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Match manufacture

Alex.K.GeorgeBSF-10-002

FSC 301 Logging,utilization of timber and non timber forest products (2+1)

Contents Match production in IndiaSpecies used in IndiaTypes of matchesMatch manufacturing processUtilization of waste wood and residues.

MatchA match is a small stick of wood with a

solidified mixture of flammable chemicals deposited on one end.

When that end is struck on a rough surface, the friction generates enough heat to ignite the chemicals and produce a small flame.

History

The first known use of matches was in 577 AD northern China.

1826 AD, John Walker of England invented the first friction matches.

In 1831, Charles Sauria of France developed a match that used white phosphorus.

These matches were strike-anywhere matches and were much easier to ignite.

.In 1844, Gustaf Pasch of Sweden proposed

placing some of the match's combustion ingredients on a separate striking surface.

J. E. Lundstrom of Sweden to introduce safety matches in 1855.

First automatic match machine was patented by Ebenezer Beecher in 1888.

Match in IndiaAround 1910 immigrant Japanese families

who settled in Calcutta began making matches with simple hand- and power-operated machines.

Import matches from Sweden and Japan. The first sulphur match that would produced

in South India in 1923, and the first safety match in the form we know today, in 1932.

.Mechanization came to the Indian match

industry in 1924 .First mechanized large scale sector in India

started by wimco.There are now 17,000 units in India from

that 12,000 in Southern India,75% to 90% are situated in Southern India.

Match in Tamil naduP. IyaNadar and A. ShanmugaNadar who went to

Calcutta to learn the process from Purna Chandra Ray, a local businessman, who had learned the trade in Germany.

where a combination of the dry climate, cheap labour and availability of raw materials from Kerala created ideal conditions for match production.

80% of match wood from kerala.5,500 units in Tamil nadu.7,500 match works in Sivakashi and Sattur(55-60%

of India’s requirement).

Wooden match production in India is split into three sector,

1. Mechanized large-scale sector

2. Handmade small-scale sector

3. Cottage sector

Handmade small-scale (67%) and cottage (15%) sectors, Mechanized large-scale sector(18%)

-Tandon (1991)

Raw materialWood(splints)Potassium chlorate- match headRed phosphorous – Side mountCardboards – Inner and outer boxesTissue paper and wax – wax matches.

Qualities of a MatchwoodStraightness of the grainGood fissilityStrength and toughnessGood white colourFreedom from knotsEasily peelableCapacity to absorb paraffinRoundLight weight

Major species.. Ailanthus excelsa (yellow mutty) Ailanthus triphysa, (white mutty) Ailanthus malabarica (mysore mutty), Populus deltoides (cotton wood), Populus tremula (Aspen), Populus balsamifera (balsam poplar) Albizia falcataria, Boswallia serrata, Alnus nephalensis, Erithrina indica, Pinus, Havea brasillensis

Alternate species.. Lania coromandelia Ceiba pendandra Melia dubia Bamboo Simarouba glauca Sterculia vilosa Gmelina arborea.

For box making..Bombax ceibaHavea brasillensisPopulus deltaitus

Types of matches1. Early matches2. Friction matches( John Walker in 1826)

3. Noiseless matches( János Irinyi in 1836)

4. Safety matches(Johan Edvard Lundström)

5. Strike anywhere matches6. Special purpose matches

1. Storm matches2. bengal matches

Size of the matches:Standard=40-43 mmHouse hold=47-55 mmLongest matches=90-200 mm

Raw material needs

manufacturing ProcessEconomics

Industrial processing

manufacturing process

Production of match splints

Wooden logs

Billets

Debarking

Peeling(2.2 mm thickness,280 mm length)

Chopping

Drying a day

Wax coating or polishing

grading

Smoking with hydrogen peroxide & sulphur (3 hours)

Splints production

Billeting Peeling

waxcoating&

Grading Carbonizing &Drying

Chopping

Debarking

BilletingThe logs are converted into small billets,the

size of which ranges from 25-40 cm/1ft length.

Debarking:The billets are manually debarked.

