Balasubr_Alternative building panels

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PROJECT TEAM

Dr. R. H. Balasubramanya (PI)Associates

Dr. A. J. Shaikh Dr. P. G. PatilDr. R. M. Gurjar Mr. V. G. Arude

Dr. K. M. Paralikar Dr. S. V. ShuklaDr. P. V. Varadarajan

ICAC



PRIVATE PARTY PARTICIPANTS

• M/s Ecoboard Industries Ltd.

• M/s Jollyboard Industries Ltd.

• M/s East India Cotton Association

ICAC



NAGPUR

DELHI

ICAC

Area 327.8 m.ha

27 States and 7 UT’s

Southern Zone

Northern Zone

Central Zone



Objectives• Analysis and optimization trials of required logistical

arrangements for collection and transportation of cotton

stalks from the field to the Particle Board Manufacturing

Plant, including possible setting-up of pre processing units

at the field level;

• Trials for minimum and optimum level of cleaning and pre-processing of cotton stalk into chips suitable for processing

at field level and factory site;

• Pilot production of cotton stalks-based particle boards;• Evaluation of technical/financial feasibility of the proposed

processes.

ICAC



ICAC

Availability of Cotton Stalks in India

Zones States Area*(million

ha)

Availability of Stalks

(million

tonnes)**

Northern(Area 1.471 m.ha

Stalks 4.06 mt)

Central (Area 6.205 m.ha

Stalks 14.86 mt)

Southern(Area 1.471 m.ha

Stalks 3.41 mt)

1. Haryana

2. Rajasthan

3. Punjab

4. Madhya Pradesh5. Gujarat

6. Maharashtra

7. Orissa

8. Andhra Pradesh

9. Tamil Nadu

10. Karnataka

11.Others

Total

0.533

0.350

0.588

0.6302.390

3.124

0.060

0.962

0.133

0.370

0.035

9.175

1.60

0.70

1.76

1.267.17

6.24

0.12

2.4

0.27

0.74

0.07

22.33

*CAB Estimate (March 09,2007)

** Cleaned Stalks



Chemical Composition of Cotton Plant Stalks

Species Holo-

Cellulose(%)

Lignin (%) Ash (%)

G.arboreum 67.3 25.8 7.0

G. herbaceum 69.1 28.1 8.3

G. hirsutum70.0 27.1 6.7

G.barbadense 69.2 28.2 8.1

Desi Hybrids 67.3 27.6 6.8

Hirsutum Hybrid 68.6 24.3 5.9

Mean Value 69.1 27.0 7.1

Range of

Values

67.3 to 70.0 24.3 to 28.2 5.9 to 8.3

ICAC



Uses of Cotton Stalks

Particle Board Hard BoardSoft Board

Medium density fiber boardMushroom

growing

Briqueting

Domestic fuel

ICAC



ICAC Cotton stalk used as domestic

fuel to cook the food.

Cotton stalk stored near the

farmers houses

Wall of a house made usingcotton stalk



Board Industries

Benefits of using stalk as Raw Material by Board Industries

Additional income

to cotton farmer

Saves Forest Wealth Establishment of cotton stalk

supply chain

Generation of

Rural Employment

Protects

environment

Renewable raw material

to board industries

ICAC



Limitations in utilization of cotton

stalks by Industries

• Absence of an established cotton stalk supply chain

(weakest link)

• Industry’s hesitation to use any new raw material• Dependence on forest based material (timber)

• Lack of legislation on ecological considerations

• Uncertainties in dry land agriculture leading toinconsistent supply of raw material

• Lack of awareness about market acceptability of

composite boards from cotton stalks

ICAC



Conceptual Logistic Models of CottonStalk Collection

Model 1

• Transportation of cotton stalks directly from the field

to factory

Model 2

• Chipping of cotton stalks by farmers and

transportation to the factory

Model 3

• Collection and transportation of cotton stalks by

farmers from the field to the chipping center, chipping

and subsequent transportation to the factory by an

entrepreneur

ICAC



Model 1

•Transportation of cotton stalks directly from the field to factory.

Mode of

Transport

Cotton Stalk

carrying

capacity (Kg)

Bullock Cart 325

Tractor Trolley 575

Lorry 1500

Advantage : No need of pre-processing

centre at village level

Limitations : Less carrying capacity.

: Not economically viable.

ICAC



Model 2

• Chipping of cotton stalks by farmers and transportation to the

factory

Advantage :

• Load carrying capacity, 4 times more

Limitations :

• Purchase of cotton stalk chipper, not affordable by

individual farmer • Shortage of electrical power in rural areas/non availability of

appropriate power source for chipper in and around farm

ICAC



Model 3

• Collection and transportation of cotton stalks by farmers from

the field to the chipping center, chipping and subsequenttransportation to the factory by local entrepreneur

Advantages1. It is easy for farmer to collect and transport cotton stalk to the

nearest chipping centre.

