IV REPORT WESTERN INDIA PVT LMTD

GROWTH

From the humble beginnings in 1942 as a sawmill and a tea chest manufacturing facility,
W.I.P grew steadily adding the latest in machinery and incorporating new manufacturing
techniques. Products ranged from Plywoods, Block boards, Flush door, Shuttering and
Marine Plywood, Aircraft Plywood etc. The Company planned and executed the hardboard
plant between the years 1956 and 1958 with an initial installed capacity of 12.5 tonnes of
hardboard per day. The Company also installed its own synthetic resin unit in 1959 with a
capacity of 200 tonnes per annum, which gradually increased to 2400 tonnes per annum, by
1975. Manufacture of dandified Wood was commenced on a small scale initially as a part of
the plywood plant. An Industrial Licence was obtained in 1974 for manufacture of Dandified
Wood with a capacity of 2000 M.T. per annum. Since then, the Company has been producing
components of dandified wood required mainly by the electrical, textile and chemical
industries, Railways, etc. In 1974 a plant for manufacture of furniture was added.

QUALITY POLICY AND OBJECTIVES

Quality policy

Quality policy of the Western India Plywoods Limited is to manufacture products as per
national and international standards and make them available as per customer requirement.
WIP endeavours to upgrade the quality of its products and related services on a continual
basis through regular improvement efforts.

A well-defined Quality Management System has been implemented. This system is

continually reviewed to enhance its effectiveness and updated to meet the changing needs.

QUALITY

Suitable equipment and machinery for process control at all stages

Provision of adequate resources including raw material and personnel to ensure consistent
product quality. Well-defined process and product characteristics, to enable monitoring

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Communication of requirements of products including customer requirements, statutory /

regulatory requirements, aspects of Quality Management System including policy and
objectives among all employees

WIP'S List's of Firsts

A. First to make Irradiated Wood.

B. First to make Aircraft Plywood.
C. First to make Fire Retardant Plywood conforming to BS:476 specification.
D. First to make high pressure industrial laminates.
E. First to develop Weather proof, Marine and Fire Retardant Hardboards.
F. First to make Metal Faced Plywood.
G. First to make Pre-finished Plywood and Hardboards using UV-cured surface finishing
technology.
H. First to obtain ISO 9002 Certification for Hardboards and Pre-finished boards.
I. First to manufacture DAP Resin in the country with indigenously developed
knowhow.

PATENTS TO WIPS CREDIT

1.Radiation induced polymerization of DAP, MMA & PE

2.Radiation induced polymerization of DAP & MMA

3.A process for manufacture of wood polymer composites by gamma irradiation

4.Manufacture of ABS plastics

5. Manufacture of SAN plastics

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PRODUCTS

PLY WOOD

WIP specializes in exquisite/moulded plywood furniture which will exceed your expectations
regarding strength and durability.

Furniture is manufactured utilizing the finest building materials available in the market. It is
made with a judicious blend of solid timber and composite panels to optimize strength and
costs. A part of WIP's range of furniture is depicted below.

TYPES OF PLYWOOD AND OTHER BOARDS

PLY WOODS

3-PLY AND 5-PLY: These common types of plywood get their name from their number of
layers: e.g., 3-ply has three layers. Uses include: Boxing in or decorative internal uses

MULTI-PLY: This is composed of many layers. Uses include: Heavyweight construction,

e.g., house framing

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OTHER BOARDS

BLOCKBOARD: Not technically a ply, but shares its characteristics. Has two thinner outer
layers that enclose thicker, square-cut lengths of wood. It is therefore stiff and durable. May
have a decorative veneer or a finish of a lesser grade of wood. Uses include: Ideal for shelves
and cabinets, and can be finished with paint

