INDUSTRY & TRADE IN FAVOR OF CHANGE IN PARAMETERS FOR PLYWOOD SEGMENT: A REPORT
Indian Plywood Industry has gone through rapid changes in manufacturing of plywood products during last 2 decades. There has been upside down change in raw materials like timber, adhesives, process, technology and product applications. The carpentry-based wood working segment has become tools driven and machine based that has altered the required specification according to modern needs. But the specifications for BIS standards are same as it was 3 decade earlier and are fast becoming obsolete. The specs are also being manipulated largely on (+/-) 10 % variation window. The rise of ambiguity in quality is also led by loop holes which must be plugged by amending it according to modern technology, available raw materials and product life cycle according to modern applications and consumer needs. This cover story is important for industry and trade to read and share and spread till change becomes reality…
The existing BIS standards were implemented in 1967 onwards and according to a note presented by the industry, the last amendment in IS:303 in the year 1989. It is more than 30 years. Although as per BIS norms, after every five years, there should be a review with the industry and BIS department, but somehow things have not been actively done and adopted and a big gap is leading to loosing relevance and trust with the standards.
T here has been on and off discussions among industry associations and markets that ‘Is it right to carry the old standard of BIS?’ Should these specifications be changed to maintain the essence of Plywood as a trustworthy and relevant product? The topic has been mentioned and raised by the Ply Reporter since years in various issues in news related to duplicity, thicknesses etc. quality seeking Industries to be alert and raised the issue on time to time. Recently the BIS norms must change’ point are raised by Greenply Industries Limited too during a BIS's CED20 meeting held on 20 July 2020. In their presentation, Greenply advised BIS to review the present standard of plywood and suggest necessary changes to the industry to maintain the importance of plywood among users.
It was mentioned “The things have changed completely and for over twenty-four years. Also, the industry has the best technology, machine and high quality resin for making plywood today. However, the industry has to rely only on plantation wood with short rotation. It is believed that 5–10-year-old plantation timbers have lower strength than mature wood from 30–50 years old. Many physio-mechanical properties of plywood made of plantation timber cannot meet all the mechanical properties set in the BIS standards.This is why making necessary amendments in the BIS standard related to plywood is the need of the hour.”
in CED-20 meeting in July,2020, Greenply has been asked to prepare a draft in terms of suggested change in the BIS standard. The scientist will give their study to Greenply and the company as an industry representative will submit the draft to BIS (Bureau of Indian Standard). The technical committee will further study and send it for wide circulation after that it may bring a change in the Standard and its testing norms.
BIS CERTIFICATION AND ITS IMPORTANCE
BIS Certification is an authentication (or third party guarantee) for the quality, safety and reliability of products to the customer. It is not mandatory; however the Government of India has made it mandatory for certain products for maintaining safety to public health. BIS Certification is provided in India by Bureau of Indian Standards (BIS), the National Standards Body headquartered at New Delhi who is involved in various activities like standards formulation, certification of products, hallmarking, testing and calibration schemes etc.
The point that is very much valid and shall be heard is, The plywood manufacturing in India depends on plantation timbers in today’s times. It is not using any forest timber now and has acted and accepted the change after Supreme Court ordered banning oflog felling timber in their verdict in December 1996.
Greenply pointers mentioned that ‘Today, the evolution and growth in plywood manufacturing has been shifted to agro-wood, which has become ready for using in 5 to 10 years, whereas before 1996, the timber were used of minimum 30 years life, and more matured. Industry now uses Short rotation Plantation timber such as Poplar, Eucalyptus, Melia Dubia, Rubber Wood, Neelgiri etc for making plywood.
Today the wood availabilityfor making plywood is getting downand that is also leading to pre-mature cutting of plantation timber like Poplar and Eucalyptus and many more to meet the requirement of increasing demand of wood based panels corresponding to the increasing population in the country. Due to cutting at younger age the tensile strength of the timber obtained from plantation comes down. The industry activities are also supported with the changed consumers’ behavior as they want frequent renovation in interior and furniture with new designs/concept and innovation in material.
Plywood manufacturing has also turned to adopt speed, volume and sophistication with innovation in machines/ material with time according to the consumption pattern changed with time in comparison to the plywood made earlier for longevity and durability.
THE WAY FORWARD:
In BIS's CED-20 meeting held on 20 July 2020, it was said to submit the draft for the revision of BIS Standard. The purpose of the modification is to include test values of the best physico-mechanical properties, which can be obtained using plantation timbers, so that the dignity of the standards is maintained and the industry also do not have to compromise with quality to the set specification.
