Plywood Process Research Articles

Optimizing Raw Material Inventory Control with Continuous and Periodic Review

PT XYZ is a company that operates in the field of plywood processing with various variations that produce products every day. Plywood or plywood is the product with the most demand every month. This company experiences problems, namely ordering raw materials that are uncertain, ordering raw materials because of probabilistic demand with an uncertain period and the quantity of raw materials that does not match the needs used in the production process, so that it often experiences overstock and stockouts. This research aims to control the optimal supply of sengon wood at PT. XYZ by comparing the company's method with the continuous review (Q) back order method and the periodic review (P) back order method to obtain the minimum total inventory costs. Based on calculations using the company method, the total inventory cost is IDR 32,502,564,700 and the minimum total inventory cost is obtained using the continuous review (Q) back order method of IDR IDR 28,829,527,844. The forecasted demand for sengon wood from May 2024 to April 2025 is 42,109 m3. The company made a total order of 944 m3 and a reorder point of 146 m3, so the total inventory cost generated was IDR 36,151,230,302.

Implementation of Fuzzy-TOPSIS as the Basis for Decision-Making in Purchasing Production Equipment at Plywood Companies

The decision-making process in a company should be based on a strong foundation. A robust decision-making basis is reflected in a methodology that can be accountable, especially in complex cases. Decision-making involving diverse criteria requires a proper methodology to achieve accurate results. Such issues often occur in small or micro-enterprises (SMEs). This study focused on plywood processing companies. The issue at hand was the absence of a standardized method for determining the purchase of production equipment. Therefore, a systematic decision-making tool becomes crucial to reduce the subjectivity among stakeholders. The most crucial production tool in the plywood industry is the press machine. The implementation of Fuzzy TOPSIS successfully provided an objective recommendation. These recommendations are in the form of rankings that inform the highest to lowest recommendations. The Cold Press Machine AKS - IR50T obtained the highest Cci value of 0.75, which can serve as the basis for decision-making in purchasing production equipment

Risk prevention of plywood product defects using Failure Mode Effect Analysis (FMEA) in the Indonesian plywood processing industry

ABSTRACT This case study aims to determine factors that cause defects in plywood products using failure mode effect analysis (FMEA) parameters. It also analyzes prevention strategies against plywood product defects in the plywood industry in Indonesia. The study involved 9 participants who are employees of different divisions. The research data were collected from direct observations of the plywood production process, analysis of documents recording plywood product defects, and focus group discussions. Based on the results of thematic analysis using FMEA parameters, this study identified five factors that significantly contribute to the failure of plywood products, as indicated by their highest Risk Priority Number (RPN) values. These factors are: (1) lack of employee discipline, (2) unstable machine temperature and excessive machine capacity usage, (3) waste on the veneer surface, (4) excessive adhesive wastage, and (5) inefficient work performance of the employees. The study suggests that the FMEA concept employed to capture product defects can potentially be used to explore employees’ perspectives and their lived experiences in plywood production. In addition, FMEA can provide improvement feedback to prevent defects in plywood products.

Association Between PM2,5 Wood Dust Exposure and Acute Respiratory Infection on Plywood Industry Workers in PT. Muara Kayu Sengon, Jatilawang District, Banyumas Regency

