The veneer composing machines are not new for the plywood manufacturing in India. Various industries have installed the imported core composer machine from Taiwan, China etc. Initially the composers had issue related to pricing, threat availability, operators skill, maintenance etc that did not yield desired results but later these machines got modified and adopted according to India’s operating conditions. Indian plywood industry mainly branded and semi-branded players have core composers who have got good response buy offering “composed core” kind of quality plywood product. During 2017-18, the plywood industry was talking about these machines when few of the Indian plywood machinery suppliers began offering these machines in India. It was expected that approximately 250 units will installed at least one core composer by 2018. It happened in a speedy manner up to 150 units after that it slowed down. Now many people run these composers, many are in process to buy the imported ones and there are few who bought and installed but do not running them. There have been various reason behind composers success and failure due to which many units are successfully running them but few have stopped. The Ply Reporter presents you a brief synopsis on market situation and future prospects related to core composers in Indian context…
There are a number of Indian Machinery suppliers such Kalyan Industries, Chopal Timber Company (CTC), Star Plywood Machinery, etc who are offering core composers in the country. All of them are optimistic about its relevance on the contrary they are of opinion that ‘present market conditions are not supporting to go with faster pace as people are asking and talking much but they are equally apprehensive about the industry scenario and actual installation of core composers. The reasons that are evident is ‘some of the industries are over budget due to recent expansion and the new entrants are unaware and even unprepared to get the benefit of composers, hence they do not want to invest in a composer line instead continuing with manual processing.
Core composer is witnessing the same situation that was there during emergence of wide belt sander. In the beginning, people installed WBS but were not using it as they could not run due to their set up or skill set was not up to that level. But the awareness and demand for quality, the usability of this machine became one of the essential machines for them. The core composer selling companies are hopeful that with increasing awareness, company’s willingness and the changing market dynamics will compel plywood manufacturers to adopt to core composer in another three to four years.
As per Mr Jagmohan Singh of Kalyan Industries, he introduced the core composer for the first time in India in 2006. “It was the time when people were not aware, but today people start asking about the utility, price and benefits if various models offered by us in range of core composers,” says Mr Jagmohan Singh.
Those who understand the importance of the machine are installing it, still many of them are in wait & watch situation and have not been able to make up their mind to install veneer core composers. He also blames the misconception and first mover fear that is largely seen in most of the plywood manufacturers.
CTC introduced core veneer composer in India in 2017. Mr. Gaurav Chopal of CTC machines says, ‘When the product was introduced to the market, there was less demand and people were not accepting as veneer composes were a myth. Being an expansive product and mixed reviews from industries, it is still going steady but there are increased queries from industries on this matter. With time, people are coming to know about its quality and workflow and when the core composers got installed at two factories in Yamuna Nagar & Punjab, the
demand has grown well, adds Mr Gaurav. considerably. After showcasing in exhibitions, the veneer composer awareness and acceptance grew and slowly they are converting in orders now, according to CTC head.
The market forces will compell them to install for better output and quality product. At present also the situation is same those who are willing to serve the industry with quality products and faster services are installing core composer and reaping the benefit. Those who still don’t understand will also have to come into this segment in future, but they will be late to get the benefit of core composer.
Mr. Vishal Gaba of Star Plywood Machinery opines ‘veneer core composers are successful in those companies who are technically specific in use of top layer. If the top layer is eucalyptus the composed core needs standard glue for better impression because eucalyptus expands and core overlap appears with non specific glue. Secondly if the top layer is Poplar, it is ok with any glue and gives better impression. The core composer facilitates fast execution with better quality of material with saving of cost.
“It has witnessed a bit of good demand time a year ago, when market situation was favorable. Since the present market situation and payment constraint has dampened the demand and impacted the mood of manufacturers hence there are hesitating in making new investments in machines. The present demand is basically coming from organised segment companies. The branded and semi-branded players have always led the innovation and improvement in the industry in from the beginning and in case of core composers, it is same way feels Mr Jagmohan of Kalyan Industries.
