KATALYST on MirpurFurniturePlant

8/3/2019 KATALYST on MirpurFurniturePlant

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FEASIBILITY OF A WOOD SEASONING PLANT FOR THE MIRPUR

FURNITURE CLUSTER

1.0 INTRODUCTIONSeasoning is one of the most important processing technologies prior to manufact

ure of wood basedproducts. It is an appropriate technology particularly for the furniture industry, because it improves thequality of the furniture significantly. It increases physical and mechanical properties, dimensionalstability, finishing, polishing painting and gluing capacity. It also saves timber and its products likefurniture from bio-deterioration by protecting from fungus and insect attacks. It, thus, also enhancesthe service life of furniture. Because of these distinct advantages, a keen interest was observedamong the owners of the furniture enterprises to have their own seasoning plants

. But the individualenterprise is handicapped due to a large investment involved in adopting the technology. This is whythey have formed a Forum and have approached KATALYST to get the technical assistances rightfrom the feasibility study to installation, operation and training to improve the quality of timber and itsproducts. It aims at strengthening the furniture and sawmill industries. Initially, the feasibility aspectwill be dealt with and after completion of this first phase, subsequent activities will be taken up. Withthis aim in view, the assignment was undertaken as per specific tasks containedin the Terms of

Reference as mentioned in Annex-1. A list of the member enterprises of the Forum, Rokeya SaraniFurniture Development Industries is presented in Annex2. The furniture enterprisesand otherorganizations visited and personnel met in this respect are shown in Annex-3.

A small number of big enterprises are already exporting furniture to different countries in a limitedform. Some of the members of the Forum are planning to enter into the export arena with theirproducts in the future. But it is a pre-requisite condition to manufacture furniture from properly

seasoned timber in case of export. They are fully aware of this aspect, which was evident during thediscussion with them. This is another reason for the Mirpur furniture cluster tohave its own seasoningplant.

2.0 METHODOLOGICAL APPROACHThe study involved an initial discussion with the key personnel of the furnitureand sawmill industriesin Mirpur zone. The questionnaire survey method was used to know the state of art of 19 furnitureenterprises comprising 22 members in the target area covering a broad range of aspects. For this, a

structured questionnaire was prepared (Annex-4). The collection of reliable information was



attempted through informal and friendly discussion with the entrepreneurs by removing theirapprehension, misgiving and then convincing the importance of sustainability ofthe Forum whichdepends on their unreserved answers. Finally, all data were compiled and the frequency analysis was

performed on relevant information (Annexes: 5-14). Some related organizations were visited,relevant documents were examined and all pertinent information were collected. For procurement ofwood seasoning kilns and basic woodworking machineries, detailed particulars were collected fromthe local and foreign sources through visits and correspondences.

3.0 FURNITURE INDUSTRY AND WOOD SEASONING PRACTICE3.1 Furniture industryThere is no reliable statistics about the furniture industry in the country. Itis estimated that there are

about 10,563 furniture enterprises in the country (Anon,1994, Kibria et al 2001). Many of them,however, may not be in operation now, and some enterprises may have recently been established.There are about 200 furniture enterprises in the Mirpur zone, and in the Begum Rokeya Sarani Roadalone, over 100 such enterprises are located (Karim, 2004), which is the targetarea of the presentstudy.

3.2.0 Wood seasoning practiceIt is considered pertinent to highlight the general information about wood seasoning and then discuss

the wood seasoning to fully understand the technology.

3.2.1 General information about seasoningGreen timber contains a large amount of moisture content ranging from 50 to above 200%1 in its dryweight. Seasoning is removing this moisture by drying timber to a level which isin equilibrium with theatmospheric temperature and relative humidity. In Bangladesh, the average equilibrium moisturecontent is 12 -14%2 and thus timber should be dried to this moisture content range for properseasoning (Anon, 1978).

3.2.2 Methods of seasoningThere are various methods of seasoning of timber. Among them, the most common methods ofseasoning are air drying, kiln drying and solar drying. These are discussed briefly.

Air drying

1 Green timber contains moisture from 50 to 80% in its dry weight2 In Northern Hemisphere like USA, Canada, EU, etc., the average equilibrium moisture content is 6-8%

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Air drying is the seasoning of timber by exposure in the direct sun or under a shed following properstacking of timber. It depends on natural flow of air, sunshine and rain. It isthus the most simple andinexpensive method. But it takes a long time and larger space and is not equallyeffective throughout

the year (Sattar and Ali 1969). The investment on timber remains blocked for a long period which isanother drawback of this method.