MEDIUM-DENSITY FIBERBOARD (MDF): Very versatile. Made up of highly

compressed wooden fibres glued together. This method of manufacturing means that cut
edges are neater than those on other materials. It can provide a rigid structural component, or
can be intricately shaped to form a decorative surface ready for paint. Available in various
thicknesses. Main drawback is that it gives off a very fine dust when cut, which must not be
inhaled. Wear a mask when MDF is being cut. Uses include: Cabinets, cabinet doors, boxing
in, shelving

MOISTURE-RESISTANT MDF: A version of MDF that can resist moisture attack. It is

often green. Uses include: Areas prone to moisture: e.g., kitchen or bathroom

FIBERBOARD: A lightweight version of MDF. Joints between sheets can be taped, and the
boards painted. Uses include: Underlay for flooring, or as an alternative to drywall on a
ceiling

PARTICLEBOARD: Central core is composed of small wooden fibres. Has no decorative

quality, so is usually covered. Some sheets fit together using a tongue-and-groove
mechanism. Available in various thicknesses. Uses include: Often used as floor sheathing

MOISTURE-RESISTANT PARTICLEBOARD: More water-resistant than normal

particleboard. It is often coloured green. Uses include: Flooring

VENEERED PARTICLEBOARD: Has a melamine (plastic) or decorative wooden

veneer. Uses include: Commonly used for shelves

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HARDBOARD: Thin, compressed fibreboard. Standard hardboard has one smooth side, and
one rougher side. Different grades and a variety of finishes are available. Uses include: Often
used for parts of kitchen cabinets with a melamine (plastic) surface or veneer

HARD BOARDS
Hardboard, an eco-friendly wood based panel manufactured using plantation species of
timber, is an extremely versatile and cost effective building material.
Weston hardboard, India's No.1 hardboard brand, was first manufactures by WIP in 1959 - on
a West German processing line.
The superior durability and finish of the boards coupled with top management commitment to
quality ensured that Hardboards was the market and technology leader since inception. In fact
WIP's hardboard division has obtained the coveted ISO 9002 certification - India's first
hardboard manufacturer to do so. Today, state-of-the-art Swedish production lines
manufacture 120 tons of quality hardboard every day.

A brief description of the range of hardboards manufactured by WIP is given below :

STANDARD HARDBOARD
Application : Automotive interior trims, shoe heel manufacture, fibre drum lid manufacture,
clock backing, photo frame backing, furniture elements, partitions etc.

Salient Features :
Manufactured under the ISO 9001 certified system.
Manufactured using plantation species of timber.
Engineered to meet all requirements under IS:1658.
Good mechanical properties due to high density.
No Formaldehyde emission.
Available in the thickness range of 2.5mm to 6mm.

OIL TEMPERED
Application: Shoe heel manufacture, automobile interior trims, and applications requiring
improved resistance to weathering.

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Salient Features:
Significantly improved mechanical properties.
100% reduction in water absorption characteristics.
Used in value added applications by automotive trim manufacturers.
Available in the thickness range of 3mm to 6mm.

PERFORATED
Salient Features :
Cladding material meeting acoustic requirements.
Available in standard and tempered form.
Available in 3mm and 4mm thickness.
Available pre-finished in the desired colour.

WIPRESS

The Western India Plywoods Ltd., an ISO 9001-2000 certified Company located in Kerala,
South India is a large and reputed panel products manufacturer for over six decades. We
produce different grades of Plywood, Fibreboard (hard board, insulation board etc.),
Blackboards, Flush doors, Dandified wood and components, mocked and knockdown
Furniture, Pre-finished Fibre board, Engineered " Wood Floorings etc. Our motto is 'total
utilization' as wood is a precious commodity and our integrated production facilities.

WIPRESS

WIPRESS, a hard and rigid board having high purity with excellent electrical and mechanical
properties, is specifically produced for the high voltage and extra high voltage Transformer
Industry. The product is made from imported virgin softwood sulphate pulp in our new
production line using 'state of art technology'. Our experience over four decades in producing
fibre boards and dandified wood guarantees product compliance to lEC 60641 B.3.1 grade
pressboard. Separate conditioning and testing facilities have been established for
uninterrupted and speedy testing and evaluation of the raw materials and the product.

