to low quality adhesive resin( solid
content 48-50 in water proof U.F and 45-46 in P.F).
10) Steam pocket or blister :- Moisture content too high in cross band
and core.
LABORATORY

The following lab work was done by me in the Janardhan Plywood Industry
Limited :-
1) Density of solid wood
2) Moisture content of the wood
3) Percentage of solid content in P.F resin

1) Density of solid wood:-
Size of the solid wood (volume) L x B x H
10.9x1.3x7.2= 102.02 cm

Weight (mass) of the solid wood 54.5 gm
Density of the solid wood = Mass / Volume = 54.5 / 102.02
= 0.49

2) Moisture content of a given wood :-
(Green wood)Initial weight of the wood 102.5 gm
Oven dried weight of the wood - 60 gm
In case of green wood weight,
Moisture content = green wood weight oven dried weight / green wood
weight
X 100
= 102.5 60 / 102.5 x 100
= 41.46 %

In case of oven dried weight,
Moisture content = Oven dried weight greenwood weight / oven dried
weight
X 100
= 60 102.5 / 60 x 100
= 70.83 %

3) Percentage of solid content in P.F Resin ;-

Empty weight of the Petri dish = 32.650 gm
Weight of the Petri dish with resin = 47.600 gm
Oven dry weight of the resin = 39.800 gm

Resin taken = 47.600 32.650 gm
= 14.950 gm


Resin that turn solid = 39.800 32.650 gm
= 7.150 gm


When 14.950 gm resin taken, the amount of resin that turn solid is = 7.150 gm
When 1 gm resin is taken, the amount of resin that turn solid is = 7.150 /
14.950
When 100gm resin taken, the amount of resin turning solid is =
7.150/14.950x100
= 47.826 gm
Therefore, the required percentage of solid content in P.F resin is 47.826 %

FINISHING, STAMPING AND DISPATCHING

Finishing: To complete the manufacture of ply board and give a good
appearance, several last process is carried out such as:-
1) Trimming : Trimming is done side wise and then length wise to give
desired size. It is done by running the ply board through the DD saw(
Double dimension saw).
There are 2 DD saw in the industry.

No. 1 D.D. Saw No. 2 D.D. Saw
R.P.M 2800 2800
Motor 7.5 H.P. 5 H.P.
Dia 18 18
Teeth 96 96

2) Gap Filling : The gap that occurs on the sides of the ply board and the
crack defects on the surface are filled with putty and lappa.

Putty and lappa formulation:

China clay 2 kg
T.S.P powder - 1 kg
Saw dust - 500 gm ( half kg)
Maida (wheat flour) 500 kg
U.F glue - 200 ml
Water - 1.5 litre


3) Sanding: This operation is done to make the surface of the ply board
smooth and fine. It is also done to clear off the T.S.P, putty from the ply
board. This operation is done by the two machine named Side sanding
machine and Belt sanding machine.

No. of belt sander - 3
H.P - 5
R.P.M - 1446
Grit size - 60

4) Table finishing : This operation requires man labour. Worker trims off
the unwanted fibres of the defects with knife, sand paper and fills it with
putty.

5) Coloured finishing and preservative: The ply board then is run through a
machine, when the ply board comes out of the machine it turns wet in
appearance and a bit red in colour. It is due to the substance called
chromic acid.

The preservatives are put over the ply board because it protects
from insects and fungal attack. In this industry following preservative
solution are made such as:

a) 200 litre water + 5 kg Na
2
Cr
2
O
7
(sodium dichromate) + 6.5 kg CuSo
4
(copper sulphate) + Chromic acid 2.5 gm.
This solution is filled into a tank where the ply board is dipped as a
preservative treatment. Plyboard red in color.

b) CCA( Chromated copper arsenate ) : This preservative is put on the
ply board by spraying. It is the best quality used in this industry. The
ply board in which this preservative is put are generally green in
color.


