SyPly plywood handbook (2016)

 
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SyPly plywood handbook of Syktyvkar Plywood Mill production, 2016, March

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HANDBOOK SYKTYVKAR PLYWOOD MILL

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ABBREVIATION BFU Bau-Furniersperrholz aus Nadelholz – birch plywood for construction and furniture BFU-100 Class of construction materials the requirements of which Plywood SyPly meets. It is confirmed by WKI certificate DNV GOST TR SPM SyPly™ Det Norske Veritas (Finnish agency) - independent classification and certification Norwegian company Russian State Standard Technical requirements Syktyvkar Plywood Mill Ltd Syktyvkar Plywood – plywood trade mark, registered March 24, 2005 in Russia and April 6, 2005 in 32 countries of the world Construction Product Directive - construction materials directive adopted by the European Union (fr. Conformite Europeenne) - European conformity – marking of construction materials according to the construction standard CPD that corresponds to European standards Forest Stewardship Council International Standard Organization Plywood glued with phenol-formaldehyde resin Plywood glued with urea-formaldehyde resin Wilhelm Klauditz Institut - Fraunhofer-Institut für Holzforschung (Germany) CPD CE FSC ISO WBP MR WKI 2

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CONTENTS About The Enterpise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diplomas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Milestones of development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ecological Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Manufacture and quality control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Plywood SyPly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Birch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Film-faced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Reference data on weight and volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Thickness Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Physic-mechanical properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Plywood Grades Birch plywood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Film-faced plywood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Plywood application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SyPly around the world . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Edition – March 2016 Authors of the current handbook do not guarantee that the information below is complete and up to date as this guide is not for technical reference but for marketing and information purposes only. Current edition cancels and replaces all previous ones. 3

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ABOUT THE ENTERPISE Syktyvkar Syktyvkar is the capital of the Komi Republic located in the North-Western part of Russia SYKTYVKAR PLYWOOD MILL SPM is one of the largest Russian manufacturers of plywood and particleboard. Rich experience in particleboard and plywood production accumulated since 1976 and 1987 respectively helps to manufacture products matching world standards. The mill is situated in the region rich with forests. Best wood is sourced from taiga and birch groves of the Komi Republic, Tatarstan and Udmurtiya, Arkhangelsk , Vologda, Kirov, Kostroma, Nizhniy Novgorod and Yaroslavl regions. Current handbook is designed for plywood end-users, trade representatives, project-planners, marketing specialists, other persons involved in this area. 4

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Qualified and competent staff is a competitive advantage of SPM. Strategic management, marketing and complex information system uniting all structures of the mill allow effective control of production and sales activities of Syktyvkar plywood mill. Quality management system is a part of corporate culture of Syktyvkar plywood mill. It is certified according to the international standard ISO 9001:2008 and all mill's operations from product engineering up to its shipment are standardized in accordance with it. High quality of plywood SyPly provides opportunity for a wide range of applications: concrete house building, construction, furniture production, auto and wagon industry, packaging. The main purpose of Syktyvkar plywood mill is to satisfy needs of customers in spheres of service, reliability and delivery convenience to a maximum extent. All information necessary for end-user was considered while creating this handbook – description of plywood types and properties, spheres of application, choice of grades. Perfect quality of plywood SyPly will help you to improve your business. 5

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Modern equipment and technologies used in the production process enable SPM to produce goods that fit the highest demands of customers. Plywood production capacity of the enterprise is more than 220 000 m3 per year. Dynamics of plywood production, th. m3 222 205 215 SPM produces birch and filmfaced plywood CONIFEROUS PLYWOOD BIRCH PLYWOOD FILM-FACED PLYWOOD 18,88 2014 2013 2015 2013 2013 6

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DIPLOMAS Certificate №220213 protects graphic representation of the trade mark «SPM ltd» concerning class 19 of goods (services) in Russia. Certificate № 212611 protects trade mark «PlyPan» concerning class 19 of goods (services) in Russia. PlyPan SyPly Certificate № 284909 protects trade mark «SyPly» concerning class 19 of goods (services) in Russia. The certificates are given by the Federal service of intellectual property, patents and trade marks International certificate №867780 protects trade mark «SyPly» concerning class 19 of goods (services) in 32 countries of the world. This number includes: Austria, Belarus, Benelux countries, China, The Czech Republic, France, Germany, Hungary, Italy, Kazakhstan, Latvia, Poland, Portugal, Serbia, Montenegro, Slovakia, Slovenia, Spain, Switzerland, Ukraine, Denmark, Estonia, Finland, Greece, Iceland, Lithuania, Norway, Sweden, Turkey, Great Britain, USA. The certificate is given by the International bureau of World organization of Intellectual property 7