Kiln drying

Kiln drying is seasoning of timber in an enclosed chamber where there is full control of all the dryingelements. Almost all commercial timbers of the world are seasoned by the kiln drying method. Timbercan be dried to a lower level of moisture content in any time of the year. It isan efficient method, but

expensive and complicated to both install and operate.Ideally, each piece of timber in a kiln should be subjected to a uniform flow ofair at a predeterminedtemperature and humidity. For this it is necessary to control the following fouressential dryingelements:

(i) heating, (ii) humidification, (iii) air circulation and (iv) ventilation.In the seasoning kilns there should be means to control these elements. Improperoperation of thekilns may lead to serious drying defects resulting in even complete damage of timber. For this, thekiln drying schedules have been developed for the timbers of Bangladesh (Sattar,

1980).There are 55 conventional seasoning kilns in 20 organizations in the country. The total capacity ofthese kilns is about 0.71 million ft³/annum. Due to various reasons, such as withdrawal of investment,lack of appropriate technical knowledge, improper maintenance, etc, these seasoning plants are notfully utilized. Some of them are not in operation now (Sattar, 1988).

Solar drying

Solar drying is drying of timber in a totally enclosed structure which derives its energy from the solarradiation with the help of a heat absorber. The short wave solar radiation is transmitted through theglazing material . The blackened sheet inside the solar kiln absorbs the radiation, heated up andsubsequently emits long wave radiation as heat energy. The glazing material is opaque to thisradiation and thus it is trapped inside the solar kiln as heat energy. This heatis used for woodseasoning (Sattar, 1991).Prompted by satisfactory performance, ease of operation and economy, 22 solar kilns wereconstructed both by public and private enterprises (Sattar, 1982, 1989). The tot

al seasoning capacitywas 36,000 ft³/annum. But most of them are not now in operation, because these solar kilns have



completed their 10 years period which is their normal life of duration, and werenot reconstructed. Instead, some of them, however, have constructed conventional seasoning kilns formore faster drying.

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3.2.3 Wood seasoning practiceExcept for some enterprises of Bangladesh Forest Industrial Development Corporation (BFIDC) and afew private industries, there is no wood based industry that possesses facilities for timber seasoning(Sattar 1988). Unseasoned timber is thus being used in almost all cases. In this

respect, a surveywas conducted in seven major cities for a study in 1988. The condition of moisture content (mc) insawn timbers and manufactured furniture was ascertained. The result of three major cities is shownbelow (Table 1).

Table 1 : Result of survey of furniture industries about seasoning

Locality No. ofindustriesMethod Range of mc reached

Sawn timber ManufacturedSeasoning conditionDhakaChittagongKhulna302304301Air dryingKiln drying

Air dryingKiln dryingAir dryingKiln drying25- 50 18 - 3516- 22 14 - 1930- 60 22 - 4515- 20 14 - 2025- 50 18 - 2415- 22 14 - 20Partially driedAlmost seasonedPartially driedAlmost seasonedPartially driedAlmost seasoned

This survey was undertaken as long as 16 years back. The condition of seasoningpractice has notimproved during this period; it may have probably deteriorated further in some cases. It is thusnecessary to determine the moisture content of sawn timber as well as manufactured furniture toknow the present condition of seasoning practice.

3.2.4 Wood seasoning practice in Mirpur zoneThe furniture industry is mostly concentrated in Mirpur area where about 200 small to medium scale



furniture enterprises are clustered in this zone. But there is only one seasoning plant consisting of twocompartment type seasoning kilns in the area. This plant was constructed about 40 years back by theBangladesh Forest Industries Development Corporation (BFIDC). The capacity of each kiln is 1,000ft³ per month. It caters the needs of its cabinet manufacturing plant. However, it

offers seasoningfacility to private enterprises on a very limited scale on payment. Proper maintenance andoverhauling were not done either on the plant itself or on the boiler. This is why one seasoning kilncan run at a time which has made the plant uneconomic. It is difficult for furniture enterprises to gettheir timber seasoned in time. On an average, this plant can season 100 ft³ of private timber permonth, whereas the need of the total seasoned timber for the 200 furniture enterprises is 37,400ft³/month in this area (Table- 2).

