Plywood Manufacture Process

According PIKA Semarang (2008) , plywood have advantage that their resistance to shrinkage of the wood and the size of the length that may not be obtained from solid wood with same quality. But that does not mean plywood has an equally strong resistance to weather. This material is only recommended for indoor furniture. It explains that plywood is very good to fulfill the needs of large board so that the plywood has the typical functions that can be developed and commercialized.  Plywood Production  a. Memilih Log
Langkah pertama dalam pembuatan papan buatan adalah memilih log. Log dipilih berdasarkan kelurusan dan diameternya bundar atau tidak. Log yang baik untuk pembuatan plywood adalah yang bebas dari mata kayu.    

 b. Debarking
Proses ini persis seperti yang dijelaskan pada proses pembuatan vinir. Dari Proses Pembersihan kulit dan benda asing ( Paku, Batu, dll ) sampai proses pengupasan di Rotary dan akhirnya masuk dalam Drying Machine   

*Vinir / Veneer (merupakan lembaran tipis kayu yang dihasilkan melalui beberapa proses mesin. Ketebalannya pun bervariasi tergantung dari fungsi dan pemakaiannya. Vinir yang digunakan untuk lapisan akhir sebuah plywood (multipleks) atau papan buatan lainnya biasanya cukup tipis namun berkualitas baik terutama dari sisi estetika atau keindahan)   c. Vinir DryingProses pengeringan vinir, agar vinir mencapai tingkat kelembaban yang dibutuhkan  

 

d. Gluing
Aplikasi bahan lem menggunakan roller coater sistem dan lem yang digunakan adalah jenis urea resin atau phenol-Formaldehyde. Jenis lem yang mengandung formaldehyde diketahui kurang baik untuk kesehatan dan lingkungan yang mana bahan kimia yang digunakan untuk membuat lem ini bisa mengakibatkan penyakit kanker.
 

 Oleh karena itulah beberapa konsumen besar saat ini mensyaratkan pabrik furniture mereka untuk menggunakan papan buatan yang bebas dari kandungan formaldehyde dengan cara melakukan test secara berkala.

Terdapat beberapa standar ukuran dan metode pengetesan untuk bahan kimia ini. Grade paling tinggi adalah E0 yang berarti NOL emisi. Kemudian terdapat grade E1, E2 san seterusnya.  e. Pressing
Lapisan-lapisan vinir diatur di bawah mesin press dengan tekanan tinggi hingga ketebalan yang diinginkan. Sebuah mesin press plywood bisa memuat sekaligus untuk 50 lembar plywood dalam sekali tekan selama 3-4 menit.
Dengan jenis lem yang berbeda, pressing bisa dilakukan dengan 2 metode yang berbeda, hot press dan cold press.

Hot Press : Lazim dilakukan untuk plywood dengan bahan baku softwood dengan suhu mencapai 120 °C selama hampir 10 menit. Akurasi waktu pengepressan, tingginya tekanan dan temperatur sangat penting pada proses ini.
 

  Cold Press : Dilakukan dengan alat tekan hidrolik atau putar. Jenis lem yang digunakan biasanya adalah resin atau urea-formaldehyde yang memiliki proses pengeringan lebih lama. Pengepresan dilakukan selama 4-24 jam. 

 f. CuttingLembaran-lembaran plywood yang telah kering kemudian di potong sesuai dengan ukuran standar arah panjang dan lebar. (Memotong sisi panjang dan sisi lebar)

   g. SandingPermukaan plywood dihaluskan dengan mesin amplas dan cacat-cacat produksi dibersihkan atau diperbaiki. 

   h. Quality Control dan Packing
Terdapat grade kualitas pada plywood yang dikenal dengan standar kualitas A hingga C. A mewakili kualitas paling tinggi dan C kualitas paling rendah. Standar kualitas untuk plywood antara lain: tidak terdapat 'overlap' vinir atau terkelupas, warna dan serat kayu dan akurasi ketebalan plywood. 

     

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Most Common Use For Softwood Plywood

Softwood plywood is a common building material for roofs, walls and floors.

Softwood comes from various species of evergreen conifers including spruce, pine and fir. Plywood made from softwood is a building product commonly found in home construction and is also used for other purposes. Softwood plywood is available in different grades for various applications. The finish on softwood plywood ranges from fully sanded to not sanded at all, depending on the intended use.

Exterior Home Sheathing

The most common wall construction on a new home consists of a 2-by-4 or 2-by-6 frame covered by exterior-grade sheathing. This type of wall forms a structural panel that performs well at high wind loads and during earthquakes. Plywood panels fastened to each stud and to the top and bottom plates of the wall frame strengthen it and resist vertical, horizontal and diagonal shifting. Strict adherence to building codes for fastener placement, distance between studs and the joints between panels ensure strong, solid walls.

