Fibre Board million m3. Particle Board million m3. Wood Based Panel products million m3. Plywood million m3. MDF million m3. Year

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1 (AN AUTONOMOUS BODY OF the Ministry of Environment & Forests) UNION MINISTER for Environment & Forests, PRESIDENT SECRETARY, E & F, GOI, CHAIRMAN BOARD OF GOVERNORS DIRECTOR Hqrs. & MAIN LABORATORY, BANGALORE FIELD STATION, KOLKATA (CALCUTTA) FIELD STATION, for NW Region (PROPOSED) Copy Rights, IPIRTI, Bangalore, March-2001 WOOD CONTINUES TO BE ONE OF THE MOST WIDELY USED RAW MATERIAL FOR INDUSTRIAL APPLICATIONS BUILDING & STRUCTURAL APPLICATION, FURNITURE, FLOORING, SHUTTERING PANELS, PERMANENT FORMWORK ETC..) PLYWOOD INDUSTRY AS ON TODAY CONSISTS OF 62 LARGE AND MEDIUM SIZE MILLS AND OVER 2500 SSI UNITS THERE ARE 25 PARTICLE BOARD UNITS AND 3 MDF MILLS PRODUCING MATERIALS WORTH Rs.20,000 CRORES AVERAGE CAPACITY OF MOST INDUSTRIES IS MUCH BELOW INTERNATIONAL STANDARD LARGEST COMPANIES ARE OWNED BY BIG PRIVATE INDUSTRIAL UNITS IT GENERATES EMPLOYMENT TO THE EXTENT OF 6 LAKHS MANDAYS FOR SKILLED AND SEMI-SKILLED LABOURS. Dwindling wood resources on one hand and increasing demand for the wood based panel products on the other, attention is gaining momentum on the utilization of crop residues for the manufacture of composite products Grain and other seeds are the main objectives of the farming activity in India There is great interest in developing uses for residues that are currently burned or ploughed back into ground Most of the developing countries are very rich in agricultural and natural fibre. Natural fibres have excellent physical and mechanical properties and can be utilized more effectively in the development of composite materials for various building applications Ever increasing pressure on the forest industry to do more with less Increasing the conversion and efficient use of wood fibre resources, producing more fibre on a shrinking land base New environmental friendly technology for turning agricultural residues like bagasse, chir pine needles, cotton stalks, coconut coirs, jute etc., have been developed. New technology highly favors environmental protection and sustainable development by recovering and reutilizing organic wastes such as crop residues. Adoption of these technologies leads to implementation of a green solution as an alternative to crop residues being burnt and disposed into soil Year Wood Based Panel products million m3 Plywood million m3 million m3 Fibre million m3 MDF million m ??? ??? ??? SOURCE: State of the world s forests 2007(FAO)

2 India China World average Plywood 90% 10% 20% board 6% 30% 55% MDF 4% 60% 25% TOTAL Source : Plyworld June July 2007 Sl. No. Particulars Tones / annum (in millions) 1. Bamboo Rice Straw Wheat Straw Rice Husk Coconut Husk Cotton Stalk Bagasse Pine Needles Non-edible grass Due to light weight, high strength to weight ratio and other advantages, natural fibre based composites are becoming important composite materials in building and engineering fields In India, natural fibre composites are emerging with an increasing role in building industry to replace timber, steel concrete, etc. Composites are being used for prefabricated, portable and modular buildings as well as for exterior cladding panels. Utilization of sisal, jute, coir and bagasse fibres has found m a n y successful applications in India. IPIRTI IS PLAYING A SIGNIFICANT ROLE IN THE DEVELOPMENT OF WOOD SUBSTITUTES THROUGH THE USE OF BAMBOO, AGRO AND FOREST RESIDUE AND OTHER LIGNOCELLULOSIC MATERIALS TECHNOLOGY DEVELOPED BY IPIRTI RICE HUSK PARTICLE BOARD PINE NEEDLE PARTICLE BOARD BAGASSE PARTICLEBOARD COFFEE HUSK PARTICLEBOARD WHEAT STRAW PARTICLEBOARD JUTE COMPOSITES BANANA LEAF SHEATH PARTICLEBOARD COIR COMPOSITES Sl no Raw material Availability in million metric tons Bulk density Kg/m 3 Chemical constituents 1 Bamboo Cellulose,Starch,Silica 2 Rice Husk Cellulose,Pentosans,Silica 3 Coconut Husk Lignin,Cellulose,Extractives 4 Coconut coir waste Lignin,Cellulose,Extractives 5 Coconut coir pith Pectins, Tannis and other water soluble substances 6 Areca nut husk Tannin,Cellulose and other water soluble substances. 7 Ground nut Cellulose,Extractives,Pentosans and ash shells 8 Cotton stalk Cellulose,Lignin,Pentosans,ash 9 Bagasse Cellulose,Pentosans and Extractives 10 Jute sticks Cellulose,Pectins,Etractives, 11 Pine needles Cellulose,Pentosans Extractives,ash Sl. No. Property Unit Wood Rice Husk Wheat straw particle board Bamboo Mat overlaid Rice Husk Groundnut Husk Bagasse 1. Density Kg/m Water absorption % 2 hr. 24 hrs Thickness Swelling % Modulus of Rupture N/mm 2 5. Modulus of elasticity N/mm Internal Bond strength N/mm 2 Dry Wet Screw withdrawal strength N/mm 2 Face Edge