Except Hatil Complex, three member enterprises claim that they get a part of their timber seasoned inthe BFIDC plant. All other enterprises mention that they air-dry timber under the sun or a shed for a

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period ranging from 15 - 50 days. By adopting this practice, timbers are partially dried and only thesurface moisture is removed as is evident from Tables-1. This means either unseasoned or partiallyseasoned timbers are used for making furniture in almost all cases. However, most of the enterprises

also agree that they cannot achieve proper seasoning, and as such they are looking for kiln drying oncollective basis (Annex- 9).

3.3 Demand of seasoned timberThe average monthly utilization of sawn timber and demand for seasoning timber have beenestimated through the survey in the Mirpur furniture cluster. The result is presented in Table- 2.

Table- 2 : Sawn timber used and requirement for seasoning in Mirpur zone

Sl.No.Amount of sawn timber and its requirement forseasoning/monthTotal amount/month (ft³)Averageamount/month (ft³)i)ii)Amount used by 21 enterprises (excluding HatilComplex)Amount needed for seasoning by 21

enterprises (excluding Hatil Complex)4,8302,520230120iii)iv)Amount used by all 22 member enterprises(including Hatil Complex)Amount needed for seasoning by these 22enterprises (including Hatil Complex)6,6224,114301187v)vi)Amount used by 200 furniture enterprises inMirpur cluster(based on average of 22 enterprises)Amount needed for seasoning by these 200enterprises in Mirpur cluster (based on averageof 21 enterprises)60,20037,400

301187



Hatil Complex, one of the biggest furniture industries in the country, has threeseasoning kilns at itsfactory site at Kasimpur. This industry seasons 90% of its monthly requirement of 2,000 ft³/month. Itdoes not need any seasoning support. So, concern lies with the rest of 21 memberfurnitureenterprises. These are small to medium sized industries which need a total of 2,

520 ft³ of timber to beseasoned per month. This is the estimated total demand of seasoned timber per month, but in actualpractice there may be a variation of the needs. Thus, provision should be made minimum for 2,400ft³/month and maximum for 3,000 ft³/month.

3.3.1 Timber species used by furniture enterprisesThere are about 26 conventional species which are commercially used in the country (Annex-15). Inthe Mirpur zone, four selective timber species are being used by the 22 enterprises as shown in

Table-3. Teak, Chapalish, Gamar and Garjan are those species. Teak is predominantly the main

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timber species representing about 71% among the four timber species, the remaining 29% is almostequally shared by three species.

3.3.2 Price and thickness of timbersTeak is the costliest one, and its price averages Taka 1,300 per ft³, while the av

erage prices of otherthree species: Chapalish, Gamar and Garjan are Taka 877, 785, 836 per ft³ respectively (Table- 3).Because of its established better quality, furniture manufactured from Teak woodis preferred by thecustomers even with much higher price. The rest three species of timbers are comparatively costliertimbers than those of other commercial timbers.

Various sizes of timber are used for different products. But it is the thicknessof timber which mattersfor seasoning. So, different thicknesses that are used by the furniture enterpri

ses have beenascertained (Table-3). It is evident from Table-3 that among the mostly used thickness class, thethickness of 0.75, 1.00 and 1.5 inches planks represent 46.2% 20.4% and 15.4% ofthe total. Thesethicknesses make 81.8%, and the rest 18.2% are 1.00, 1.25, 1.75. 2.00 and otherspecial thickness.So, the planks representing 81.8% thickness class fall under priority group which needs to beseasoned.

Table- 3 : Information regarding species, thickness and price of timbers

a) Timber species AveragepercentRangeof percentFrequencyof industriesPercenti) Teak (Tectona grandis) 70.8 40 85 22 100ii) Chapalish (Artocarpus chaplasha) 11.5 5 20 20 90.9iii) Gamar (Gmelina arborea) 8.6 6 30 18 81.8iv) Garjan (Dipterocarpus spp.) 9.1 7 30 21 95.5b) Price of timber species AveragePrice/cft(Tk)Price rangeMin. Maxi) Teak 1300 1000 1500ii) Chapalish 877 800 1000iii) Gamar 785 700 850iv) Garjan 836 750 900c) Mostly used thickness of planksThickness (inch)Percent Sawn timbers are obtained fromOwn sawmills Other sawmillsi) 0.75 46.2 8 14ii) 1.00 20.2 (36.4%) (63.6%)