 

Home Roofing and Flooring

Plywood for building construction has a span rating that governs how it is used to build subfloors and to sheath roofs. On floors, the plywood panels have tongue-and-groove edges that fit together. On a roof, the plywood carries less load and the tongue-and-groove edges are not required. The manufacturer-assigned span rating for roofs and floors specifies the maximum allowed distance between rafters for a roof and between joists for a floor.

 

Other Construction

Softwood plywood has other applications in home building in addition to roofs, walls and floors. Eaves and soffits are often covered with plywood. Some plywood is manufactured specifically as a siding product, most notably T-111 siding, a grooved sheet product made to appear similar to reverse board and batten siding. Builders also use plywood for building detached garages and sheds, temporary flooring and concrete forms. Plywood is also used for many of the same purposes in commercial building construction.

General Projects

Softwood plywood has many uses beyond building homes and is used for a wide range of projects from skateboard ramps to doghouses. In the workshop, softwood plywood covers work tables and is used to build sawhorses and general-purpose shelving. It is inexpensive, available in a wide range of thicknesses and grades, ranging from exterior with exposure to the elements to interior dry areas.

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Indonesian Standard For Plywood Product

Indonesia has National Standard Product for Plywood ( SNI - Standard Nasional Indonesia ), which we can seen in INTERNAL GRADING STANDARD - SNI 01-5008.2-2000. 

National Standards provide a broad picture of what plywood product should be and  process to be on track for successful outcomes across the whole process. They are nationally consistent reference points describing what plywood should be describing for or beyond as they progress constantly.

PPI as one of the largest Plywood Industry on Indonesia has implemented SNI as our standard to raise our product qualification and also fulfill customer aim to has great product with low cost. There are some standard that PPI used for plywood manufacturing :

So with plywood standard that has been implemented. We can guarantee PPI product must be excellent in quality and price

Grab it Fast !!!!

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Knowing Our Product

Plywood was divided into two criteria, They are Hard Plywood and Soft Plywood. We will introduce you to identify our product.

First, Hardwood plywood has a distinct face and a distinct back. In a cabinet door, for example, you want the best appearance possible on the outside. On the inside, you still want it to look good, but small areas of burl, mineral streaks or sap wood won't be the distractions they would be on a surface that is always exposed.

Different than hardwood plywood, Softwood Plywood is plywood which has a face and back veneer of softwood as opposed to a hardwood such as Sengon, Birch, Maple, Oak, etc. Softwood plywood panels are comprised of a core made from either softwood then faced and backed with a veneer of soft wood and therefore are used for structural applications. It is manufactured from a long-grained, homogenous Nordic conifer with straight fibers. Its veneer structure gives this versatile plywood panel considerable strength and rigidity. Softwood spruce plywood panels are light, easy to work with and easy to install using conventional wood-working tools and fasteners. As well as being beautifully light coloured, Softwood plywood is also up to 20% lighter than many alternatives whilst maintaining similar strength characteristic and resistance to humidity. Excellent weather and boil-proofing is ensured by using fully water proof adhesives in our manufacturing process.

Softwood Plywood is used mainly in the construction industry for structural purposes. There are many grades, size, and thicknesses of softwood plywood depending how they are to be used however in the highest of grades they are sometimes used for decorative purposes such as furniture and cabinet making. Most softwood plywood are made with moisture resistant glue (such as phenol resin adhesive#2) and are exterior grade panels.

Softwood Plywood can be handled with ordinary woodworking tools and basic skills. When hand sawing or cutting on a table saw, support the panels firmly with the best face up. Cut with the best side down when using a portable power saw. Do not force-feed the panel into the tool or the tool into the panel too quickly because this will increase the roughness of the cut and may induce splintering-out on the exit side. Proper backup of the material also can reduce splintering.

Softwood Plywood major advantages
- Light and dimensional stable
- Strong and rigid
- Can act simultaneously as load-bearing construction and stiffening element
- Easy to machine and fasten using conventional woodworking tools and fasteners
- Can withstand impacts and other forms of bruising
- Environmental friendly
- Available with square edges and tongue-and-groove profiles
- Weather and boil proof bonding

Softwood Plywood in Perhutani Plywood Industry is made of Sengon Wood. We are supported by sustainable forest management unit, and covers more than 2.4 milion Ha in Java and Madura so we mainly produce Plywood form softwood of Natural Wood (Paraserianthes Falcataria).

Here is the Specification of our Softwood Plywood in Perhutani Plywood Industry :

Sizes	1220 Х 2440 mm and cut-to-size
Thickness	2.7 / 4.8 / 7.5 / 11.5 mm
Grades	UTY, UTY/BTR
Formaldehyde emission	E-2
Density	500-550 Kg/m3
Moisture content	Max. 10%
Ultimate shearing strength	1,5 mPa after one hour boiling
Static bending strength	mPa not less - 40
Ultimate creasing strength	mPa not less - 70

Our Factory Certification are:
· ISO 9000 Management System Certificate

· Indonesian SVLK (Legal Wood)

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