Stamping: It is done to spread the extension of the industry in the market
and among customers. Stickers and ink is stamp over the ply board according
to variety and grade.
Dispatching : After the stamping operation, the ply boards are stacked over
each other and stored in a room temperature. But before that, with the
surface and the sides of the ply board are checked if any defect is still
appearing. The fibre defect over the surface of the ply board is cleaned with
steel brush and the cracks and gap filled with putty.
The ply board are than stack over each other and
stored in the room temperature. From here on, the ply board are ready for
dispatch.


QUALITY CONTROL

Plywood factories in India prepare plywood from various species using
conventional synthetic resins like UF and PF. Nobody cares for the fact that lot
of timber, glue and human energy are wasted in the process of plywood
manufacturing. If all these accounts are taken, it is a huge loss of materials in
big plywood factories where proper quality control measures at each stage of
manufacture can be considerably increased. However, such quality control
measures can be exercised according to following stages in a plywood factory
for its manufacture:

SELECTION OF LOGS AND ITS STORAGE: Quality control applied to
those products manufactured from log means obtaining highest possible value
from every log cut. This process is applicable trees and timber tracts. Thus,
quality control in logging means marking of logs which are supposed to yield
best products with .highest possible value. Carpenter in 1953 gave a theory of
quality control becoming a matter of selection.
Logs for plywood manufacturing should be
straight, cylindrical and free from any type of decay, knots and cracks. They
have to be free from buttresses, crotches, brash wood, insect attack and any
other defects which may reduce its performance. The girth of log should be
above 1.5m and necessary precautions should be taken to prevent end
cracking. Staining and decaying can be prevented by storing the logs in a log
pond or under continuous spraying of water (Gupta, 1980).

PERMISSIBLE DEFECT: The IS: 656-1988 covers the grading rules of
logs for manufacturing of plywood as follows:
I. Deviation in straightness: Straightness up to 10 cm X 3 m length is
permissible.
II. Taper: A taper up to 1 cm per 10 cm of diameter or girth in every 2.5 m
length of wood.
III. Hollow or Spongy Heart: In case hollow or spongy hearts are present,
diameter of about 5cm is accepted.
IV. End splits and Heart shakes: A total length of 12 cm for every 3 m of the
log is permissible for the longest end splits and heart shakes.
V. Cup shakes: Cup shakes located within 5 cm from the centre heart (pith)
of the log is permissible.
VI. Knots:
A) Live knots: Live knots of up to 50 mm in diameter and occurring not
more than twice in length of 3 m each shall be permissible.
B) Dead knots: Dead knots of up to 25 mm diameter and occurring not
more than twice in length of 3 m each shall be permissible.
VII. Wounds, Bird Pecks or Bark Pocket: Wounds, Bird pecks or Bird pocket not
exceeding more than 10 mm in diameter and 25 mm in depth shall be
permissible only twice in length of 3 m of wood.
VIII. Flutes: If flutes occur during exchange of logs between purchaser and
supplier, the right reduction in girth is to be made.

PRE-TREATMENT OF LOGS BEFORE VENEERING:
Steaming/Boiling the logs before peeling is a common
treatment. Heating pits are constructed so that the logs are not directly
seamed which may increase the cracks and checks in logs. For obtaining the
best quality veneer, it depends on the species gravity, diameter, MC, presence
of knots, tendency to splits and colour change in wood.
1. Proper storage and preventive measures.
2. Rejection of already damaged wood before treatment.
3. Ensuring proper moisture content depending upon the type of
treatment and preservatives.
4. Preconditioning or preparation of timber.
5. Matching the exact standards required for wood preservation.
6. Checking the solution charge for each.
7. Ensuring proper functioning of vacuum-pressure gauges and
thermometers and continuous recorders to control treatments.
8. Chemical analysis of the treated wood.
The following steps hardly require any equipments and can
be done even with little knowledge or experience.
ADJUSTMENT IN THE PEELING LATHE FOR VENEERING:
The quality of veneers depends upon the machine settings,
the gap and knife angle. The gap in the pressure bar and knife edge should be
fixed on the basis of desired thickness of the veneers and the timber being
peeled. For veneer processing, the following machines are used:
i. Horizontal gap indicator
ii. Vertical gap indicator
iii. Knife angle indicator
iv. Knife height gauge
METHODS FOR ASSESSMENT OF VENEER QUALITY:
The main characteristics for assessing veneer peel quality reported by
Singh and Das (1998) are:
i. Thickness uniformity
ii. Surface roughness
iii. Depth of lathe checks