The plywood processing industry is one of the fastest growing industries. However, this has a negative impact and may cause the emergence of air pollution by dust produced from the plywood processing industry. Air pollution caused by the plywood processing industry can trigger problems such as the atmosphere, the economy, and health. The plywood processing industry has potential to create a source of pollution in the form of dust which is harmful to the environment and the health of workers. This study aimed to determine and analyze the assosiation between PM2,5 wood dust exposure and the case of acute respiratory infection (ARI) in plywood industry workers. The research method used is cross-sectional with a total sample of 142 female workers at 17 locations PM2,5 wood dust measurement and using a standardized Questionnaire British Medical Research Council (QUES BMRC -86). PM2,5 wood dust measurement using tools DustTrak. Based on the results of the study showed that the average of PM2,5 at 17 points of 5.23 mg/m3 which exceeds the Threshold Value according to the Regulation of the Minister of Manpower of the Republic of Indonesia Number 5 of 2018 concerning the Threshold Value of Chemical Factors in the Air of the Work Environment for Types of Softwood Dust, namely 5 mg/m3 who are at risk of experiencing the case of acute respiratory infection. The results of the analysis and the results of the logistic regression test show that there are 4 significant variables is a assosiation between with the case of acute respiratory infection, for exposure to PM2,5 dust (p = <0.001; RP = 12,757; 95% CI = 1,819 - 89,477), working period (p value = <0.001; RP = 13.048; 95% CI = 4.217 – 40.377), use of personal protective equipment (p value = <0.001; IDR 7,568; 95% CI = 2.453 – 23.352), and age (p value = <0.001, RP = 5.582, 95% CI = 2.323 – 13.413). The conclusion of this study is that there is a assosiation between exposure to PM2,5, wood dust, years of service, use of personal protective equipment, age and the case of acute respiratory infection in plywood industry workers. Therefore, to prevent the occurrence of acute respiratory infection, workers are advised to use complete personal protective equipment when doing work in the plywood industry of PT. Muara Kayu Sengon, Jatilawang District, Banyumas Regency.

An environmentally friendly and high wet-bond strength adhesive based on starch, itaconic acid and silicone

A novel approach is proposed to solve the problem of the starch adhesive’s low strength in humid environment. Herein, silicone and itaconic acid were grafted with native starch, and then the starch-based adhesive (IA-M/B-OSt) was obtained with a high wet-bond strength and environmentally friendly. Subsequently, the IA-M/B-OSt adhesive was applied in plywood processing, and the plywood turned out to have strong bonding strength even after soaking in hot water at 63 ℃ for 3 h. The results of SEM, FT-IR, Confocal Raman and 1H NMR confirmed that grafting reactions occurred between silicone and starch. Hot-pressing was necessary for the application of IA-M/B-OSt adhesive, which facilitated the transformation of Si-OH into Si-O-Si and achieved high wet-bond strength. This study provides a simple and efficient approach for preparing starch based adhesive, and opens up a new way for applying biomass materials in the green and sustainable adhesive industry.

The energy and ecological performance of the hot water boiler burning linden bark and wood briquettes

The North-West of Russia possesses huge wood resources reserves, therefore the issues of the most efficient use of wood biomass are relevant for this region. The implication of wood biofuels into fuel and energy budget provides an opportunity to reduce the negative impact of power industry facilities on the environment and preserve the potential of non-renewable fuels for future generations. An effective way of the complex solution of energy and ecological problems, while providing heating loads for consumers, is the use of modern devices operating on solid biofuel. Technical analysis of foreign and domestic high-performance heating units has great importance. The aim of the research is an evaluation of energy and ecological performance of the Firematic 60 hot water boiler burning bark of linden, briquettes from wood sanding dust and sawdust of plywood processing, as well as briquettes obtained by pressing softwood sawdust and shavings. The paper presents thermotechnical characteristics of burning biofuels and the components of boiler heat balance and gaseous emission from the burning linden bark and briquettes. Particulate matter emission and content of soot were studied. The shape and composition of soot particles were determined with a Zeiss SIGMA VP electronic scanning microscope. Presented data were obtained using equipment of the Research Center of Power Engineering Innovations. The results of the comprehensive energy audit have shown that the Firematic 60 boiler provides high technical and economic performance with minimum emission of harmful substances to the atmosphere. It can be used for low-rise buildings heat supply in weather conditions of the Arctic region especially.