iii) 1.25 6.5iv) 1.50 15.4v) 1.75 5.4



vi) 2.00 4.1vii) Other thickness 2.2Total number of enterprises 22 100

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4.0 W0OD SEASONING KILNSThere are different types of conventional seasoning kilns using different sourceof energy for heating.Some kiln uses electricity for heating and production of steam to humidify the kiln chambers as andwhen necessary. It is expensive due to consumption of a large amount of electric

ity. Otherconventional kilns have boilers for the production of steam which is used both for heating andhumidification. Again, the fuel used for the boiler may either be electricity, gas or waste wood. Amongthe three energy sources, the waste wood is obviously the cheapest one. The second alternativeenergy source is gas which is comparatively cheaper than electricity, but costlier than waste wood.Since there will not be waste wood available for the kiln, gas should be preferred to other two sourcesof energy.

4.1 Quotations of wood seasoning kilnsKeeping in mind the above type of seasoning kiln, specifications were prepared.The addresses ofthe suppliers and manufacturers were collected from the trade centres of Embassies/Highcommissions. A large number of foreign manufacturers and suppliers of the following countries werecommunicated through fax and e-mail :

i) India, ii) China, iii) Taiwan, iv) Korea, v) Indonesia, vi) Japan, vii) UK, viii) Ireland, ix) Italy and x)South Africa.

Out of these countries, nine manufacturers/ suppliers responded initially. All of them were requestedto submit the price offers according to the specified requirements. Finally, twosuppliers from Indiahave submitted the quotatins of wood seasoning kilns with detailed specifications (Quotations: 1-2).These are all compartment type steam-heated kilns using gas as energy source forthe boiler.

One Italian manufacturer named, Coplan srl has also submitted a quotation for one set of 550 ft³capacity seasoning kilns and other relevant accessories (Quotation-3). It is also of compartment typekiln using gas in the boiler.

The suppliers from India have offered for 500 ft³, 550 ft³, 750 ft³, and 1250 ft³ capacity seasoningkilns. It is always convenient to install a number of small capacity kilns rather than a single big kiln. Itis thus convenient to install two units of compartment type seasoning kilns. Thecapacity of each unitmay be 500 ft³ per charge. These two units will provide 2,400- 3,000 ft³ of seasonedtimber permonth.

From the offers, the total costs of construction of two units of seasoning kilnof 500 ft³ capacity have



been estimated and a comparative statement is presented in Table-4.

Table- 4: Comparative statement of two 500 ft³ capacity seasoning kilns as offeredbydifferent suppliers/ manufacturer

Sl. Gangotri Impex Aditya Coplan srl

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No. Items (India)Cost & Freight- Benapole(Taka)CastingUdyog

(India):Cost only- Punjab(Taka)(Italy):Cost only(Ex-factory)(Taka)1 Kiln equipments-fixed type 7,15,380 9,66,360 26,21,6402 Boiler - 300kg/hr :complete set 9,66,900 8,99,400 3,30,780(without accessories)3 a) Freight upto Benapole

(approx)b) Freight upto Chittagong port(approx)--50,000--1,20,0004 a) Taxes & transport fromBenapole to Dhakab) Taxes & transport fromChittagong to Dhaka2,00,000

-2,00,000--3,90,0005 Construction of 2 kiln chambers+ boiler room + office room5,50,000 7,00,000 3,00,0006 a) Other works & materialsb) Computer & printer50,000 50,000 90,00075,000Sub-total 25,82,280 28,65,760 39,27,4207 Water treatment plant 1,93,620 --Sub-total 27,75,900 28,65,760 39,27,4208 Installation & commissioningcharge including board & lodging60,000 60,000 3,36,840Total 27,35,900 29,25,760 42,64,260

4.2 Assessment of the quotations4.2.1 Technical aspect(a) The Gangotri Impex has quoted for all relevant machineries and components in its offer. The fullspecifications of the machineries and components have also been mentioned (Quota

tion-1). Thecapacity of each kiln is 500 and 750 ft³ per charge. Two boilers of 300 and 500 kg/hour capacity have



been offered. So, this offer may be considered as complete one. Since these arefixed type, the kilnchambers have to be constructed locally with brick and other materials. It has also offered one watertreatment plant to supply iron-free water to the boiler.(b) The second offer is of Aditya Casting Udyog who has quoted for kilns of 500, 750 and 1250 ft³

capacity along with necessary components except the water treating plant (Quotation-2). LikeGangotri Impex, these are fixed type compartment kilns using gas in the boiler.The kiln chambershave to be constructed locally with brick and other materials. The specifications are not detailed ones,and so it is difficult to know exactly what they will supply. In this respect, this offer cannot be termed8



as fully complete one. It is also mentioned in the offer that these kilns are not suitable for drying Teakwood using gas in the boiler.