2. Entrepreneur can purchase tractor operated chipper, as

sufficient quantity of cotton stalk at one place is assured

3. Assured and timely supply of cotton stalk chips to the Board

Industry

• Model 3 appears to be economically feasible

ICAC



Flow Chart on the

Availability of Cotton Stalks in Nagpur District, Maharashtra, India

3.0 tonnes/ha 40% moisture

2.4 tonnes/ha 25% moisture

1.7 tonnes/ha 20%moisture

1.5 tonnes/ha 15%moisture

1.3 tonne/ha 10% moisture

Uprooted cotton stalks immediately after the

completion of last picking of seed cotton (contains

green leaves, boll rinds and unopened bolls)

Devoid of leaves after 5 days of drying in open in the

field (leaves contribute to about 5%)

Manual cleaning of cotton stalks (Removal of boll

rinds, unopened bolls and small branches which

contribute to about 25%)

Chipping of whole cotton stalks (loss during

chipping, about 10%)

Transportation of chips to a maximum distance of

50 km (loss during loading, unloading and

transportation, 5%)

ICAC



Uprooting

Collection

Chipping

Loading

Transportation

Logistics of Cotton Stalk Collection

Chipping & Transportation

Cleaning

ICAC





Collection of Cotton Stalk ICAC



Effect of Impurities on the Quality of Board

Particulars Density

(g/cc)

Thickness (mm)

BendingStrength

(MOR)

(kg/cm2)

InternalBond

Strength

(N/mm2)

Water Absorption

(%)

2 h

Dried cotton stalks with

boll rinds

0.78 13.0 105 0.25 128

Dried cotton stalks with

boll rinds partly removed

0.78 13.2 113 0.26 115

Cleaned cotton stalks

(No boll rinds)

0.78 13.5 106 0.31 96

Debarked cleaned cotton

stalks

0.78 12.8 181 0.60 77

Therefore it is felt necessary to design and develop a cotton stalk cleaning

system.

Advantages of cotton stalk cleaning :

• Significant reduction in water absorption by bark removal• Enhanced Modulus of Rupture after cleaning and bark removal

• Improvement in Internal bond strength

ICAC



Cotton Stalks Cleaning System

System Comprises of :

Scratching system (peeler)

Conveyor system

Air blowing chamber

Air suction chamber

ICAC



COTTON STALK

CLEANING SYSTEM

( FEEDING UNCLEANED

STALKS )

COTTON STALK

CLEANING SYSTEM(CLEANED STALKS )

ICAC



Cleaning SystemICAC



UNCLEANED COTTON STALKS BOLL RIND

LEAVESBARK

ICAC



Performance Evaluation of Cotton Stalks Cleaning System*

Initial

Weight of

Cotton

Stalks (Kg)

Moisture

Content

(%)

Weight of

Stalks after

Passing the

system

(Kg)

Moisture

Content of

cleaned

Stalks

(%)

Weight of

Removed

Material

(Kg)

Moisture

Content of

peeled

Material

(%)

1 2 3

100 10.5 77 11 16.0 0.6 6.2 6.0

*Performance is based on 5 trials1. Material collected in the first unit

2. Material collected in cyclone

3. Material Collected at the end of conveyor

PS : Moisture content of stalk is around 11% whereas that of wastes (boll rinds,leaves, lint and small branches) is around 6%

ICAC



Storage Studies

1. Stalks stored in the open cemented platform

2. Chipped stalks stored in the open cementedplatform

3. Chipped cotton stalks placed as such inside a shed

4. Chipped cotton stalks packed in gunny bags andstacked inside a shed

5. In addition to this about 35 tonnes of chips packed

in gunny bags covered with tarpaulin sheets werestored outside the commercial factory for ninemonths

ICAC



Chemical analysis of cotton stalk chips stored in open ground and in shed

Sr.No

MONTH + MOISTURE (%) LIGNIN(%)

HOLO CELLULOSE(%)

ETHER EXTRACTIVES(%)

1* 2** 1* 2** 1* 2** 1* 2**

1 July 14.2 16.0 26.6 25.4 82.1 77.1 7.1 7.2

2 August 14.0 15.9 26.1 25.0 81.4 76.4 7.0 7.1

3 September 12.0 11.9 26.0 24.8 81.2 75.7 7.0 7.2

4 October 11.2 12.9 25.9 24.5 81.1 75.4 6.5 6.8

5 November 11.8 11.4 25.8 24.2 80.9 75.2 6.8 7.1

6 December 11.1 11.2 25.5 24.1 80.7 75.2 6.7 6.5

7 January 11.3 11.4 25.2 24.1 80.5 75.1 6.7 6.8

8 February 11.3 11.4 25.5 24.7 81.1 75.0 6.5 6.3

9 March 11.2 11.4 25.5 24.6 80.9 74.7 6.9 4.5

10 April 11.0 11.1 25.6 24.5 80.5 75.1 6.6 6.4

11 May 10.1 11.5 25.3 24.7 80.4 74.9 6.5 6.4

12 June 13.2 14.1 25.2 24.4 81.0 74.8 6.4 6.3

1*– Stored in shed 2** – Stored outside + Month wise meteorological data recorded