Modeling of the plywood making process glued with thermoplastic polymer

A promising variety of the wood composite materials is plywood glued with thermoplastic polymers. However, making such a wood composite requires adjustment of the pressing modes, because there is a slightly difference between the hot method of the veneer packages pressing glued with thermoplastic films and the method of the veneer packages pressing glued with thermosetting adhesives. Among the main processes that occur in the gluing plywood process are heat and mass transfer. The availability of the thermoplastic film between the veneer sheets is going to change the thermal conductivity of the package, and therefore will affect the pressing duration. If suppose, that the package has a plate appearance, which is located between heated to the certain temperature pressed plates, then the known Fourier-Kirchhoff thermal differential equation can be applied. The basis for the model development of the warming package veneer process glued with thermoplastic film are laid methods of nonlinear programming, uniform search and conjugate gradient. On the offered mathematical model basis, the temperature field change in the package thickness during the plywood gluing with plastic film is calculated, the calculation of the warming duration indicators of the package veneer is done and this indicator dependence on the thermoplastic film flow rate and the pressing temperature is established. The duration of the warming package veneer glued with thermoplastic film depends on the temperature at which the thermoplastic polymer will change from a highly elastic to the viscous state. The transition of the thermoplastic film LDPE to the viscous state begins at 125оС and lasts up to 240 оС. With increasing of the press temperature plates from 140 to 180оС the duration of warming up the middle of the package to 125оС decreases by 89% for all investigated polymer costs is established. Changing the polymer content in the package does not significantly affect the duration of its warming. With increasing of the thermoplastic film flow rate from 130 g/m2 to 190 g/m2, the duration of warming up the middle of the veneer package to 125оС increases slightly from 3,8 to 4,2% depending on the pressing temperature. Suggested mathematical model allows to set the material parameters and plywood pressing mode influence on the duration of the warming package veneer while plywood making glued with the thermoplastic film LDPE.

Life Cycle Assessment of Plywood Manufacturing Process in China.

Life cycle assessment (LCA) has been an important issue in the development of a circular economy. LCA is used to identify environmental impacts and hotspots associated with plywood manufacturing. Based on our results and a literature review of LCA studies involving plywood, a sustainable and environmentally friendly scenario was proposed for the plywood processing industry to improve environmental performance and sustainability. This study covers the life cycle of plywood production from a cradle-to-gate perspective, including raw material preparation and plywood manufacturing and processing to analysis of environment impacts and hotspots. Analysis of abiotic depletion (ADP), acidification effect (AP), primary energy depletion (PED), freshwater eutrophication (EP), global warming potential (GWP), and particulate matter (RI) were selected as major impact categories in this study. All data were obtained from on-site measurements (plywood production) and investigations of the Eco-invent database and CLCD database (upstream data of materials and energy). These data can be ignored when environmental contributions comprise less than 0.001% of environmental impact and auxiliary material quality is less than 0.01% of total raw material consumption. An eco-design strategy with eco-alternatives was proposed: pyrolysis bio-oil can be used to produce green resin to replace traditional phenolic formaldehyde (PF) resin to decrease the impacts of GWP, PED, AP, PM, and especially ADP and EP. A new technology of gluing green wood was used to replace conventional plywood production technology; wood waste could undergo a gasification process to produce resultant gas rather than combusting. Plywood was also compared with other wood-based panels in China to identify additional scenarios to improve environmental sustainability.

Analysis Growth and Makro Hara Elements Jabon (Anthocephalus cadamba), JATI (Tectona grandis) in Gorontalo