(c) The Coplan srl has offered a relatively sophisticated type of 500 ft³ capacity seasoning kiln using

modular units (Quotation-3). The support of a computer will be taken for monitoring the progress ofdrying. Gas will be used for production of steam for humidification. There is nomention of a watertreatment plant in its offer. Technically, it will be difficult for the furniture enterprises to operate andmaintain these seasoning kilns.4.2.2 Financial aspect(a) The estimated total cost of two kilns of Gangotri Impex is Tk 27,35,900 including a boiler of300kg/hr (equivalent to 200 psi) capacity and a water treatment plant. The costalso includes

installation and commissioning charge of the supplier (Table-4). Without a watertreatment plant, theprice is Tk 25,42,280.(b) The total cost of two kilns of Aditya Casting Udyog is estimated at Tk 29,25,760 without a watertreatment plant. If the cost of a water treatment plant is included from the Gangotri Impexs offer, thetotal cost becomes Tk 31,19,380 (Table-4).(c) The estimated total cost of Coplans two kilns is Tk 42,64,260 including the approximate cost offreight from Italy to Chittagong port which was not included in the offer. It isthe costliest among thethree offers (Table-4).

4.2.3 Overall evaluationThere were initially many responses for supplying seasoning kilns of different types. But finally, offersof fixed type compartment kilns have been received. Among these offers, an appropriate seasoningkiln has to be selected.

(a) Incoplans kiln is sophisticated one and it will need qualified operators. Also, it is the mostexpensive among the three offers. So this offer cannot be accepted.3(b) The offer of Aditya Casting Udyog is not a complete one since it has not quoted for a watertreatment plant. Further, the supplier has mentioned that Teak wood cannot be seasoned with thiskiln. The price is also higher than that of other remaining offer. So, this offer cannot also beacceptable one.3 Though Incoplans Kiln might not be a good idea if the market is domestic, but for export market this type ofkiln drying is needed.

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(c) The offer of Gangotri Impex is the only one which has fulfilled all requirements. Its price is alsothe lowest among the three offers. It may be mentioned that two seasoning kilnsof each 750 ft³capacity are being installed by a member enterprise at Kashimpur near Savar. Itwill be advantageous

to the member enterprises to visit the plant and see the performance of this type of kilns beforepurchase. So, the offer of Gangotri Impex is acceptable one.Two seasoning kilns of capacity 500 ft³ each using gas as heat energy in the boiler as offered byGangotri Impex are thus suitable for the furniture enterprises. The boiler of 300 kg/hour (200 psi)capacity is recommended. These fixed type kilns are comparatively simple to install and operate.Generally, the life of this compartment type seasoning kiln is about 50 years.

For the fixed type seasoning kilns, the superstructure needs to be constructed w

ith brick and othermaterials. So, the seasoning plant preferably be installed in own land. In caseit cannot have its ownland, it should be rented for a long term basis, say at least for 10 years.

5.0 ECONOMIC ASPECTS OF STEAM HEATED KILNSThe costs of seasoning per cubic feet of Teak and Chapalish timbers of 1.0 inchand 1.5 inch thickhave been calculated for both 500 and 750 ft³ capacity seasoning kilns as shown inTables- 5(a & b).The details of the calculation are given in Annexes- 19(a & b). The total costsof construction of twofixed type seasoning kilns of Gangotri Impex have been taken as basis of the cos

t of the kilns.