i. Thick nesss uniformity : Variation in veneer thickness is due to one of
the following reasons:
a) Due to improper lathe setting.
b) Faults in performance of rotary lathe, such as worn out or
loosened feed screw, check spindle etc.
The evidence of thickness variation may be observed from the following
phenomena:
a) Veneers peeled from outer layers of veneer block are thick,
thinning as they approach the core.
b) The veneer sheet is thicker in the middle than at both ends.
Assessment should be made by sampling full size veneer sheets respectively
from the outer layer of the blocks and near the core also by measuring at the
middle and at the both ends of the veneer with a precision up to 0.01 mm. the
measurement is done by thickness indicator since thickness is very important,
it should be checked on a regular basis.

ii. Surface roughness: Surface roughness is due to:
a) In adequate temperature and time duration of that treatment.
b) Faults in the height of the knife tip, compression and other peeling
parameters and sharpness of the cutting knife.
Evidence of surface roughness are:
a) Surface from grain or lacalised collapse.
b) Waviness in large pitch appearing periodically.
It will cause more consumption of the glue which may result in blister
formation during hot press and improper sanding. The roughness is measured
by Dial micrometer.
iii) Depth of lathe checks: Using some dyes to the loose side of veneer helps
the worker to make the lathe checks readily visible. The lathe checks effects
the veneer ability to remain at flexible without breaking into strips when
handled and it determines the amount of wood which can be removed without
exposing the lathe checks when producing sanded panels as the final products.
Veneer clipping : Veneer are found to be wedge shaped in width after clipping,
when the process is not under control. If let pas un noticed, the finished panels
have to be rejected.
Veneer drying : The purpose of veneer drying is to reduce the moisture of
veneer to the desired level of gluing. Under drying or over drying during veneer
drying will have a serious effect o bond quality. The quality requirements of
dried veneer are:-
a) Moisture content shall be acceptable for gluing.
b) Moisture content should be evenly distributed.
c) Veneer should remain flat after leaving the drier.
We can construct a control limit by taking different moisture content in a
veneer and see whether the variation is under control for a given moisture
range.
Grading of veneer :- Grading is necessary and according to that care will be
exercise, eg- Grade A,B,C. The veneer of A grade should not be put for B,C
grade because it will result in non-uniformity due to uneven thickness in
veneers and even a high pressure treatment in hot press might not give a good
bonding to the boards.
Quality control of adhesive
Adhesive to be used in the production bonding of parts should be sampled and
tested with a period of time not exceeding 24 hours prior to use. According to
Charles (1993) production responsibility on material control are as follows :
1) When the adhesive reach the production area, qualification date should
be checked and the floor inspector notified before storage.
2) A chart showing type of material, lot and batch number, date, result of
quality test lab report should be posted near the storage area.
3) Liquid adhesive should be mixed or thinned according to the applicable
specifications ( IS: 848:1974) and should be accomplished in an isolated
area.
Gluing : The glue to be applied must have adequate viscosity depending
upon the porosity of the veneer. Too much thick glue will not spread well
and also would not form mechanical binding age with the veneer surface
and thin glue will penetrate too much inside the pores of veneer.
The percentage of wood failure and glue shear strength are
the two main criteria for the judgement of ply wood bond quality. There are
two main reasons for unsatisfactory gluing reported by Sing and Das (1998):
a) The time allowed between glue spreading.
b) Surface temperature of the veneer.( measured by photometric
method).
Hot pressing: The function of hot pressing is:
i. To effect a tight contact of the layers under the action of pressure.
ii. To evaporate the solvent contained in the adhesive and to expedite the
curing of the adhesive.
Two rules of application of heat and pressure during hot press are :-
i. Heat applied and time of heating should be kept to minimum.