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MILESTONES OF DEVELOPMENT Main phases of project development and modernization of the plywood production 1987 1997 1999 2000 Plywood manufacturing shop start up (Finnish equipment Raute Wood is installed, 3 an nual production capacity is 100 000 m per year ) Syktyvkar Plywood Mill becomes a subsidiary of Syktyvkar Forest Enterprise Plywood and particleboard range of sizes and thicknesses is increased New plywood sanding line (Steinemann/Switzerland) is installed; Plywood certification in accordance with BFU 100 DIN 68705 (Germany); Peeling and splicing line (Raute/Finland) is installed 2001 Syktyvkar Plywood Mill ltd. quits the holding company Syktyvkar Forest Enterprise and becomes an independent company 2003 New defect chopping and veneer splicing line “Raute" (Finland) is installed; New long grain veneer drying line Grenzebach BSH (Germany) is installed; New additional plywood format cutting line "IMA Klessmann GmbH" (Germany) is installed which allows to produce plywood with cut edge profile 2004 Chain of custody certification – from log harvesting to production and sales – according to FSC system within «Smart Wood» program 8

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2005 New peeling line «Meinan» (Japan) is installed; Second long and cross grain veneer drying line “Grenzebach BSH” (Germany) is installed; Replacement of the existing chipping machine in veneer shop by new Raute (Finland) line allows to process waste wood products more effectively Modernization of drive mechanisms and increase of plywood film-facing capacity; New cold press «Kitagawa Engineering» (Japan) is installed which helps to increase hot press productivity Improvement of ecological situation due to launch of filter plant «Moldow» (Denmark) on the system of aspiration at sanding lines; Change of gantry crane helped to optimize time of unloading, and increased reliability of wood supply 2007 2008 2009 2010 2011 New plywood sanding line «Steinemann» (Switzerland) increased the production capacity and improved the quality of sanding due to the additional sanding with granularity of 120 mk/mm2 Installation of additional spreaders increased plywood production capacity up to 200 000 m3 per year New debarking and log-cutting line is installed; Upgrade of short grain peeling lines; Upgrade of loading and processing system of lamination press increased film-faced plywood production capacity by 11,4% Upgrade of long grain peeling line Raute (Finland); Veneer splicing line Hashimoto (Japan) is put into operation; Renovation of the hot presses Reconstruction of plywood hot presses; Replacement of cold presses; Installation of a water heating equipment for pools of hydro- thermal processing of raw materials; Modernization of veneer drying equipment Modernization of conveyors of log yard. Modernization of Raute peeling lines 4x8 and 8х4 Replacement of Grenzebach veneer scanners with scanners Mecano New veneer dryer Sunway New glue mixer «Industry Technologies», Latvia 2012 2013 2014 2015 9

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ECOLOGICAL PRINCIPLES TO THINK OF THE FUTURE One of principles of SPM work is to take care of a regional ecology. One of the oldest known building materials - wood - self-renewed and non-polluting - is used for plywood production. Wood is easy to process and utilize without damage to the environment. Plywood manufacture is practically zero waste as wood chips and sawdust are used in manufacturing of particleboard. Other wood waste is completely utilized, turning into “green thermal energy”. Application of modern technologies in resins and different additives for production of woodbased panels allowed to reduce environmental impact greatly while preserving high physic-mechanical properties. Plywood meets the requirements of the German national standard DIN 68705-3 for BFU 100 class construction plywood and the requirements of the European standard EN 636 as well. FSC - CERTIFICATE Oil heating equipment works on wood waste (Classen / Germany) The main principles of the company in environment protection are based on constant development and the use of the unique self-renewed raw materials and controlled processes. The ecological program of the enterprise provides stepby-step introduction of adequate measures, constant monitoring of the results and updating of plans in accordance with the international standards of economic forest-use. In June 24, 2014 SPM passed the certification confirming that the chain of custody corresponds to the norms of Forest Stewardship Council – international independent organization that develops standards in the field of forest-use, wood processing and manufacture of wood-based products. Goal of FSC is to help ecologically responsible, socially oriented and economically stable forest-use and world forest resource management Due to the certification of the chain of custody buyers of FSC-certified plywood can be sure that: Ё Ё Logs that were used for the production were legally harvested; While harvesting these logs stable forest-use methods, rights of employees, local and native population were respected. 10

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MANUFACTURE AND QUALITY СONTROL OF PLYWOOD SyPly™ WOOD RAW MATERIAL Process of plywood manufacture begins with a selection and delivery of high-quality wood. Northern wood is especially durable due to annual rings which are narrow because of slow tree growth in a severe climate. Plywood SyPly reflects the best characteristics of birch wood: perfect physic-mechanical properties and excellent quality of surface. It is the basis of SyPly quality. USE of GLUE Plywood glued with urea-formaldehyde glue (MR) – according to standard EN 636-1 can be used in dry conditions (W*< 65 %), it refers to the first class of biological durability. Wood stock provides stable work of the Plywood glued with phenolic-formaldehyde glue (WBP) – Enterprise through all seasons according to standard EN 636-2 can be used in damp conditions (W*< 85 %), it refers to the second class of biological durability. Plywood glued with phenolic-formaldehyde glue (WBP) and faced with resin impregnated paper (laminated) – according to standard EN 636-3 can be used in the open air (W*> 85 %), it refers to the second class of biological durability. Adhesive strength and content of formaldehyde correspond to the requirements of BFU 100 DIN 68705-3 standard. Plywood SyPly has ultra-low emission of formaldehyde (class E1). QUALITY CONTROL THE SYSTEM OF QUALITY CONTROL Quality control Internal control is carried out by the quality department, external - by independent certification institutes. Internal quality control Independent quality control Quality department of SPM WKI (Germany) Internal auditing service Management system of quality control is certified in accordance with the international standard ISO 90012000, that is all operations and processes inside the mill are standardized and traced under the standard: Quality control under ISO 9001-2000 Russian State standard ь control of raw wood and materials ь parameters of technological production process ь service and operation (running, exploration) of the equipment ь staff training *W - parameter of relative atmospheric humidity 11

