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IN-HOUSE R&D IN WIP ppt

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This PPT prepared by Dr.E.Sreenivasan, is about the past and the present activities of the R&D Division of THE WESTERN INDIA PLYWOODS LTD,KANNUR,KERALA

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IN-HOUSE R&D IN WIP ppt

  1. 1. RESEARCH AND DEVELOPMENTRESEARCH AND DEVELOPMENT ININ THE WESTERN INDIA PLYWOODSTHE WESTERN INDIA PLYWOODS LTDLTD -AN OVERVIEW-AN OVERVIEW Dr.E.SREENIVASANDr.E.SREENIVASAN Technical Manager, R&DTechnical Manager, R&D THE WESTERN INDIA PLYWOODS LTDTHE WESTERN INDIA PLYWOODS LTD BALIAPATAM,BALIAPATAM, KANNUR-670010KANNUR-670010 Ph:8289865990Ph:8289865990 E-Mail: dr.sreeniettammal@gmail.comE-Mail: dr.sreeniettammal@gmail.com
  2. 2. THE WESTERN INDIA PLYWOODSTHE WESTERN INDIA PLYWOODS LTDLTD
  3. 3. OUR RESPECTFUL HOMAGEOUR RESPECTFUL HOMAGE A.K.KADERKUTTY P.K.MOHAMEDA.K.KADERKUTTY P.K.MOHAMED Founder Managing DirectorFounder Managing Director Former Managing DirectorFormer Managing Director
  4. 4. COMPANY PROFILECOMPANY PROFILE
  5. 5. ORIGINORIGIN Established in 1942, the company started manufactureEstablished in 1942, the company started manufacture of sawn timber and plywood on a modest scale with aof sawn timber and plywood on a modest scale with a few indigenous and lent-leased machinery . Due to thefew indigenous and lent-leased machinery . Due to the progressive outlook and relentless efforts of WIP’sprogressive outlook and relentless efforts of WIP’s founder Managing Director Shri. A. K. Kaderkutty, afounder Managing Director Shri. A. K. Kaderkutty, a doyen of the wood based panel industry in India, thedoyen of the wood based panel industry in India, the company made steady progress over the years andcompany made steady progress over the years and business expanded to its present stature and is todaybusiness expanded to its present stature and is today one of the biggest wood based industrial integratedone of the biggest wood based industrial integrated complexes in the country and also in South-East Asiacomplexes in the country and also in South-East Asia with an employee strength of 1200.with an employee strength of 1200.
  6. 6. GROWTHGROWTH  The Company diversified from Tea Chests and CommercialThe Company diversified from Tea Chests and Commercial Plywood to Decorative Plywood, Blockboards, Flushdoors,Plywood to Decorative Plywood, Blockboards, Flushdoors, Shuttering and Marine Plywood, Aircraft Plywood, etc.Shuttering and Marine Plywood, Aircraft Plywood, etc.  The Company planned and executed the hardboard plant betweenThe Company planned and executed the hardboard plant between the years 1956 and 1958 with an initial installed capacity of 12.5the years 1956 and 1958 with an initial installed capacity of 12.5 tones of hardboard per day.tones of hardboard per day.  The Company also installed its own synthetic resin unit in 1959The Company also installed its own synthetic resin unit in 1959 with a capacity of 200 tones per annum, which graduallywith a capacity of 200 tones per annum, which gradually increased to 2400 tones per annum, by 1975.increased to 2400 tones per annum, by 1975.  An Industrial License was obtained in 1974 for manufacture ofAn Industrial License was obtained in 1974 for manufacture of Densified Wood with a capacity of 2000 M.T. per annum. In 1974Densified Wood with a capacity of 2000 M.T. per annum. In 1974 a plant for manufacture of Furniture was added.a plant for manufacture of Furniture was added.  A Reverse Osmosis based Desalination plant, the first in KeralaA Reverse Osmosis based Desalination plant, the first in Kerala with the most modern technology to purify brackish ground waterwith the most modern technology to purify brackish ground water and sea water, having a capacity of 300 cum per day wasand sea water, having a capacity of 300 cum per day was successfully commissioned in the year 1996.successfully commissioned in the year 1996.