ICAC

• No significant change in the chemical composition in case of chips stored inside• Slight reduction in holocellulose content in case of chips stored outside

Flow Chart of Particle Board Demonstration Plant



ICAC

FineCoarse

Mat

Glue

Silo

Mat

Silo

GlueGlue service

tank

Resin, Wax, Hardener etc

Glue service

tank

Finished Board

Cut to size saw

Sanding M/c

Trimmed Board

Cold press

Hot Press

Raw Board

Carrier plate

Fine particle layer Fine particle layer Coarse particle layer

Cotton Stalk

Over Size particle

Chipper

Hammer Mill

Dryer

Rotary Screen



Particle Board

Demonstration

Plant at GTC,

Nagpur

Particle Boards

produced atDemonstration

Plant

ICAC



ICAC

Particle Board Demonstration Plant at GTC, Nagpur



Material Balance for the Preparation of Particle Boards

from Cotton Plant Stalks

Cotton Stalk chips (10 % moisture) (1 tonne)

Rechipped Material (950 kg) 10% moisture

Dried Material (884 kg) 3 % moisture

Particle Separation Loss (813 kg) 3 % moisture

Finished Boards (674 kg) 6 % moisture

ICAC

Furnish Material (959 kg) 12 % moisture

Mat Formation (911 kg)

Pressing of Board (856 kg) 6 % moisture

Trimming & Sanding loss 20 %

Resin + Wax Addition

5 % loss

7 % loss

8 % loss

5 % loss

6 % loss



• One tonne of cleaned cotton stalk chips

with 10% moisture yields 0.7 tonne of plain boards with 6% moisture

• To prepare 1 tonne of plain boards

with 6% moisture, about 1.4 tonnes of cleaned cotton stalk chips with 10 %

moisture are required

ICAC

ICAC



Properties of Particle Boards Made in Pilot Plant

Parameters Urea Formaldehyde

Bonded Cotton Stalk

Boards *

BIS Specification

Thickness (mm) 18 18

Density (kg/m3) 671 500-900

Bending Strength (MOR)

(N/mm2)

14.64 11.00

Internal Bond Strength

(N/mm2)

0.6 0.3

Screw Nail Withdrawal

(Face - Newton)

2118 1250

Water Absorption (%)

2 h

24 hSurface Absorption (%)

28

313

40

809

ICAC

ICACM/s Eco-board Industries Ltd



ICACM/s Eco-board Industries Ltd

Velapur, Maharashtra, India

ICAC



Properties of Particle Boards prepared at

Ecoboard Industries Ltd., Velapur

Parameters Urea Formaldehyde

Bonded Cotton Stalk

Boards

BIS Specification

Thickness (mm) 18* 18** 18

Density (kg/m3) 699

12.0

0.5

1610

28

31

2.5

731 500-900

Bending Strength

(MOR) (N/mm2

)

13.0 11.00

Internal Bond Strength

(N/mm2)

0.5 0.3

Screw Nail Withdrawal

(Face - Newton)

1250 1250

Water Absorption (%)

2 h

24 h

Surface Absorption (%)

36

80

2.8

40

80

9

* Drum chipper **Chaff cutter

ICAC



Room Paneled with Particle Board from cotton stalks

ICAC

False Ceiling

Shuttering

Partitioning

ICAC



Uses of particle boards manufactured from cotton stalks

ICAC



Dignitaries and Entrepreneurs in the Demonstration Plant

Training hall paneled with

particle boards manufactured

from cotton stalks

Entrepreneurs visit to particle

board demonstration plant at

Ginning Training Centre of CIRCOT Nagpur

ICAC



Awareness & co-ordination among stake holders isnecessary to popularize this technology

Cotton Farmers IndustryCIRCOT

ConclusionsICAC



Conclusions

Collection and transportation of cotton stalks by farmersfrom the field to the chipping center, chipping and

subsequent transportation to the factory by local

entrepreneur is found to be economically viable Cleaning of cotton stalks has a direct bearing on the

quality of boards

Boards manufactured from Cotton Plant Stalks Conform toBIS Specification

Boards can be laminated with different surface finishes

Suitable for wall paneling, false ceiling and different

furniture items Assured additional income to the cotton farmers

Additional raw material to the Board Industry

Generation of rural employment and saving of forestresources

ICAC



Acknowledgement

We gratefully acknowledge the financial support and

guidance from CFC, Netherlands, ICAC, Washington &ICAR, New Delhi.

ICAC



THANK YOU

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Balasubr_Alternative building panels