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THE PROCESS OF MANUFACTURE Wood stock 1. Hydro thermal treatment 2. Debarking and cutting 3. Peeling 14. Manual repair 13. Grading Birch plywood SyPly™ 12. Sanding 11. Cutting to size 15. Film-facing 16. Cutting to size and edge profile trimming 17. Grading 18. Edge sealing Stages 1 to 6 Logs are hydrothermal treated with steam and hot water to improve smoothness and density of veneer. After treatment logs are cut into pieces sized for peeling, debarked and peeled. Veneer which is produced on peeling lines is then cut into sheets, dried and graded Stage 7 Graded veneer is patched (veneer defects are removed from a veneer sheet and replaced with patches that are made from high-quality veneer), pieces of veneer are joint at splicing lines Stages 8 to 10 Graded, patched and spliced veneer continues to the composing shop where dry veneer sheets are interlaced with sheets that are covered with glue. Ready batches are then cold pressed. Final gluing is made in hot presses under high pressure and temperature 12

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veneer pieces 4. Cutting of veneer sheet 5. Drying 6. Grading full size veneer 7. Patching and splicing 10. Hot pressing 9. Cold pressing (prepressing) 8. Composing 19. Packaging 20. Warehousing and shipping Stages 11 to 14 After pressing plywood sheets are cut to size, sanded to get smooth surface, graded and manually repaired. Graded birch plywood SyPly is packed into bundles after that Stages 15 to 18 During film-facing plywood is covered with impregnated (soaked with phenolic resin) paper, pressed, cut to size and edge sealed. After grading plywood is packed and transferred to the warehouse Plywood sheets are packed into bundles (number of sheets in each bundle depends on a thickness of plywood). Each bundle is tied with plastic bands, marked and transferred to the warehouse. Plywood is shipped with rail transport (wagons and containers) and trucks Stages 19 to 20 13

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PLYWOOD SyPly™ BIRCH PLYWOOD SyPly™ Birch plywood SyPly is a strong and water-resistant material. Birch wood gives its beautiful structure and high physic-mechanical characteristics to plywood. These qualities made it popular in furniture industry, construction, interior and exterior design THICKNESS, mm 3 5 5 7 4 6 6,5 9 12 15 18 40 35 30 27 24 21 17 13,15 21 20 25 29 FORMATS, mm 2500 mm 2440 mm 1250 mm 1220 mm 9 11 11,13 Number of plies, pcs. long cross Grain direction Water resistance Class of formaldehyde emission Humidity Length / width tolerance WBP (high), MR (standard) Е1 5-10% +/- 2 mm PLYWOOD GRADES There is a difference between grades of plywood and grades of veneer. Grades of plywood depend on the grade of veneer used as for the top ply. For example, plywood panels faced with veneer grade “B” on one side and “BB” on the other side will have “B/BB” grade –the highest grade is indicated in the first place B/BB E/BB BB BB/CP BB/C CP/CP CP/C C/C (NS*) *NS - not sanded BB/CP В B/BB C СР/CP CP/C В BB Е 14 E/BB BB/C С/C C/C NS* C Scheme of plywood composition from different grades of veneer

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FILM-FACED PLYWOOD SyPly™ Film-faced surface of SyPly panel has a high resistance to various natural and chemical effects. It makes film-faced plywood SyPly irreplaceable for the manufacture of wearproof surfaces (concrete formwork, storage and transportation of food and pharmaceutical goods, motor vans and wagons, ship decks, scaffolding) RANGE OF POSSIBLE COLORS SyPly DBR dark brown GR gray BLK black YLW yellow dark brown with logo SyPly GRN green LBR light brown RED any film color from the range with one-side wiremesh (W) DBR dark brown with your logo TYPE OF FILM SURFACE Smooth (F/F) smooth/meshed (F/W) THICKNESSES: 6 - 35 мм Water resistance: WBP (high) Class of formaldehyde Е1 emission: Humidity: 5-12% ADVANTAGES Exclusive durability Choice of color and density of film Ability to combine with other materials Big format Fast installation and easy processing Increased water resistance PLYWOOD FOR FILM-FACING Birch plywood SyPly™ is faced with phenolic resin impregnated paper 15

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