Table-5(a): Seasoning cost of Teak and Chapalish timbers and other economicaspects using two 500 ft³ capacity steam heated seasoning kilns

Sl..Items 2 units of 500 ft³1.0-inch timbers2 units of 500 ft³1.5-inch timbers1 Output of seasoned timber per annum 44,000 ft³( 44 charges:7 days/charge)28,000 ft³( 28 charges:12 days/charge)2 Total recurring expenditure(land rent + gas + electricity + operation + loading &unloading + water + maintenance)14,48,884 14,91,5563 Total capital investment(initial installation + working capital)30,98,121 31,08,7894 Total cost

(recurring exp + interest on total capital investment+ depreciation)19,55,539 19,99,704



5 Kiln seasoning cost per ft³ = Total cost/output Tk 44.4 Tk 71.46 Return on investment 89.4 % 29. 3%7 Pay back period 18.4 months 56.0 months

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Table-5(b): Seasoning cost of Teak and Chapalish timbers and other economicaspects using two 750 ft³ capacity steam heated seasoning kilns

Sl..Items 2 units of 750 ft³

1.0-inch timbers2 units of 750 ft³1.5-inch timbers1 Output of seasoned timber per annum 66,000 ft³( 44 charges:7 days/charge)42,000 ft³( 28 charges:12 days/charge)2 Total recurring expenditure(land rent + gas + electricity + operation + loading &unloading + water + maintenance)

17,60,472 19,24,4163 Total capital investment(initial installation + working capital)35,19,160 35,60,1464 Total cost(recurring exp + interest on total capital investment+ depreciation)23,14,735 24,84,4175 Kiln seasoning cost per ft³ = Total cost/output Tk 35.1 Tk 59.26 Return on investment 139.1 % 52.4%7 Pay back period 8.6 months 21.6 months

5.1 Seasoning cost of steam heated kilns

From Table-5(a), it is apparent that seasoning cost for 1.0-inch Teak and Chpalish will be about Tk44.4/ ft³, whereas for 1.5-inch Teak and Chapalish it will be about Tk 71.4/ ft³ for500 ft³ capacityseasoning kilns. If one kiln chamber seasons 1.0-inch timber and another kiln chamber seasons 1.5inchtimber simultaneously, then the combined seasoning cost will become (Tk 44.4/ ft³+ Tk 71.4/ft³)/2 = Tk 57.9/ ft³.If two 750 ft³ capacity kilns are installed, then the combined seasoning cost willbe less, i.e. (Tk 35.1/ft³ +Tk 59.2/ ft³)/2= Tk 47.2/ ft³.

It may be mentioned here that the lowest current cost of commercial seasoning isTk 110 per ft³ ofBFIDC plant, whereas it is charged at Tk 250 per ft³ in some private wood seasoning plant.

5.2 Pay back period of steam heated kilnsIt is seen from Table- 5(a) that the initial investment of Tk 27,35,900 for two500 ft³ kilns will be paidback in 18.4 months for drying 1.0-inch Teak and Chapalish timber, and for 1.5-inch Teak and

Chapalish it will be in 56.0 months. But for combined seasoning, the pay back period will become(18.4+ 56.0)months/2 = 37.4 months, i.e. in about 3 years.



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If two 750 ft³ kilns are considered, the combined pay back period will be only (8.6+21.6)months/2=

15.1 months (Table-5b).5.3 Increase in cost of furniture due to seasoningThere will be increase in cost of production of furniture due to added cost of s

easoning of timbers. It isfound that if 1.0-inch timber is seasoned in one kiln chamber and another kiln chamber seasons 1.5inchtimbers simultaneously, then the combined seasoning cost will be Tk 57.9/ ft³ for500 ft³ capacityseasoning kilns. Now, if a furniture like chest of drawer is made from seasonedTeak wood using 8ft³ wood. The cost of seasoning this amount of timber will be Tk 463. If the costof the furniture is Tk25,000, then Tk 463 have to be added to it. So the total cost of the furniture becomes Tk 25,463. Forthis, the increase in cost of production will be only 1.8% for Teak furniture. I

f the same furniture ismade from Chapalish, the cost of production will be about Tk 18,000. If seasoning cost of Tk 463 isadded to it, the cost will be increased by 2.5%.

It was observed during survey that if the customers are fully convinced that thefurniture are madefrom properly seasoned timber, they are prepared to pay higher price compared tofurniture madefrom rather unreliable seasoned timber or partially dried timber. This fact is well demonstrated in theproducts of Hatil Complex. So, there will not be any problem in fetching reasonably higher price due

to increased cost for seasoning. The owners are aware of this attitude of the customers (Annex- 10).

6.0 RELEVANT ASPECTS OF KILN INSTALLATION AND OPERATION6.1 Requirement of area of landThe requirement of land for both fixed and portable seasoning kilns is not much.An area of about(25 x 25) = 625 sft will be required for two fixed type kilns. A boiler and a water treatment plant willneed an additional area of about 600 sft. Timbers will have to be kept near thekilns for some timesprior to and after seasoning. A small office room will also be required for theKiln operators andBoilermen. For these purposes, another 800 sft will be needed. Combining all these requirements, itbecomes 2025 sft. So, the preferable area for the installation of the seasoningplant will be about3,600 sft which is equivalent to 5 katha of land.