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Pre compressed pressboards are cellulose based and are produced from Kraft unbleached
softwood pulp having high chemical purity and low conductivity. They are produced on
intermittent board machine and compacted without added bonding agents in multi day-light
press under heat and pressure to achieve required properties. The boards are characterized by
high density, high purity, uniform thickness, dimensional stability, low compressibility, low
shrinkage and high electrical strength.
Pre compressed pressboards have high dielectric strength and find use as insulating material
in different types of Power and Distribution Transformers, Capacitors, Switch Gears etc., in
the form of winding cylinders, spacers, washers, keyway strips. etc.

Water : Quality Water is the most critical factor in the manufacture of Pressboard. Kerala,
particularly Cannaore receiving more than 3000 mm of rainfall every year has an abundant
resource of excellent quality water available throughout the year. This water is further treated
by a most modern Water Treatment Plant.

Hydraulic Press: A most modern multiday-light Hydraulic Press of 1200 tonnes capacity of
size 2.2 x 1.1 meters with Thermic Fluid Heating is used for the manufacture of
Recompressed pressboards.

WIP'S RESEARCH & DEVELOPMENT DIVISION

The Research and Development Division of The Western India Plywood Ltd., has earned
recognition from the Dept. of Scientific &Industrial Research, Ministry of Science and
Technology, Govt. of India, as an in-house research wing of high calibre. It has the required
analytical, conditioning and testing facilities for product / process development, evaluation,
rigid quality control and new technology analysis. The testing equipment available consist of
the standard machines for conducting physical, mechanical and electrical tests of all kinds.

They include the Weather-o-meter in which the extreme weather conditions can be simulated
in an accelerated manner in order to arrive at quick inferences. Sophisticated analytical
equipments like the Spectrophotometer, Gas Chromatograph, FTA Flammability unit, Torque
Rheometer and Gel permeation Chromatograph are available in the testing labs of WIP's
R&D Division for accurate analysis and assay of raw materials and finished products.

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The R&D Division, besides keeping pace with technological advances in the field of wood
technology, assists in the diversification programmes & development of new products. The
products developed and process / product modified by the Division include Diallyl phthalate
(D.A.P) Moulding powder and Fibreglass Reinforced Plastic Sheet Moulding Compounds
(S.M.C) which find use in the manufacture of sophisticated products required in highly
specialized electrical and electronics applications. S.M.C can also be overlaid on plywood.

The manufacture of D.A.P. Moulding Powder has been achieved for the first time in South
East Asia in The Western India Plywoods Ltd. This has put India on the road to self-reliance
in this material of strategic importance. In a recent break through, our R&D division
succeeded in developing a fire retardant variety of DAP ( Diallyl Phthalate) Moulding
powder. The U.S.A., Holland and Japan are the only other countries manufacturing D.A.P.

Conversion of non-durable species of timber like Holigarnaarnottiana(Cheru),

Lophopetalumwightianum(Banati) etc. into stable and durable wood polymer composites by
irradiation with gamma rays represents a land mark in the conservation of wood resources
achieved by WIP's R&D Division. With the active assistance of Bhaba Atomic Research
Centre, Trombay, a Gamma ray irradiation source of adequate strength was established for
the first time in India, in WIP's Research Division. With the help of this radiation source great
technical improvements in the basic properties of species with poor durability and quality
were achieved, to render them fit for specialized industrial applications. This is a big step
towards utilization of abundantly available plantation species of timber for specialized
applications.

WIP's R&D Department has also succeeded in developing a unique, cost effective and highly
efficient rubber wood treatment process which enhances not only the durability but also the
strength of wood

Our R&D scientists have developed weather proof and fire retardant grades of
HARDBOARD.Developed through wholly independent research, these products promise an
end to the use of commercial hardwood in common exterior applications. These panels

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combine the economy and eco-friendliness of hardboard along with the utility and durability
of specialized plywood panels.