In fact, the existing BIS standard for plywood is determined based on plies which were made many years ago from old and mature wood, obtained from the natural forest. Those days, select wood was very much suitable for plywood manufacturing. BIS certifications facilitates that any product manufactured under the set norms of certification is standard, tried and tested for quality of the products. The industry fraternity wants the standard according to the needs and the availability of wood/raw material and its sustainability, which shall be actually plantation timber based parameters.
It is to be noted that in CED-20 meeting in July,2020, Greenply has been asked to prepare a draft in terms of suggested change in the BIS standard. The scientist will give their study to Greenply and the company as an industry representative will submit the draft to BIS (Bureau of Indian Standard). The technical committee will further study and send it for wide circulation after that it may bring a change in the Standard and its testing norms.
Mr Rajesh Mittal, MD and CEO, Greenply Industries Ltd has sought the view of Industry Association bodies along with All India Plywood Manufacturers Association (AIPMA) on this issue. The purpose of the BIS to promote this study is to get the best result from the timber used in the industry.
The scientists are trying to study the data of testing done by the institutes, research department of industry and obtained a best result on average and do the needful for the amendment in BIS standard. For the new standard most of the available timber will be studied and decide further
“Industry need to understand that national standard should be dignity, as in coming days if the industry has to export them the material must pass the international norms for the standard,” RAJESH MITTAL, MD, GREENPLY
Scientist and industry must be trying to make the way forward to match the international standard, because at present when we talk about the quality of the products at international market we are not able to present specifications equal to them and hence loose big market. After including the VOC norms in the standard, ‘made in India plywood products’ acceptability will increase in international market.
“The current objective is to prepare the standards and display them in such a way that consumers have all the information about the product before them and they can understand that which type of products they are buying and what material has been used within. The purpose of standard is to facilitate the benefit to the consumers as well as the producers and the consumers have faith in the quality of the product.
Till date three meetings of CED – 20 have been done and probably by the next meeting the draft can be discussed. The acceptability of the standard is important for being it functional properly. The acceptability of the standard depends on the desire of a particular industry as is not binding to them. The standard should be prepared in such a way that the company as well as the consumers both can be benefited and its acceptability increases.
Talking with The Ply Reporter Mr MP Singh, Director, IPIRTI said that at present in the BIS norms there is no discussion about formaldehyde emissions in Plywood. Formaldehyde is a volatile organic compound (VOC) which has been included recently in BIS norms for MDF and Particle Board. We have sought for the suggestion from the stake holders and after studying them a draft will be prepared and sent for wide circulation and then the review committee will discuss and amendment will done in BIS. People say that plywood standard is based on forest wood species, that need to change I hope by the next meeting of CED-20 or before the draft would be ready to present before the review committee,” added Mr Singh.
The consumers of plywood do not have much information and they used exterior purpose plywood for interior purposes in need of good quality products. In this way why they have to spend more for the product what they do not need? We are also working on to avoid this confusion and for that as well the standard would be included something different. The product may have such description as is in practice in many countries they even indicate that for making particular plywood which specie of wood has been used along with many other details about the plywood are displayed on it,” Said Mr MP Singh.
The awareness is being created in this regard and for the change the suggestions has been asked. The whole process may take time and it will also depend on the activeness of the industry and how quick the suggestions come. Till date three meetings of CED – 20 have been done and probably by the next meeting the draft can be discussed. The acceptability of the standard is important for being it functional properly. The acceptability of the standard depends on the desire of a particular industry as is not binding to them. The standard should be prepared in such a way that the company as well as the consumers both can be benefited and its acceptability increases.
Dr SK Nath, Ex Joint Director of IPIRTI, who is preparing the draft on behalf of Industry said, The ongoing BIS standards were made on basis of 50-60 years old timber which is not possible to find now. The timber availability from the forest is also a herculean as well as not a law abidingtask for the industry. Some of the industry representative opined that they are using those timbers which are not included for higher grade plywood specification in manufacturing. If we have to make higher grade plywood and timber is not available in that case what timber is available should be included in specification for higher grade plywood manufacturing. We seek note from Industry Associations for the list of timbers which are being used and are not in the list and we will make effort to get included them in the list of BIS standard. In general purpose plywood there is specifications that any timber can be used but for higher grade and shuttering plywood the specification need to be changed as there is timber limitation according to old standard. Scientists from IPIRTI are studying on it to prepare the draft on request of Greenply,” he added.