3 Paneling Partitioning Ceiling Floors & Sub floors Door and Window shutters Furniture and built-in furniture Thermal insulation Acoustic insulation Panel materials like rice husk board, coconut husk board, pine needle board, wheat straw etc. can also be used for rodent proof construction and exterior cladding. Most abundantly available among, all the crop residues A by-product of the agro based industry in the country namely paddy milling Available to the extent of 2 million tones per annum Technology was transferred in 1985 to NRDC, India Technology has also got adopted internationally through establishment of a unit in Malaysia Recently IPIRTI has refined the technology for the manufacture of multi layered particle board. Panels conforms to the requirement of IS 3087: Specification for medium density particle board and these panels pocesses high termite decay and fire resistant properties. Highly environmental impact since utilization of rice husk in one way prevents deforestation Modified leaves from chir pine or casuarinas trees form a thick layer on ground due to slow decomposition A major source of ground fires in the forests recurring annually Ceiling in Hospital Reception Door Infill Ceiling in Class Room A multi layered particle board with different combinations hav e been developed at IPIRTI and the panels meets the requirement of strength properties as per relevant specification Chir pine needles can be efficiently and effectively used for manufacturing particle boards, overlaid particle boards and hard boards that will be ideal for ceiling tiles, door infill's, table tops etc., Kitchen Cabinets Veneer Overlaid Flooring Coconut is available in india in abundance and is the second highest in the world 3.7 million tons of husk is produced annually and 1.2 million t o n s a r e utilized for making coirs Designed door infill board Feasibility of manufacturing particle board out of dry husk and coconut coir pith has been well established boards, insulation board and hard boards using coconut coir pith have been successfully developed at IPIRTI The strength properties of the panels conforms to the requirement of relevant specifications. Coconut coir fibre has been recognized has highly durable fibre in all types of matrices Veneer overlaid Used for Door infill Used for stool top Technologies for the manufacture of coir board, trays, compregs and coir corrugated sheets have been developed at IPIRTI