  7. 7. LIST OF FIRSTS IN THE COUNTRYLIST OF FIRSTS IN THE COUNTRY  First to make irradiated woodFirst to make irradiated wood  First to make aircraft plywoodFirst to make aircraft plywood  First to make synthetic resin adhesive bonded plywood using hotFirst to make synthetic resin adhesive bonded plywood using hot pressing techniquespressing techniques  First to make high pressure industrial laminatesFirst to make high pressure industrial laminates  First to make quality hardboard way back in 1959-60First to make quality hardboard way back in 1959-60  First to manufacture Di Allyl Phthalate moulding powderFirst to manufacture Di Allyl Phthalate moulding powder  First to manufacture GI – Plywood – GI sandwich panel forFirst to manufacture GI – Plywood – GI sandwich panel for anechoic chamberanechoic chamber  First to make pre-finished plywoods and hardboards using UVFirst to make pre-finished plywoods and hardboards using UV cured surface finishing techniques.cured surface finishing techniques.  First to get ISO 9000 certification for hardboard and prefinishedFirst to get ISO 9000 certification for hardboard and prefinished boardsboards
  8. 8. IN HOUSE R&D UNITIN HOUSE R&D UNIT
  9. 9. NEED OF R&DNEED OF R&D In these days, R&D becomes increasingly important in order toIn these days, R&D becomes increasingly important in order to overcome the unprecedented transition stage of currentovercome the unprecedented transition stage of current technologies, social needs and to succeed in meeting thetechnologies, social needs and to succeed in meeting the requirements for the need of the hour. The ability to predict marketrequirements for the need of the hour. The ability to predict market needs, select and focus on research themes, keep relevantneeds, select and focus on research themes, keep relevant divisions working together as a team, and operate with flexibilitydivisions working together as a team, and operate with flexibility and speed is of the highest importance. Due to theseand speed is of the highest importance. Due to these relationships, we can develop a comprehensive understanding ofrelationships, we can develop a comprehensive understanding of advanced market needs and can provide products that are deadvanced market needs and can provide products that are de facto standards of excellence in the market. As a responsiblefacto standards of excellence in the market. As a responsible technology-oriented people, we should intend to providetechnology-oriented people, we should intend to provide innovative products and leveraging solutions to enhance ourinnovative products and leveraging solutions to enhance our national power by further developing pioneering technologies.national power by further developing pioneering technologies.
  10. 10. VISION AND MISSIONVISION AND MISSION  VISION:VISION: The Objective of the Research & Development Unit is to build orThe Objective of the Research & Development Unit is to build or improve research capabilities of the organization and to innovate,improve research capabilities of the organization and to innovate, create and develop key technologies.create and develop key technologies.  MISSIOIN:MISSIOIN: The mission of the Research & Development Unit is to support,The mission of the Research & Development Unit is to support, encourage and develop the research activities for new knowledgeencourage and develop the research activities for new knowledge and understanding.and understanding.
  11. 11. OBJECTIVESOBJECTIVES  To promote and disseminate a culture of innovation, creativity andTo promote and disseminate a culture of innovation, creativity and development in the field of wood science and technology.development in the field of wood science and technology.  Develop new processes or products as per the needs of theDevelop new processes or products as per the needs of the industry through Innovation and Research.industry through Innovation and Research.  To determine present and future research needs, and to know wellTo determine present and future research needs, and to know well about current and anticipated problems in the technology.about current and anticipated problems in the technology.
