Production procedure
1 core veneer peeling
2 core veneer clipping
3 core veneer drying
4 Core veneer clipping and sorting
5 core veneer gluing
6 setting of face veneer and core veneer
7 hot pressing
8 trimming, finishing and sanding
1. Core veneer peeling
a) Core veneer is the main raw material of the plywood and block board. It is peeled out from
the wood, which has cut in to required length.
b) The core veneer peeling machine is an adjustable on and it is adjustable such that thickness
of the peeled core veneer are required.
c) Core veneer from different type of wood are used for various of plywood board and block
board
Width of the plywood Width of the veneer Length of the wood
36 inches 38 inch 40 inches
48 inches 50 inches 52 inches
2. Core veneer clipping
Core veneer coming out of the peeling machine will be in the shape of rolls and it will undergo
manual machine clipping to reduce the size width of 6,9,12,15,18,21 and 25 inches to avoided
wastages.
Core veneer drying / machine clipping and sorting
1. Tenderized core veneer will undergo drying process in the dryer. This is to bring down the
moisture level to below 6.8%. if the moister level is higher bonding will not be strong
enough
2. For A Grade and marine grade products chemical treatment will be done. This is achieved by
dipping the core veneer in the chemical treatment will be done. This is achieved by Boric
acid, borax,copper,sulphate are the chemical and other wise the customer is specified.
3. The dried core veneers are then clipped by machine. This will help to avoid gaps in help to
veneer while plywood setting. Now the core veneers are sorted for various grades.
TABLE 2 Grade Core veneer Veneer Face veneer
made from thickness
A Gurjan(Calpine) 1.5/2/2.5/3 Gurjan 0.5
Eucalypt as
Marine Silver oak
B Rubber wood
4. Core veneer gluing
After applicable process like cutting/ Tenderizing/ Chemical treatment the core veneer will
pass through a machine called Glue spreader. It will apply the uniformly on both faces of the
veneer.
5. Setting of face venner and core veneer
a) Now the face veneer is kept ready on an aluminum tig sheet for stacking of the blued
core veneer and panel core veneer
b) On the face veneer one layer of glued width wise. To cover the entire area, a number of
panel core veneer of different width are placed length wise.
c) On the top of this another layer of glued width wise. These core veneer are stapled
together using a gun taker for better strength and to avoid slipping the position creating
core gap.
d) On top of this another face veneer will be placed and glue will not apply on the face
veneer (Refer table 2 ) finally on this gluid core veneer, panel core veneer and face
veneer setting, another aluminu jig sheet will be kept. Similarly 5,7 and 9 plw board can
be manufactured
6. Hot pressing
a) The glued veneer stacking is now kept in hot the press for pressing together at specified
temperature and time (refer table 45)
b) Seven set of pre settled plywood stacking can be kept for hot pressing in the “10
delight” hot pressing machine at a time for macking final product “PLYWOOD BOARD”
and “BLOCK BORAD”
GlUE PREPARATION (USING MIXING MACHINE- 15 TO 30 MINUTS OPERATIONS)
FOR MARINE GRADE FOR NON MARINE GRADE
ITEM QUALITY ITEM QUALITY
Phenol 100 Ureaformuldehya 100
formaldehyde
Tamarind seed or 20 Maida 20
cocnuntshell power
Melaimine 4 Water 25
Durban 4 Melamine 4
borax 4 Durham 4
Ammonium 300
chloride
Liquid ammonia 500
borax 4
In addition to the above antifungal chemicals insecticides and termite proof power will
be added, suitable depending up on the requirement
Process flow chart
WOOD CUTTING INSPECTION &
GRANDING
WOOD PEELING
VENEER
VISUAL INSPECTION
VENEER CLIPPING
DIPPING IN CHEMICAL
SETTING
VENEER TENDERISING DRYING & GRANDING OF
OPTIONAL PANEL
CORE
VENEER
CORE VENEER SIZE GLUE SPREADING WITH
CUTTING ON CORE VENEER GLUED
CORE
VENEER
D FACE
FACE VENNER PREPARATION
VENEEE
R
HEAT
HOT PRESSING
BOILED
TIME
PLYWOOD BOARD
COMPRES PRESSUR
SOR E
TRIMMING/STANDING FINISHING
AND FINISHING PLYWOOD BOARD
SUPPLY STORE FINAL INSPECTION
Work instruction
Core drying
1. Select the core veneer for drying
2. Temperature of the dryer small be maintained between 150 c to 180 c
3. Dryer speed shall be maintained in dryer depend the species and thickness of veneer
4. Moisture content shall maintain between 6-8%
5. Core shall be taken for over drying of veneer.
6. Veneer in drying shall be feed continuously without any gap in vertically and
horizontally
7. While feeding overlaps are not allowed
8. Check the moisture content correctly
Rising mixing
For preparing MR grade resin the following formulation shall applied
UF resin – 100 kg
Maida – 8 kg
TSP – 0.5 kg
Ammonium chloride – 0.5 Ltr
BWR Grade resin
Pf resin – 100 kg
CSP – 5 kg
BWP
Pf resin – 100 kg
FOR ASSEMBLING
1. Caul sheet shall be cooled down before use
2. Place the cooled aluminium caul sheet on assembling table
3. Required face veneer and core veneer shall be stacked separately near assembling table
4. Avoid over lap and sap while assembling of plywood
5. Face veneers joint shall be checked for perfectly taped condition
6. Assembled boards are loaded in to the press through scissor lift only
HOT PRESSIING
For manufacturing MR & BWR grade plywood following press chart instruction clearly
1.caul sheet shall be cooled down before use
2. pressure, temperature and time shall be adjusted as per hot press chart.
3. assembled board shall be loaded in to the press centrally balanced and accurately
4. use scissor lift for loading assembled, board in to the press
5. unloaded board shall be stacked for acclimatization at ambient temperature
D.D. SAW CUTTING
1. Hot pressed boards are cut into required size using cutting machine
2. Cutting must be straight and right angle
3. Use proper grinded saw bladed only
4. Place the boards on the cutting trolley
5. Push the trolley in uniform speed to get smooth cutting
6. Don’t put the hand near the saw blade
SANDING
1. After DD saw cutting board shall be sanded
2. Use appropriate belt grit to get smooth sanding
3. Place the board on the sanding bed
4. Apply sanding pad along and across
5. Repeat the operation opposite side also
6. Re-sand if required
7. Visually examine the surfaces
8. Use proper dust collector equipment
ROW MATERIAL
1. Face veneer
2. Core veneer
3. Resin