4 NON-WOVEN FELT AS FACE IN WOOD PANEL MOULDED PRODUCTS HIGH DENSITY STRUCTURAL PRODUCTS PARTICLE BOARD A fibrous reside left after extraction of juice from sugarcane India is the largest producer of sugar in the world. Ranks 14 th in the utilization of bagasse NON-WOVEN COIR FELT As a fire and environmental hazard, this material possesses a challenge in waste management during storage and disposal Technology has been developed at IPIRTI to manufacture particle board which emits less formaldehyde and meets the requirement of strength properties as per IS 3087: Specification for medium density particle boards The long lasting problem of storage has been overcome by adopting technological innovations bye Eco- Eco-, in Maharasthra has been successful in producing bagasse boards commercially and the market acceptance of the product is encouraging TRAY DOOR INFILL COMPREG FROM COIR FIBRE Wheat a major cereal and extensively grown in northern India Estimated production is 73 million tones Due to high cost involved in collection, storage and transport, no significant increase in utilization is foreseen Research has been initiated at IPIRTI to formulate special adhesives to bond wheat straw with suitable chemical modification to th e straw and develop a cost effective particle board from wheat straw which would meet the requirement of strength properties as p er IS 3087: Specification for medium density particle b o a r ds Obtained in various physical forms from raw fibre to woven/non woven fabrics and sticks Abundantly available in eastern & north eastern part of the country Wide option for choice of jute substrates for the manufacture of composite materials Jute stick particle board has been developed and commercialized Number of technologies using jute as an alternative to core materials have been developed at IPIRTI. Helps to a great extent for the commercialization of jute based composites A waste from banana plantation that gets rot and is of no value Adoption will reduce wood consumption while utilizing as waste from horticulture. Technology has been developed to produce particle board from banana leaf sheath for ceiling tiles, door infills etc., BANANA SHEATH PARTICLE Generates additional income to the farmers who grow banana plants. Needs further refinement in technology for commercial viability of the product. BANANA SHEATH & VENEER COMPOSITE BOARD BANANA SHEATH PARTICLE BOARD

5 BAMBOO MAT BOARD BAMBOO MAT RIDGE CAP BMB APPLICATIONS (FURNITURE) BAMBOO MAT CORRUGATED SHEET GRAIN STORAGE BINS BAMBOO MAT MOULDED SKIN BOARD Copy Rights, IPIRTI, Bangalore,2002 Pre-Fabricated Bamboo House at IPIRTI Security Cabin at IPIRTI MAGAZINE HOLDER CENTRE TABLE Bamboo House at Agartala Bamboo House at Chennai TABLE TOP CALENDAR HOLDER Sl. No Sales Resin Salarie Mainte Cost of Inter promo Thickness Cost Wages Cost Product Raw Material Cost /Adhesive Energy s & nance Final Panel Product est -tion per Rs. in Lakh Sq/Mt. Plywood 4 mm veneer of size 2.44 PF resin x 1.22 x Rs.25/per sheet. Rs.40/kg Rs Bamboo Mat 3 mm Bamboo Rs.78/ Bamboo Mat 12 mm Bamboo mat Veneer veneer Rs.208/- Composite Wood 12 mm 1400 per tonne Rs.301/ Rice husk 12 mm Rice Rs.300/- per tonne Rs.255/- 135 Coconut Husk 12 mm Coconut Rs.400 per tonne Rs.153/- 180 Bagasse 12 mm board Rs.600/- per tonne Rs.286/- 270 Ground nut husk 12 mm Rs.500/- per tonne particle board Rs.274/- Sl no Raw material Insulation Hard Others 1 Areca nut Husk E E Bagasse E1 E1 E1 E Plaster boards 3 Bamboo E E1 E1 E1 BMB, BMVC, BMCS and Bamboo mat Tray E bamboo Laminate 4 Banana Stem -- E Cassava Stalk E E Coir dust Husk E1 E1 E -- 7 Cottan stalk E E Ground nut -- E E1 -- shell Husk 9 Jute sticks -- E E1 E Asphalted roofing material 10 Pine needle E Tried in pilot plant and found to be suitable for commercial production Rice Husk E - E1 E with cement for bricks Note: E indicates that the material has been subject of laboratory experiments only. E1 indicates that the materials are commercialized and used industrially for board manufacture.

6 Concept on protection of environment has necessitated the development of environmentally friendly technologies for turning agricultural residues into quality value added composite products Implementation of the new technologies developed using crop residues will result in waste materials (agri waste) being efficiently utilized. Forms a sustainable resource for the industrial manufacture of products like particle boards and fibre boards. Eliminates the pollution occasioned by the burning of crop residues 1. Research on cost effective adhesives with special reference to adhesive based on bio materials. 2. Development of suitable machineries for plantation timbers and agro waste with special focus on defibreating machine,resin applicator, mat former etc., 3. Technological capacity mechanism for commercialization of research results and transfer of technology needs to be established. 4. Training of the technical personnel in particle and Fibre industries. 5. Marketing strategies Website