  12. 12. SPECIFIC AREAS OF INTERESTSPECIFIC AREAS OF INTEREST  Development of wood panel products,  Wood preservation,  Synthetic resin adhesives and  Wood waste utilization
  13. 13. INFRASTRUCTUREINFRASTRUCTURE  Year of establishment: 1972Year of establishment: 1972  Land and Building area earmarked for R&D activities:Land and Building area earmarked for R&D activities: 6700 sq. ft6700 sq. ft  Laboratory facilities:Laboratory facilities:  UV-VIS & IR Spectrophotometers, Waters HPLC,UV-VIS & IR Spectrophotometers, Waters HPLC, Weather-o-meter, Vertical Fluorescence Microscope,Weather-o-meter, Vertical Fluorescence Microscope, Universal Testing Machines, Optical Microscope, HighUniversal Testing Machines, Optical Microscope, High Voltage Electrical Tester, Humidity Chamber, etcVoltage Electrical Tester, Humidity Chamber, etc  Pilot plant facilities:Pilot plant facilities:  Bench UV coater, Bench UV curing machineBench UV coater, Bench UV curing machine
  14. 14. MAJOR EQUIPMENTSMAJOR EQUIPMENTS  Weather-O-MeterWeather-O-Meter  UV-Vis SpectrophotometerUV-Vis Spectrophotometer  Breakdown Voltage testerBreakdown Voltage tester (150KV & 120 KV)(150KV & 120 KV)  Universal Testing Machine ( 2Universal Testing Machine ( 2 tonnes)tonnes)  Universal Testing MachineUniversal Testing Machine (20 tonnes)(20 tonnes)  Cooling CentrifugeCooling Centrifuge  MicrotomeMicrotome  Abrasion TesterAbrasion Tester  Muffle furnaceMuffle furnace  Fluorescence MicroscopeFluorescence Microscope  Horizontal AutoclaveHorizontal Autoclave  Laminar Airflow ChamberLaminar Airflow Chamber  Toxicity Testing ChamberToxicity Testing Chamber  Smoke Density TestingSmoke Density Testing ChamberChamber  Limiting Oxygen Index TesterLimiting Oxygen Index Tester  PH MeterPH Meter  Conductivity MeterConductivity Meter  Gloss meterGloss meter  Digital Moisture MeterDigital Moisture Meter  Digital Ultrasonic CleanerDigital Ultrasonic Cleaner  Optical MicroscopeOptical Microscope  Electronic BalanceElectronic Balance
  15. 15. QUALITY CONTROL LABQUALITY CONTROL LAB
  16. 16. CHEMICAL TESTING LABCHEMICAL TESTING LAB
  17. 17. BIOCONVERSION LABBIOCONVERSION LAB
  18. 18. LIBRARYLIBRARY The well-stockedThe well-stocked library is one of thelibrary is one of the best in wood-workingbest in wood-working industry.industry. With over 6000 titles,With over 6000 titles, it is a point ofit is a point of scholastic pilgrimagescholastic pilgrimage for professionals andfor professionals and academics.academics.
  19. 19. MAJOR ACHIEVEMENTSMAJOR ACHIEVEMENTS
  20. 20. DIALLYL PHTHALATE(D.A.P)DIALLYL PHTHALATE(D.A.P)  Process / product modified by the R&D DivisionProcess / product modified by the R&D Division include Diallyl phthalate (D.A.P) Mouldinginclude Diallyl phthalate (D.A.P) Moulding powder and Fibreglass Reinforced Plasticpowder and Fibreglass Reinforced Plastic Sheet Moulding Compounds (S.M.C) whichSheet Moulding Compounds (S.M.C) which find use in the manufacture of sophisticatedfind use in the manufacture of sophisticated products required in highly specializedproducts required in highly specialized electrical and electronics applications.electrical and electronics applications.