Dr DP Khali, Scientist F, Forest Product Division, FRI, Dehradun said, “There is a need of improvement and it is possible as BIS is a dynamic document that can be changed with inputs coming in to them. Every product has different specifications and with time several amendments have been done. For example the thermosetting resin’s IS -848 specification is being followed since 1974, but in 1992 it has been revised and 2002 many more parameters were included on the basis of MOE-MOR, besides having initial specifications based on Glues Sear strength. That time cyclic test has also been incorporated.
It will be discussed in CED-20 and CED-19 as well after getting the industry inputs in this regards as how much difficulties they are getting with the threshold limit given to them. There are three prospective industry inputs regarding technical as well as feasibility point of views, secondly technical labs input like how they can give best possible quality and data and thirdly the users’ prospective as they should not compromise with quality. So, to depending on what is the industry feedback and inputs have come from testing labs and whether the industry demand is technically feasible without compromising the quality the norms are set. If the industry puts its sincere efforts using their technical manpower, maintaining quality is not difficult” opines Mr Khali.
THE PLYWOOD INDUSTRY AND ASSOCIATIONS RECOMMENDATIONS ON BIS MATTER
Mr Naresh Tiwari, President, All India Plywood Manufacturers’ Association (AIPMA): All available timber with right properties, shall be under BIS norms. The hearing committee of the association has recommended that the Face Veneer should be less than 0.5mm and tensile strength should also be less. If the specification does not change, there are 200 companies who are willing to surrender the existing standard as many leading companies are also not using it. In that case AIPMA will formally write to the member for surrendering the ISI mark what they are using at present. There are practices in the industry for using ISI without any testing under the existing specifications.
If they are willing to discuss and reduce the limit for tensile strength, Face Veneer thickness etc they should change it for all the specifications like IS 303, 4990, 710, etc. according to the available quality of timer under agro-forestry. There are 15 recommended fast growing plantation timbers to be considered for the new norms. If its best values are considered under the specifications for BIS in different category of plywood, we can achieve and this way, BIS standards will be successfully implemented. We are also under consultation with prominent members of the industry and after reviewing them we will recommend to the BIS for the change.
If the specification does not change, there are 200 companies who are willing to surrender the existing standard as many leading companies are also not using it. In that case AIPMA will formally write to the member for surrendering the ISI mark what they are using at present.
Mr M. M. Mujeeb Rahman, President, AKPBMA, Kerala: I suggest the following as Marine Plywood as per IS 710 - Clause No.5.2.2.1- In the case of multiply boards the thickness of any veneer shall not exceed twice the thickness of any other veneer in the same board. Clause No.9.1.6- Most of the Marine plywood samples are failing the requirement of Modulus of Elasticity along the Face grain only. Clause No.5.3-Vacuum pressure process is not practical, need an alternate method like dipping process in the treatment of Marine plywood. And Block Board as per IS 1659 - Clause 7.3- Difficult to maintain the test parameter Variations in thickness on a Board not more than 0.5mm. In Shuttering Plywood as per IS 4990 - Clause 6.2- Non Availability of 1.2mm thickness Face Veneer Clause 10.1.7- Most of the Shuttering Plywoods are failing the requirements of Modulus of Elasticity along the Face Veneer grain only.
Mr JK Bihani, President, Haryana Plywood Manufacturers’ Association: We have given the recommendation to industry core committee where we have demanded for Face Veneer thickness, number of core in Marine plywood, Tensile strength, Retention, MOE-MOR for shuttering, new standard for plywood without pressure treatment etc. Many species in BIS are not available must be included now. I think, if we define the Face and Core properties, there won’t be much use of species to mention also must be seen with respect to marine grade and film face plywood perspective. We have recommended for reducing the MOR-MOE in Shuttering plywood as with younger wood it comes down. For the high grade plywood there are already set standard like COMPREG, Structured wood, 10701 etc. If anyone wants premium quality they should use it. But Marine grade is being used in general purpose also, so we have recommended to reducing the norms according to available wood and practices going on in the industry.
Mr. Ashok Juneja, Chairman, Punjab Plywood Manufacturers Association (PPMA): The 99 percent factories based at Punjab uses Poplar and Eucalyptus. We are following earlier ISI norms which are becoming irrelevant and purchasers don’t check ISI norms particularly. So, we want either it should be completely removed or fix liberal norms considering available timber and its plantation patterns. Inclusion of Okoume as specie for Face Veneer and the thickness of Face should be reduced according to the need of the industry and its availability. The face thickness should be 0.23+. In order to have proper implementation they should appoint a nodal officer who can listen problems coming before the industry to follow the ease of doing business. BIS standard should be divided into different category like A, B, C. Renewal should be in three years as it costs and is very lengthy, the change will increase its acceptance.
