Block Board And Flush Door Shutters (Wooden) (Solid Core)

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Product Code 270201009
Quality and Standards Block Board - IS1659:1990
Flush Doors - IS 2202:1991
Production Capacity Qty. : Block Board/Plywood-1.26 lakhs
Value : Rs. 646.8 Lakhs
Uploaded on May 2007


Block Board: Block Boards are a kind of plywood in which the veneers are glued on both sides on wooden battens frame. Wooden strips are placed across a surface of one or more boards to prevent, warping and strengthening etc. Block Boards are used for making furniture, cabinets, partitions, interior/ exterior decorative wood working etc.

Flush Door: Flush Doors are also a kind of block board which is used to make door panels and differ in sizes according to the size of door.

Market Potential

As a raw material, wood has several unique characteristics and properties. Properly seasoned wood is light in weight compared to most materials of constructions and fabrication. Wood is a poor transmitter of sound, heat and electricity. Wood is easier to work, to paint and to preserve in the presence of sea water than most competitive materials. There are many other remarkable properties and characteristics of wood which provide for a variety of its usage and products. Block boards and flush doors are among these products.

Block boards and flush doors are seasoned boards and have all the properties of wood like, ease to work, to paint etc. These have advantages over raw wooden planks for the reason that these boards are more strong and free from war page. Now a days in almost all the sectors of society, the use of plywood, board is becoming common for it is cheaper than wood and stronger as well. These boards doors are available in standard sizes. They can also be used in partitions, making furnitures, interior and exterior decorations etc. The surfaces of the boards are always smooth so laminating board with mica or otherwise is easy. Looking at these advantageous properties of boards, these are now becoming popular and used in almost all the houses, offices, bungalows, commercial complexes etc. In view of the urban/rural development and growth of construction activities and increasing replacement of old traditional wooden fittings with the boards, it can be easily presumed that these boards have a tremendous market potential.

Basis and Presumptions

This project scheme has been prepared on the basis of prevailing rates, which may vary from time to time and place to place. The entrepreneurs putting up this unit must check up/verify the following points at the time of conception

  • Unit should run in single shift of 8 hours, 300 working days in a year.
  • It is envisaged that the unit can utilise 75% of its total installed capacity.
  • Labour wages, cost of plant and machinery, interest on capital investment etc. have been taken as prevailing at the time of preparation of this report.
  • Margin money requirement, terms of loan etc. may vary from institution to institution.
  • Interest on capital investment has been taken @ 12% per annum.

Implementation Schedule

It is estimated to take about 6 months, from conception to implementation and commercial production, which includes preparation of project report, liaison with financial institutions, purchase of plant and machinery, erection and
commissioning, recruitment of staff and labour, clearance from all the concerned departments etc.

Technical Aspects

Process of Manufacture

Plywood, block boards and flush doors are made from a similar process, the difference between block board/ flush doors and plywood is only that the solid core of block boards and flush doors is made up of wooden battens frame, whereas the plywood is made from veneer gluing on one another. Plywood consists of three or more sheets of veneer glued together, with the grains of alternate sheet usually laid cross wise. The resulting material has distinct advantages for many uses as it is strong and free from war page etc. There are many gluing materials available in the market but Urea Formaldehyde is normally used and Phenyl Formaldehyde is used in plywood or block boards for exterior uses as this type of gluing material provides water or weather resistance properly to the boards.

  • Water is mixed in proportionate quantity in powder resin with small quantities of GHCP, TSP, LA and Maida to make liquid glue in glue mixer.
  • Liquid glue is spread on core veneer with the help of rollers on glue spreader.
  • Different layers of core and face veneers are set manually on wooden battens frame and stacked in the press and compressed with the help of steam in Hydraulic hot press.
  • After the boards are properly pressed and dried, these are taken out and side cutting is done on DD saw. Saw wastage of side cutting is used as fuel in boiler.
  • Top layer finishing is done on sanding machine by sanding belt.

Flow Process

Glue mixer - Glue spreader - Face and core veneer stacking - Hydraulic hot press - DD saw - sanding - finished boards.

In case of manufacture of flush doors, the production process remains same except the solid core is made from, a frame of battens in required sizes and face veneers are glued with phenyl formaldehyde which gives the door water resistance property.

Quality Control and Standards

Block boards are required to be manufactured as per IS 1659:1990 (Third revision, Amendment No. 3). Flush doors are to be manufactured conforming to IS 2202:1991 (Part I : Fifth revision).

Bureau of Indian Standards has suggested some tests for block boards and flush doors in IS 4020:1998 (Parts 1 to 16) which should also be followed.

Production Capacity





Amt. (In Rs.)

Block Board/ Plywood 126000 Sq. Mts 220 27720000
Flush Door 84000 Sq.Mts 440 36960000
Total 64680000
Motive Power 25 K.W.

Pollution Control

As such the unit does not need any special features for pollution control, however general precautions must be taken care of. Financial Aspects

Energy Conservation

No special measures are needed. However while selecting machinery etc., one should be careful.