  21. 21. Wood polymer composites by irradiationWood polymer composites by irradiation  Conversion of non-durable species of timber likeConversion of non-durable species of timber like Holigarna arnottianaHoligarna arnottiana (Cheru),(Cheru), LophopetalumLophopetalum wightianumwightianum (Banati) etc. into stable and durable wood(Banati) etc. into stable and durable wood polymer composites by irradiation with gamma rayspolymer composites by irradiation with gamma rays represents a landmark in the conservation of woodrepresents a landmark in the conservation of wood resources achieved by WIP's R&D Division. With theresources achieved by WIP's R&D Division. With the active assistance of Bhaba Atomic Research Centre,active assistance of Bhaba Atomic Research Centre, Trombay, a Gamma ray irradiation source of adequateTrombay, a Gamma ray irradiation source of adequate strength was established for the first time in India, instrength was established for the first time in India, in WIP's research division.WIP's research division.
  22. 22. Rubber wood treatmentRubber wood treatment  Developed a unique, cost effective and highlyDeveloped a unique, cost effective and highly efficient rubber wood treatment process whichefficient rubber wood treatment process which enhances not only the durability but also theenhances not only the durability but also the strength of the treated wood.strength of the treated wood.
  23. 23. HardboardHardboard  Developed weather proof and fire retardant gradesDeveloped weather proof and fire retardant grades of Hardboard. Developed through wholly independentof Hardboard. Developed through wholly independent research, these products promise an end to the use ofresearch, these products promise an end to the use of commercial hardwood in common exterior applications.commercial hardwood in common exterior applications.
  24. 24. Metal-faced plywoodMetal-faced plywood Developed a technology for producing metalDeveloped a technology for producing metal faced plywood.1200 GI faced plywood panelsfaced plywood.1200 GI faced plywood panels were produced and supplied to ISRO,were produced and supplied to ISRO, Bangalore for use in Anechoic Chambers asBangalore for use in Anechoic Chambers as electromagnetic shield based on in houseelectromagnetic shield based on in house technology.technology.
  25. 25. WOOD WASTE MANAGEMENTWOOD WASTE MANAGEMENT PROJECTSPROJECTS
  26. 26. Vermicomposting of chip wash residueVermicomposting of chip wash residue Developed a technologyDeveloped a technology for vermicomposting offor vermicomposting of chip wash residue, achip wash residue, a lignocellulosic wastelignocellulosic waste from the hardboard unit.from the hardboard unit. The organic manureThe organic manure produced from thisproduced from this activity is a mixture ofactivity is a mixture of castings of earthwormscastings of earthworms containing aerobicallycontaining aerobically composted organiccomposted organic matter.matter.
  27. 27. COMPOSTING BY EFFECTIVECOMPOSTING BY EFFECTIVE MICROORGANISMSMICROORGANISMS Developed a technologyDeveloped a technology for composting of woodfor composting of wood wastes including chipwastes including chip wash residue and boilerwash residue and boiler ash from the hardboardash from the hardboard and plywood units, usingand plywood units, using microbial consortium.microbial consortium. The organic manureThe organic manure produced from thisproduced from this aerobic activity is calledaerobic activity is called compost.compost.
  28. 28. VEGETABLE DEVELOPMENT PROJECTVEGETABLE DEVELOPMENT PROJECT FUNDED BY AGRICULTURE DEPT.,GOVT.OF KERALAFUNDED BY AGRICULTURE DEPT.,GOVT.OF KERALA Organic cultivation ofOrganic cultivation of vegetables in a landvegetables in a land area of 50 cents inarea of 50 cents in the campus usingthe campus using vermicompostvermicompost produced from woodproduced from wood wastes during 2013-wastes during 2013- 20142014
  29. 29. AWARDSAWARDS Received the bestReceived the best private institutionprivate institution award (district level)award (district level) from Agriculturefrom Agriculture dept., Govt. of Keraladept., Govt. of Kerala for the vegetablefor the vegetable development projectdevelopment project undertaken duringundertaken during 2013-20142013-2014
  30. 30. PATENTSPATENTS 1.Radiation induced polymerization of DAP,1.Radiation induced polymerization of DAP, MMA & PEMMA & PE 2.Radiation induced polymerization of DAP &2.Radiation induced polymerization of DAP & MMAMMA 3.A process for manufacture of wood polymer3.A process for manufacture of wood polymer composites by gamma irradiationcomposites by gamma irradiation 4.Manufacture of ABS plastics4.Manufacture of ABS plastics 5.Manufacture of SAN plastics5.Manufacture of SAN plastics
  31. 31. INDUSTRY-ACADEMIC PARTICIPATIONINDUSTRY-ACADEMIC PARTICIPATION Kannur UniversityKannur University inin association withassociation with The WesternThe Western India Plywoods LtdIndia Plywoods Ltd startedstarted M.Sc. course in WoodM.Sc. course in Wood Science and TechnologyScience and Technology inin 2007 as part of the industry-2007 as part of the industry- academic participationacademic participation programme.programme.  WIPL provides the laboratoryWIPL provides the laboratory facilities and expert guidancefacilities and expert guidance required for handling therequired for handling the practical sessions, industrialpractical sessions, industrial training and project works.training and project works.