ii. There should not be any attempt to speed up production by using
excessive heat or pressure.
Sanding and surface finishing : Defects often happens in the process of
sanding are :-
1) Sand through
2) Waviness in finishing
3) Taper on one end of the panel
4) Damage of leading end of panel
5) Damage on trailing end of panel
Rectification of these defects and established control by adjusting driving
mechanism, replacement of bearing, etc.
Quality control by testing of product
Before dispatch the various products should be tested by quality controller in
its well equipped laboratory according to I.S. 848-1974. Some of the test
which are practiced in most of the countries are as follows:-
1. The tensile glue shear strength test can alone be judge as the most
adequate test for evaluating the adhesive bond quality of plywood.
2. The knife test however popular it maybe in some countries, can only be
treated as a qualitative test which may be used as ancillary test to verify
the quality of adhesion between the plies.
3. The process of scanning glue lines which involves numerous variable and
almost innumerable difficulties in designing and developing the
necessary equipment in the field.
4. The methods of analyzing the results of tensile glue shear strength teats
have to be standardized.
5. Simplification of test procedures and elimination of costly equipment for
determining the adhesive bond strength of ply wood should receive high
priority in the research and development effort in the field.
6. The torsion shear method and the plug tension method deserve to be
investigated further as they seem to be promising for simplifying the test
procedure.
Quality control with reference to electronic instruments
Shyamsundar and Victor (1980) has developed following quality control
electronic instruments using indigenous components, which are as follows:
a) Moisture meters : Moisture meters are used to measure the
percentage of water in wood . This information can be used to
determine if the material is ready for use.
b) Electronic moisture scanner: The scanner developed at IPIRTI works on
the principle that the dielectric constant of wood varies with moisture
constant. The variation of dielectric constant is to measure moisture
content of veneers.
c) Temperature indicator for hot press: A temperature indicator has
been developed using the silicon device for surface temperature
measurement. The junction silicon device depends on:
i. Ambient temperature
ii. Heat developed because of current passing through it.
Importance of quality control
The advantages of quality control are as follows:-
1) Improvement in quality
2) Efficient use of men and machine, removal of production bottlenecks
3) scientific evaluation of tolerances and process capability
4) Increase in economy and reduction of wastage
5) Increase in productivity and decrease of production cost.
6) Maintenance of desired quality level
7) Reducing the scrap so that material won`t be rejected
Conclusion


Wood has been the material man used most for many purpose from the
nature since early days, now in modern day the numbers of wood is
depleting as the forest, whereas the demand for it is becoming more.
The ply wood act as a substitute and fills the requirement of human
wants, therefore it decreases the depletion of forest.
And the plywood industry maybe be benefited by
quality control maybe such as ; customer loyalty through satisfaction of
the material they were provided, increase penetration of all markets
through exemplary services in technology and cost, increase productivity
in manufacturing, increase product and service quality, suitable
equipment and machinery for particular process control at different
stages, provisions of adequate resources including raw materials and
personnel to ensure consistent product quality, well defined process and
product characteristics, analysis and continual improvement.
Lastly, I would like to mention that it was a great
experience and opportunity to be able to get the chance to work on a
project in Janardhan Plyboard Industries Limited on the topic `quality
control and its necessities in the industry`. Here, I could enlighten
myself about the importance of quality control for manufacturing the ply
board which is used in so many different fields by man. And I would wind
this up by saying that `the economical profit of the industry can be
enhanced or maximized only by quality control`.