Development of technology for producing metal faced plywood by the R&D is noteworthy.
1200 GI faced plywood panels were produced and supplied to ISRO, Bangalore for use in
Anechoic Chambers as electromagnetic shield based on in-house technology.

WEATHER-O-METER

While doing Weather o meter testing we use calibrated lamps, specific filters, very accurately
monitored irradiance, purified water, controlled atmosphere (humidity and temperature) and
predefined light, dark and rain cycles durations. On the other hand, Outdoor exposure
depends on when and where you are: Latitude, altitude, cloudiness, humidity, smog, rain,
temperature, orientation, season, time of day all those parameters have a major influence
on the efficiency of outdoor exposure.

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RHEOTOMETER

A rheotometer is a laboratory device used to measure the way in which a liquid, suspension
or slurry flows in response to applied forces. It is used for those fluids which cannot be
defined by a single value of viscosity and therefore require more parameters to be set and
measured than is the case for a viscometer.

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BREAKDOWN VOLTAGE TESTER FOR DIELCTRIC STRENGTH IN OIL

UNIVERSAL TESTING MACHINE

The set-up and usage are detailed in a test method often published by a standardorganization.
This specifies the sample preparation, fixturing, gauge length (the length which is under
study or observation), analysis, etc.

The specimen is placed in the machine between the grips and an extensometer if required can
automatically record the change in gauge length during the test. If an extensometer is not
fitted, the machine itself can record the displacement between its cross heads on which the
specimen is held. However, this method not only records the change in length of the
specimen but also all other extending / elastic components of the testing machine and its
drive systems including any slipping of the specimen in the grips.

Once the machine is started it begins to apply an increasing load on specimen. Throughout
the tests the control system and its associated software record the load and extension or
compression of the specimen.

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Topics of research in polymers include the following:

1. UV curable Coatings: Development of new formulation for our products like WIPLAC,
ULTRAKLICK, WIPGLOSS etc that have improved toughness and scratch./abrasion
resistance, application of nanofillers for improving the performance and studies on various
monomers, oligomers etc.

2. Waterborne Polyurethane (PU) dispersion based coatings are increasingly becoming

popular for finishing wood furniture as well as flooring, due to the unmatched performance
and environmental friendliness that the technology offers. Developing a range of high
performance and cost effective PU coatings is progressing.

3. A number of polymer/composite problems are being investigated which include polymer

dispersions for water resistant waterborne coatings, improved PF resins and Wood-polymer
composites.
4. WIP is committed to cent percent utilization of wood. The utilization of wood wastes
generated during the manufacturing process, a step towards achieving safe disposal of wood
wastes, has led to the development of the process of vermicomposting. The product, the
vermicompost, is produced from chipwash residue, a lignocelluloses waste from the
fibreboard unit, by the action of earthworms after mixing with suitable activators to initiate
the degradation process. It is a mixture of castings of earthworms containing aerobically
composted organic matter

WIP'S MATERIAL TESTING LAB

WIP possesses a full- fledged material testing lab which is monitored by its Govt. recognized
Research and Development Division.The lab is equipped to perform various physical,
mechanical and electrical tests specified in the national and international standards.
Every day random samples drawn from panels produced in WIP's plants are tested for
conformance to the relevant Specification.The integrity and quality of WIP's testing division
can be gauged by the fact that representative samples drawn from material to be supplied to
the Indian Railways, Defence and other Government Organizations are tested in its own
material testing lab under the supervision of inspectors deputed by the respective inspection

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agencies.
If required test certificates confirming the conformance of the panels supplied to its relevant
Specification can be provided. (Tests are performed on random samples drawn as per the
sampling procedure stipulated by IS Specifications.)

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