  32. 32. PRODUCTION UNITSPRODUCTION UNITS MANAGED BY R&D TEAMMANAGED BY R&D TEAM
  33. 33. RESIN PLANTRESIN PLANT
  34. 34. RESIN-IMPREGNATED PAPER PLANTRESIN-IMPREGNATED PAPER PLANT
  35. 35. DAP UNITDAP UNIT
  36. 36. PAINT UNITPAINT UNIT
  37. 37. VERMICOMPOSTING UNITVERMICOMPOSTING UNIT
  38. 38. PRESENT ACTIVITIES  UV curable Coatings: Development of new formulations that have improved toughness and scratch/abrasion resistance, application of micronised and nano fillers for improving the performance, studies on various monomers/oligomers etc. constitute key areas of current interests.  Waterborne Polyurethane (PU) dispersion based coatings for finishing wood furniture as well as flooring.  Improved PF resins, Wood-polymer composites  Wood waste management by bioconversion methods.  Non conventional raw materials for pulping.  Cost effective wood preservation
  39. 39. ON GOING PROJECTSON GOING PROJECTS  Studies on identifying non-conventional raw-materialsStudies on identifying non-conventional raw-materials for thermo mechanical pulpingfor thermo mechanical pulping  Studies on termite resistance of wood and wood basedStudies on termite resistance of wood and wood based panels treated with common fire retardantspanels treated with common fire retardants  Studies on the use of tannin and tree bark extracts inStudies on the use of tannin and tree bark extracts in phenol-formaldehyde resin preparationphenol-formaldehyde resin preparation  Dimensional stability of wooden flooring boardsDimensional stability of wooden flooring boards  Bioconversion of wood residues into useful productsBioconversion of wood residues into useful products
  40. 40. RECENT PUBLICATIONSRECENT PUBLICATIONS  E.Sreenivasan (2013): Bioconversion of industrial wood wastesE.Sreenivasan (2013): Bioconversion of industrial wood wastes into vermicompost by utilizing African Night Crawlers (into vermicompost by utilizing African Night Crawlers (EudrilusEudrilus eugeniae).eugeniae). Int.J.Adv. Engg.Tech,IV/III/Jul-Sept.2013/19-20Int.J.Adv. Engg.Tech,IV/III/Jul-Sept.2013/19-20  E.Sreenivasan (2013): Evaluation of Effective MicroorganismsE.Sreenivasan (2013): Evaluation of Effective Microorganisms Technology in industrial wood waste management. Int.J.Adv.Technology in industrial wood waste management. Int.J.Adv. Engg.Tech, IV/III/Jul-Sept.2013/21-22Engg.Tech, IV/III/Jul-Sept.2013/21-22  Bindu.K.P, Jayasree.N.R, Sreenivasan.E (2013): Control, Automation and Monitoring Of Hardboard Production Process Using PLC-SCADA System. Int.J.Adv.Res.Electr.Electro.Instr. Eng. Vol. 2, Issue 7,p.3281-3286
  41. 41. THANK YOUTHANK YOU

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