To know the growth analysis of Jabon (Antocephaluscadamba) and Teak (Tectona grandis). Need to measure and see the growth in a certain period where a certain moment of growth will decrease, analyze the soil nutrients in the lab so that the consideration in the maintenance and fertilizer done regularly. Consideration for harvesting as needed in wood or plywood processing. The method used Where all the jabon, mahogany, gmelina, pine, and teak trees in the pathway are measured in height and perimeter for use in the calculation of the basal area and the content or volume of the tree (100% Census). To find out the macronutrients on the soil, the samples were extracted by digging a depth of A. 0-20 cm, depth B, 20 - 40 cm, C depth, 40 - 60 cm at 4 (four) points in each type and mixed evenly each plot or stand as much as 1 kg for the macro elements analyzed namely: N, P, K, Ca, Mg S, to know which element is lacking on each stand of plant forest [1]. Implementation of research. This implementation was carried out to make a plot by using a metering string of raffia for the plot’s circumference; the tree began to be measured by using tree labels with sequential numbering. The tree was measured around using a tall meter of trees using Christenmeter with a 4 m. Soil sampling on topsoil using a crowbar to 0-60 cm depth of 1 kg each type of stand at each layer 0-20 m, 20-40 m and 40-60 m to be analyzed in laboratory quantitative and qualitative. Mean Growth at age 3 years and diameter of jabon 4.66 cm of trees, year total volume 52.28 m3ha1, MAI 17,43 m3, CAI 30,95 m3, Medium point intersection MAI (mean annual increment) 30,52 m3 and CAI (current annual increment) 30.69 m3 occurs at the age of 10 years with some of Volume 305,21 m3 ha1. In Jabon growing area it can be seen that the availability of macronutrients in Jabon plants, N content, at a depth of 20 cm low 0.1%, medium K element so low at a depth of 20, 40, 60 cm only 0.37, 0.29 and 0.61 me 100gr1 (< 10 me 100 gr1), Slayer 20 is 9.97 me 100gr1 (6- 20 me 100gr1) neutral soil with pH 7. So the jabon plants still lack N, P, K and S need to be added to the layer of 20 cm depth. Teak growth at age 10 years after the inventory of an area of I ha of 614 trees with a diameter of 13 cm tahun1, volume amount 42.40.m3 ha1 and MAI 4.24 and CAI 9.83 m3. At the time when MAI 10.55 m3 and CAI 10.26 m3, intersected at one point then it was allowed to harvest age 32 years the amount of volume 337.45 m3 ha1. Analysis of the growth of a tree species and know the nutrient needs of the soil nutrient qualitative nutrients needed Teak plant can be seen element N on the soil is still very low, Mg very high because more than 8 me 100gr1 medium Ca also very high more than 20me 100gr1, P 0.37 me 100gr1, K 0.32 me 100gr1 and S 0.16 depth 20 cm Very low at pH 7.7 So it is necessary to add N, P, K, and S.

Plywood production wastes to energy

Wood and by-products of its processing are a renewable energy source with carbon neutral and may be used in solving energy problems. ZAO «Arkhangelsk plywood factory» installed and put into operation the boiler with capacity of 22 MW (saturated steam of 1.2 MPa) to reduce the cost of thermal energy, the impact of environmental factors on stability of the company’s development and for reduction of harmful emissions into the environment. Fuel for boiler is the mixture consists of chip plywood, birch bark, wood sanding dust (WSD) and sawdust of the plywood processing. The components of the fuel mixture significantly differ in thermotechnical characteristics and technological parameters but especially in size composition. Particle dimensions in the fuel mixture differ by more than a thousand times which makes it «unique» and very difficult to ensure the effective and non-explosive use. WSD and sawdust from line of cutting of plywood are small fraction material and relate to IV group of explosion. Criterion of explosive for them has great values (КfWSD=10.85; Кfsaw=9.66). Boiler’s furnace equipped with reciprocating grate where implemented a three-stage scheme of combustion. For a comprehensive survey of the effectiveness of installed equipment was analyzed the design features of the boiler, defined the components of thermal balance, studied nitrogen oxide emissions, carbon and particulate matter with the determination of soot emissions. Amount of solid particles depending on their shape and size was analyzed.

Thermal Degradation and Combustion Performance Comparison of Plywood Based on Inorganic Adhesive and Phenol-Formaldehyde Resin

The main objective of this work was to study a new inorganic adhesive used for wood-based panel. Inorganic adhesive and its poplar plywood were prepared to investigate their properties. Thermo-gravimetric analysis tests revealed that the total mass loss of inorganic adhesive was 76.24%, which was higher than that of phenol-formaldehyde resin (64.97%). The results showed better thermal stability of inorganic adhesive. For inorganic adhesive plywood, approximately 30% decrease in peak of heat release rate, 62% in total smoke production and 20% in mean CO2 yield, respectively, were seen compared to the control by cone calorimeter analysis. Scanning electron microscopy imaged wider glue line of inorganic adhesives plywood, which was related to the bonding strength of plywood. Thus the inorganic adhesive of fireproofing made in lab could be better used for plywood processing.