Billeting and Debarking

Peeling:There are three types of peeling machine used

viz.1.Indian peeling machine-manual debarking2.sweden peeling machine-manual

debarking3.chinese peeling machine-no debarking is

neededThe moisture content is 40-50%

Peeling

Chopping:Here german made

chopper and Indian made chopper are used.

The capacity of the german chopper is 15 tonnes/day.

The blade has to be changed for every eight cut.

.Carbonizing:The chopped splints are carbonized by

setting up in a yard for 3 hours under the vapours of hydrogen peroxide & sulphur in order to enhance the color of the splints.

Drying :After carbonizing ,the splints are dried in

the presence of sunlight in courtyard for a period of eight hours. Incase of rainy days, the splints are dried using steam driers.

Drying

Wax coating : This is more important for any stick to get fire and keep up

the fire for a long time. The sticks are poured over a wax coating machine which

coats wax over the stick and also polishes the stick that gives quality cum attraction.

The sticks become more strength than the normal stick after this application.

Grading: After that the splints are grated by grading machine. In small scale industries graded by hand

CHEMICAL UNIT

Strike Anywhere matchesphosphorus sesquisulfidepotassium chloratzinc oxide

• MECHANICAL STIRRER

• POWDERING THE CHEMICALS

• CHEMICAL MIXING

The dried match sticks are poured over the stick holder where it fixes the sticks to a metal belt.

The metal belt with the attached sticks runs over the chemical liquid and dips it at the base level.

Then it runs continuously till the top storey where it gets completely dried by the fans provided by the side ways.

Then the dried sticks are collected and are passed on to the packing unit.

Dipping and filling unit

Outer box & inner box production unit In previous days, both boxes where

prepared out of wood viz., Ceiba pentendra

for outer box & rubber for inner box.

But due to non-availability, both boxes are

made of card boards.

In outer box production unit , a mixture of

phosphorus and varnish is used for side

mounting.

For inner box, the card board is cut in

different sizes, the cut card boards are made

as inner boxes manually and also is

mechanized.

Dried matches are collected and they are filled in appropriate boxes in 50’s or 70’s according to demand. This process is carried out manually.

Then these are finally packed in bundles of different sizes.

Box filling unit

Packing unit

Done manually.

Packing 10 boxes is one

unit and packing 6unit is

one bundle.

The filling quantity is

four types, 40s, 50s, 70s,

and 200s.

Production of wax match sleeks

Manufacturing process of match sticks

Economics.Annual requirement of wood in India is

200000 Cu.mFor the production of one bundle(i.e.600

match boxes) 2 kg of wood is required. Yellow mutty=Rs.5,200/tonneWhite mutty=1 cft=Rs.250-300

Current supply of match wood from Tamil Nadu 100-250 tonnes/month.

Sticks per kgAilanthus excelsa -13,227/kgAilanthus tryphysa-14,320/kgCeiba pentandra-13,297/kg

Nearly 80 per cent of the matchwood is now supplied by kerala

For making 2 to 2.5 lakh match bundles, nearly 4,000 tones of wood per month is required.

For producing one crore bundles per month, match wood requirement is around 10,000-12,000 tonnes

Process whereby biomass like straw, sawdust is concentrated by machines into small pellets or briquettes.

Moisture content of the compacted biomass between 7% and 14%.

Briquetting

Densification of biomass to produce homogeneous, uniformly sized solid pieces of high bulk density which can be conveniently used as a fuel.

Process

Two main high pressure technologies are in use 1. Ram or piston press 2. Screw extrusion machines

Technologies

ISSUES AND CONSTRAINTS

Shortages of raw materials, particularly match quality soft woods, chemicals, match wax and wax paper ( Samachar.in, 2008)

Geographical distribution of the industry in one region and resulting labour shortages

Monopoly of the 18 “Match Kings” Exploitation of women and child labour by these monopolists Failure of the cottage sector Introduction of new technology in the hand made sector Unique problems of the veneer and splint making industry. Mechanization and causes Excess production (ie 38% surplus

than demand).

ReferencesProject report on vason makwin –match industry Case study on the saftey match industries in India by:

J.C. Tandon T. Mehta, 1981. A Hand Book Of Forest Utilization.

International book distributors, Dehra Dun, India.http://en.Wikipedia.Org/wiki/match

Thanks