Echoing a similar view, market exhorted the same sentiment during Ply Reporter story making. It was evident that despite of keen interest in full core material production, the pressure on price has led to lesser interest in machine segment. Adding to the views on composers demand, director production of a big brand said that ‘Organised brands have put their total
production process on core composer pattern’. While outsourcing also, we are very concerned on hence we prefer only composed core based plywood. He adds that ‘those companies who are manufacturing best quality plywood are installing core composer without any doubt’. The machine importer, Mr Vishal Gaba said “We have installed nearly ten core composers in a year and we have many enquires from upcoming units in Uttar Pradesh. On the contrary, the manufacturers of Yamunanagar are doubtful on availability of raw material due to new
plants coming up in UP state hence there is a drop in sentiment in Yamuna Nagar and Jagadhari region. The easier availability of Poplar and Eucalyptus timber, Uttar Pradesh companies are placing more queries than any other state said Mr. Vishal Gaba.
Core Veneer Composer
Core veneer composer is a machine which stitches the core veneer to avoid gap and overlapping of core while manufacturing quality plywood. These are the issues which cannot be controlled manually. Core composing is done by composing core with five layers thread inside which joins the core and make it streamline in different required standard size for making plywood in different specifications. Even expert manual handling leaves 10 to 20 percent problem of over and gap. The core composer makes single core sheet of 8x4 or desired specifications by stitching all dried core inserted into it. The core composer facilitates three major advantages in plywood manufacturing.
Reduce wastage: This machine reduces wastage of core and glue. In manual process the core is made oversize of five inches or more in both the sides, while core veneer composer leaves just two inch the actual size of plywood.
Quality output: Without overlapping and gapping between cores give excellent output.
Manpower saving: For plywood manufacturing fifteen delight one press require 25 manpower while the core composer can be operated by only one person due to which the manpower saving comes 10 to 50%.
The future is bright, as in China most of the companies who are manufacturing plywood are using core composer. If the manufacturers who are willing to go into decorative material, which is evident with international trend and changing the test of Indian consumers also, they will have to go for core composer.
installed nearly ten core composers in a year and we have many enquires from upcoming units in Uttar Pradesh. On the contrary, the manufacturers of Yamunanagar are doubtful on availability of raw material due to new plants coming up in UP state hence there is a drop in sentiment in Yamuna Nagar and Jagadhari region. The easier availability of Poplar and Eucalyptus timber, Uttar Pradesh companies are placing more queries than any other state said Mr. Vishal Gaba.
Mr. Gaurav Chopal said, “According to an estimate there is nearly 30 to 40% decrease in demand due to industry constraint and issues related to payment and sales at present. We are very hopeful that is with improvement in demand and supply in market, the demand of core composer will also reach to next level as it happened in case of peelings and wide belt sanders or automatic DD saw. The overseas market has huge potential for core composers where people have manpower issue along with high quality material demand. A number of plywood manufacturing companies are coming up in countries like Gabon, Indonesia, Vietnam, Malaysia, etc where composers are a must commented Mr Gaurav Chopal.
He adds, “If the companies or suppliers do not look overseas market the situation will aggravate to further level. So, my suggestion to the industry is to look beyond boundaries, the way China does.
What seems genuine need of the present is to focus on the quality that overseas market asks for. Indian market is flourishing with economic development and ease of doing business is providing new avenues. USA antidumping duty on China for wood products may give a way to Indian products too as India is the second largest producers of plywood after China. The manufacturers should focus on quality and look for overseas market for sustainable development of the industry and thus new machines like core composers, scarf jointers, zero gap board composers could be the need of the hour.
The Future Prospect of Core Composer
Mr Gaurav believes that the future is bright, as in China most of the companies who are manufacturing plywood are using core composer. If the manufacturers who are willing to go into decorative material, which is evident with international trend and changing the test of Indian consumers also, they will have to go for core composer. For example now melamine is being pasted on plywood also like happening in particle board. For this purpose, it is mandatory to use core composer as it gives fine quality without core gap and overlap.”
Mr Vishal Gaba also opines that the future is bright and within four years it will become one of essentials of every unit, as many players are using core composers and their products
acceptability is good compared to manual processing due to quality and finish. It also reduces the production cost, wastage and use of manpower. Mr Jagmohan says that the market forces have compelled them to install for better output and quality product. At present also the situation is same those who are willing to serve the industry with quality products and faster services are installing core composer and reaping the benefit. Those who still don’t understand will also have to come into this segment in future, but they will be late to get the benefit of core composer.
Mr Jagmohan Singh says, “It will make a room for quality players as wide belt sander took time and later when understand the importance and it becomes a necessity. With core composer the story is same as some people have installed it but not using. Secondly the customers’ choice is also moving towards quality products so, manufacturers will be bound to use core composer to meet the expectations of customers.”