Principal component regression-based control charts for monitoring count data

Control charts based on regression models are appropriate for monitoring in which the quality characteristics of products vary depending on the behavior of predecessor variables. Its use enables monitoring the correlation structure between input variables and the response variable through residuals from the fitted model according to historical process data. However, such strategy is restricted to data from input variables which are not significantly correlated. Otherwise, colinear variables that hold substantial information on the variability of the response variable might be absent in the regression model adjustment. This paper proposes a strategy for monitoring count data combining Poisson regression and principal component analysis. In such strategy, colinear variables are turned into uncorrelated variables by principal component analysis and a Poisson regression is performed on principal component scores. A deviance residual control chart from the fitted model is then used to evaluate the process. The performance of that new approach is illustrated through a case study in a plastic plywood process with real and simulated data.

Chemical characteristics of squeezable sap of hydrothermally treated silver birch logs (Betula pendula): effect of treatment time and the quality of the soaking water in pilot scale experiment

Little is currently known about the chemical changes that birch logs undergo during soaking in the plywood process. In order to probe the chemical changes in the log during soaking, sap obtained by mechanical compression from the log was chemically analyzed after pilot scale soaking at 70 °C. The results from the experiments revealed that the physical interaction between the core part of the log and the soaking water is limited. It was also suggested a water extraction causing significant increases in free monosaccharides and organic carbon concentrations in the sap. Assessment of the soaking water in the tank after soaking showed that the level of organic loading in water increases as the soaking temperature increases, probably due to the elution of organic substances from the bark. The dominant-free monosaccharides were glucose and fructose. Xylose and galactose also emerged during soaking. From the results, it is suspected that the majority of organic loadings in the water after soaking originate from the bark. This methodology for the sap collection seemed a reasonable approach to analyze the chemical characteristics of the xylem part of a log. Another aspect, relating to the seasonal variation of these changes in birch logs, is briefly discussed.

Carbon balance assessments of harvested wood products in Japan taking account of inter-regional flows

We constructed a model to assess the carbon balance of harvested wood products (HWP) used for building, furniture, paper/paperboard and energy, taking into account flows of wood between regions of Japan. We projected the carbon balance in each region until 2050 under two future scenarios, a BAU (business as usual) scenario and a wood use promotion scenario. We found the carbon stock in domestic harvested wood products became a carbon emission source, with Central Japan becoming the largest emission source, after 2020 in the BAU scenario but continued to function as a carbon sink in every region over the whole period in the wood promotion scenario. Therefore, unless future supply and demand amounts of domestic wood are increased by factors such as policies promoting the use of wood, the carbon stock of domestic wood may become an emission source rather than a sink. By promoting the use of domestic wood, the carbon stock acts as a carbon sink in every region. Carbon emissions from fossil fuel consumption with respect to HWP in the whole of Japan fell to 72% of the 2004 value in 2050 in the BAU scenario, but rose to 112% in the wood promotion scenario. Emissions from wood transport were greatest in Central Japan, emissions from sawn wood processing were highest in West Japan, and emissions from plywood processing and woodchip processing were greatest in East Japan. In carbon balances that included the annual changes in the carbon stock amounts of domestic harvested wood, only Central Japan in the wood promotion scenario had carbon removals greater than its carbon emissions from fossil fuel consumption in the years 2005–2045. In addition, when considering reductions in carbon emissions by substitution of fossil fuels with wood residues and waste wood in the carbon balances, the sum of the removals from carbon stock changes and the reductions of carbon emissions were greater than the carbon emissions associated with HWP over the entire period in all three regions in both scenarios.

Constructional Bamboo Plywood Process Control and Production Process

Focusing on the problems of the bamboo plywood existing in the construction field, we have proposed an optimal process for the building bamboo plywood through controlling the preparation process of the bamboo plywood. In our work, moso bamboo was selected as the objective and then a variety of performances of the bamboo plywood were tested with the heat-up-heat-down process. Experiments show that in the same conditions of MC 10%, RC 7%-8%, the best optimum processes of 12mm thick constructional bamboo plywood is 15min pressing time, the pressing temperature between 155°C to 160°C and the sheet density of 0.85 g/cm3. The optimal process to make the performance of bamboo plywood substantially exceeded the European standard the OSB/4 levels. It can provide practical application of engineering and production design with reference value and theoretical basis for the bamboo plywood.