Mr BP Agarwal, President, Bareilly Plywood Manufacturers’ Association: The present BIS norms are already old with higher thickness of Face Veneer from 0.8mm to 1mm where as it is less than 0.3mm. We want, BIS must inspect the industry practices, availability of wood and set the standard according to it. Today the consumer prospects have also changed with fast observation of ready to use houses and products for interiors due to lack of time. For the large part of the industry, BIS is no relevance as the industry is largely unorganized.
Mr. Ashok Agarwal, President, UP Plywood Manufacturers Welfare Association: The bureau should review the set parameters and change according to the availability of goods and going on practices in manufacturing process. The strength of timber depends on line of the timber. The standard is based on over 20 years old timber and what are being used today are just having 4 to 7 years old plant timber so there is density variation in timber used earlier and now, so the tensile strength in them also varies. The timber used today in making plywood do not fall under the BIS recommended list of timber so there is no relevance of the standard in today’s practices.
In last ten years the timbers like Poplar, Eucalyptus are in use, should continue to meet the needs of the industry in North, Rubber in South, Aadu in Rajasthan etc. There are over 15 species must be included in new norms with 0.2 mm to 0.3 mm Face Veneer thickness made permissible. I think the total system needs overhauling right from testing center to reducing the norms.
Secondly, within the standard there is no focus on making products which are environmental friendly, formaldehyde emission, etc. Today most of even undeveloped countries to India is practicing these norms in their standards. The testing facilities here are insufficient according to the needs, so it should be improved and being in more in number for better regulation of the set parameters and its practices.
For flush doors also the changes should be according to the material available like today Pine is used in its Face as Gurjan is not readily available to us. For all these to discuss we are forming a committee of association members from different region and after coming to conclusion we will forward recommendations.
Mr Vikas Khanna, President, Delhi NCR Plywood Manufacturers’ Association: The norms should be according to the raw material available today, Eucalyptus, Poplar and Okoume which is readily available and will sustain. So, reduce the Face veneer thickness. For flush doors also the changes should be according to the material available like today Pine is used in its Face as Gurjan is not readily available to us. For all these to discuss we are forming a committee of association members from different region and after coming to conclusion we will forward recommendations. We are also trying to send some members in review committee of BIS to discuss the matter on behalf of the industry.
Mr Sameer Garg, Committee member of Kandla Timber Association: The old BIS standard has been made according to Gurjan and its strength which is not available today. They should allow length of plywood from 0.6+ mm to 6 - + mm and thickness is recommended for 0.5% - + that should be 1% because earlier set norms do not adjust with available timber. Secondly, they should include melamine phenolic resin also to make it standard according to International standard norms. With it we can use it for international market because in overseas phenolic resin is not acceptable. For Shuttering plywood Face thickness is 1.2mm, it should be 0.5mm and in Marine plywood thickness is 0.5mm that should be 0.3mm. If there comes BIS standard that certify for borer/termite proof, we will not have to use levelling for it
Dr Prashant MA, VP, South Indian Plywood Manufacturers Association: The world has observed considerable change in uses/consumption and innovation of the product for wood panel industry. They have adopted the standard and shifted from wood to hollow wood to particle board and now paper honeycomb. But, we are still at only wood with BIS STANDARD. We want change in BIS for doors and to include the bigger size of it in the standard. There is only on standard for doors, i.e waterproof. Secondly, it also bring into commercial doors as it will benefit to the consumers and producers both for the availability for affordable housing doors. Thirdly include HDHMR and Particle Board also under BIS as its demand is increasing day by day.
INDUSTRY VIEWS, CONCLUSION
1. Include new species and special thrust on plantation and short rotation timbers.
2. Reduce Face thickness from 0.8 mm to 0.25 to 0.4 mm
3. Gurjan is scarce hence property of core veneers must be defined not the species.
4. Include new species in Face veneer options and mention reconstituted.
5. There shall be a clarity on calibrated plywood characteristics.
6. Mention of Emission norm parameters, VOC content.
7. Review of present needs and relevant parameter and uses of chemicals.
8. Thickness variation limit need to be re-evaluated.
9. IS 710 norms shall be reviewed according to modern times and save its grace.
10 Review all plywood categories including Marine grade, Film Face shuttering, Water proof plywood, Fire retardant, etc
Entire plywood industry has accepted that the plywood products manufactured in present time is not suitable as per present BIS norms and standard. The agreement on change is unanimous and BIS standards must be reviewed for overhaul with urgency or industry may abandon using ISI Marks.