Financial Aspects

Fixed Capital

(i) Land and Building

Amount (In Rs.)

Land 700 sq. mtr. @ Rs. 6000/sq. mt. 4200000
Construction of work sheds 400 sq. mts. @ Rs. 5000 per sq. mtr. 2000000
Total 6200000

(ii) Machinery and Equipment



Rate (In Rs.)

Amount (In Rs.)

(A) Production Unit
Glue Mixer complete with motor and electricals (3 HP) Ind. 1 40000
Glue Spreading Machine with 56" rubber rollers, tank and complete accessories and 3 HP Motor Ind. 1 180000
Thermi fluid Boiler Capacity 4,00,000 calories (agriculture or municipal waste conversion) Ind. 1 500000
Hydraulic Press (640 Tonne capacity) complete with
heating plates, bolt case, pressing table, electrical panels, cylindrical Ram unit, jack cylinder hydraulic power jack etc.
Ind. 1 2000000
Double Diamond saw cutter machine complete with table, saw blades motors (5+5) total 10 HP and accessories Ind. 1 150000
Sanding machine complete with 5 HP motor and accessories Ind. 2 200000
Water system including borewell & over head tank     200000
Total 3270000
Erection and commissioning @ 10% of machinery     327000
Cost of spare blades, dies, fixture and other tools including measuring tools     200000
Cost of working tables, office furniture and equipmen     200000
Total 3997000
(iii) Pre-operative Expenses 150000
Total 4147000
Total Fixed Capital (In Rs.)
(i) Land and Building 6200000
(ii) Plant and Machinery 4147000
(iii) Pre-Operative Expenses 150000
Total 10497000

Working Capital (per month)

(i) Personnel




Amount (In Rs.)

Manager 1 15000 15000
Supervisor 1 8000 8000
Clerk/Store Keeper 1 6000 6000
Typist cum Clerk 1 5000 5000
Skilled Worker 10 6000 60000
Helpers 15 4000 60000
Watchman 2 3000 6000
Total 160000
Add 22% Perquisites 35200
Total 195200

(ii) Raw Material





Amount (In Rs.)

Veneer (for core and face) Ind. 70,000 Sq.mts. 22 1540000
Batten frames (for solid core) Ind. 17500 120 2100000
Glue U.F. Resin Ind. 4 60000 240000
Glue Phenyl Resin Ind. 4 100000 400000
Total       4280000

(iii) Utilities


Amt.(In Rs.)

Power 7000 KWH Units @ Rs. 5.5 per unit 38500
Total 38500

(iv) Other Contingent Expenses


(In Rs.)

Transportation and Conveyance 70000
Maintenance and Repairs 15000
Telephone Charges 5000
Postage and Stationery 5000
Petty Purchases 10000
Fuel for Boiler 20000
Insurance 3000
Miscellaneous Expenses 10000
Total 138000
(v) Total Recurring Expenditure  
(per month) [i+ii+iii+iv] 4651700
(vi) Working Capital (for 1.5 Months)  
Rs. 4651700 × 1.5 6977550

Total Capital Investment

(i) Fixed Capital 10497000
(ii) Working Capital (for 1.5months) 6977550
Total 17474550

Financial Analysis

Cost of Production (per year)

(In Rs.)

Total Recurring Cost 55820400
Depreciation on Machinery @ 10% 327000
Depreciation on Tools etc. @ 25% 50000
Depreciation on Office Equipments @ 20% 40000
Depreciation on Building @ 5% 310000
Interest on Capital Investment @ 12% 2096946
Total 58644346
Say 5,86,44,346

Turnover (per year)





Amount (Rs.)

Block Board/Plywood (Assorted Thickness) 126000 Sq Mtr 220 27720000
Flush Doors (Assorted Thickness) 84000 Sq Mtr 440 36960000
Total 64680000

Profit (Before Taxes)

  64680000 – 58644346
  = 6035654

Net Profit Ratio

  Net Profit × 100
  6035654 × 100
  = 9.33

Rate of Return

  Net Profit × 100
  Capital Investment
  6035654 × 100
  = 34.54

Break-even Point

Fixed Cost

(In Rs.)

Total Depreciation 727000
Total Interest 2096946
Insurance 36000
40% of Salary and Wages 936960
40% of Other Contingent Expenses (Excluding Insurance) 662400
Total 4459306

B.E.P Fixed Cost × 100
  Fixed Cost + Profit
  4459306 × 100
  4459306 + 6035654
  = 42.49

Addresses of Machinery and Raw Material Suppliers

  • M/s. Energy Machines
    Vithal Udyog Nagar,
    Vallabh Vidya Nagar
  • M/s. Ambica Hydraulics Pvt. Ltd.
    Chhotral District,
    Mehsana, (Gujarat).
  • M/s. Pal Singh and Sons
    Kirti Nagar, Delhi.

Raw Material Suppliers

All the raw materials are easily available in the local market

For further information please contact

Information Manager
TIMEIS Project