The Structure and Curing Acceleration of PMUF Resins with Sodium Carbonate

The phenol-melamine-urea-formaldehyde (PMUF) cocondensed resin adhesive was prepared by using phenol, urea, melamine and formaldehyde as reactants. It was characterized by 13C NMR and the results indicated that the PMUF could reduce the content of free formaldehyde, and it could make wood-based panel with high water resistance and weatherability. Sodium carbonate (Na2CO3) was able to shorten the curing time by 40% when applied to the plywood process. The addition of Na2CO3 as the curing accelerator of a PMUF had little influence on the bonding strength of waterproof layer and could shorten the hot-press time.

Fast curing PF resin mixed with various resins and accelerators for building composite materials

The objective of this research is to investigate the fast curing effect of phenol–formaldehyde (PF) resin by employing three methods: mixing with novolac phenol–formaldehyde, adding amino-based resin and the use of accelerators. The effects of shorting phenolic resin curing time and adhesion strength were determined. The gelation time of phenolic resin mixed with novolac resin shortened the curing time by 20–50% compared to that of the phenolic resin itself (at 100 °C). The hot-press time of the phenolic resin was considerably lessened by varying the composition of the amino-based resin, but it introduced the problem of low bonding strength of waterproof layer for plywood constructed with the radiata-pine solid veneer. Among the various phenolic resin types of curing accelerators, sodium carbonate was the most effective and was able to shorten the curing time by 30% when applied to the plywood process. The addition of sodium carbonate as the curing accelerator of a phenolic resin gave a bonding strength of waterproof layer equal to that of phenolic resin (no sodium carbonate addition) and shortened the hot-press time by about 30 s/mm (135 °C). These test results suggested 4–5% as a suitable addition level for sodium carbonate in phenol use.

A General Equilibrium Analysis of the Economic Aspects of the Imposition of an Export Tax on the Plywood Sector in Indonesia

Computable general equilibrium (CGE) models are extensively used to simulate the economic impact of forest policies. In this study, we conduct a counterfactual analysis to assess the impact of an export tax ranging from 5 to 20% on the plywood sector to the Indonesian economy. The indonesian economy is aggregated into 5 sectors: 2 sectors are related to forest,i.e., (1) log, and (2) plywood. The other three sectors are not related to forest,i.e., (3) non-wood manufacturing, (4) agriculture, quarrying, and services, and (5) construction. The simulation results show that an export tax on the plywood processing sector is negatively correlated with real GDP and labor demand in log and plywood sectors, but is positively correlated with total labor demand, government revenue, income distribution, wood resources and social welfare. Reduction in labor demand by log and plywood sectors, due to a plywood export tax, can be absorbed in other sectors. The simulated policy of an export tax on plywood can reserve trees in production forests for future use.

A review of the utilisation of hardwoods for LVL

This review on the use of hardwoods for the production of LVL revealed that a large number of research studies have been carried out, particularly in North America and three Asian countries (Japan, Malaysia and China). However, the studies have been restricted to species of low to medium density, i.e. 290 to 693 kg/m3. Two major potential uses of hardwood LVL have been investigated in these studies: domestic and industrial structures, and various furniture components. The production of structural LVL in North America and Asia was based predominantly on low density hardwoods. A study currently carried out in Europe aims at using medium density hardwoods for structural LVL. The LVL used for furniture components was produced from medium density hardwoods. No work has been undertaken outside Australia on the use of high density species for LVL. In Australia, studies undertaken on the production of LVL and hardwood plywood from eucalypts revealed that there were significant problems in gluing the dense raw material which often had a high level of extractives. Peeling low quality, small diameter eucalypt logs also created problems when the traditional plywood processing techniques were used.