6.2 Requirement of time to raise fundIt is difficult to estimate the time frame for the Forum to raise required amount of fund for the plant.The Forum consists of 22 members who pay Tk 110,000 per month. If they collect usual amount ofmonthly subscription @ Tk 5,000, it may take more than 24 months. After 24 month

s, the total

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amount will be Tk 26,40,000. But it is learnt that they are planning to raise alarge amount of fund at atime from each member so that they can establish a seasoning plant within 9- 12months.

6.3 Seasoning of different species

Four timber species, namely Teak, Chapalish, Gamar and Garjan are used by the memberenterprises. Chapalish can be seasoned with minimum time and Teak takes normallyone day morethan Chapalish timber. Garjan does not pose any difficulty, but dries a little bit slowly. Gamar is aproblematic species which is the slowest among the commercial timber species andtakes aboutthree times longer than that of Teak and chapalish (Sattar et al . 1991).

Ideally, one species of same size of timber should be dried in a single charge irrespective of using

gas or electricity as a source of energy. If it necessitates drying more than one species, then a specialkiln drying schedule has to be employed (Sattar, 1980). For this, appropriate kiln drying scheduleshave to be developed for the particular type of wood seasoning kilns.

6.4 Seasoning of different sizes of timberIt is apparent from Table-3 that the thickness of 0.75, 1.00 and 1.5 inches planks are the mostly usedsizes. These thicknesses make about 81.8%, and the rest all other sizes make 18.2% of the use. So,the planks representing 81.8% thickness class fall under the priority group which needs to be

seasoned. Like timber species, it is also an ideal condition to season differentsizes of timberseparately. But, if necessary, it is possible to season two or three sizes of timber together following aappropriate kiln drying schedule.

6.5 Time to install a seasoning plantThe supplier has mentioned that the machineries will be delivered within 3- 4 months from the date ofreceipt of a firm order along with an advance of 40% of the order value. The kiln chambers need to beconstructed locally. This can be done after getting the structural design from the supplier within twomonths. So, the total time will be about 5- 6 months.

6.6 Technical support from the supplierThe supplier will provide technical support in respect of installation and operation of seasoning kilnsand other machineries. The services for this will be charged which will includeper diem for theengineer/technician, to and fro expenses from Kolkata and local conveyance pluslodging andboarding. The total expenses may be about Tk 60,000 for the Indian supplier.

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7.0 MANAGEMENT OF THE FORUM AND THE SEASONING PLANT7.1 Management of the ForumFor any collaborative effort, the principal concern lies with its sustainability. There are many people init, and it is natural that they have conflicting opinions about the management and activities. These

may even threaten the existence of the forum. But all these need to be handled rationally with propermanagement.There is no alternative than capable and committed leadership for its success. The owners of themember enterprises expressed high priority on this aspect during discussion withthem. They havealso stressed the importance on other personal qualities of management personnelin addition tofinancial dealings (Annex-14). Considering all these, the member enterprises have formed a Forumwith the following structure:

a) Convener - 1, b) Secretary -1, and c) the rest 20 are general members.Within this framework, certain policies have been adopted for its management which are as follows:

i) Monthly subscriptions will be collected @ Tk 5,000 per member.

ii) There will be a meeting in every month with all members. All issues regarding the Forum will be

discussed and decision should be taken in the meeting.

iii) There will not be any withdrawal of fund within a year.

It is learnt that the members are thinking to raise a large amount of fund at atime from each memberso that they can establish a seasoning plant within 9- 12 months.

For proper management of the Forum, it should be registered as a limited companywith the properauthority. It will be then easier for them to arrange bank loan for installing the seasoning plant, ifthere is any shortage of fund. The management committee of the limited company will be responsiblefor managing the seasoning plant.

7.2 Management and operation of the seasoning plantA seasoning plant is meant for drying of sawn timbers up to certain thickness class to a desired 12%moisture content. It is equipped with some specialized equipments depending on the type and designof seasoning kilns. The steam heated compartment type is comparatively cheaper and easier thanother modern designs. As mentioned earlier, this design is considered for the forum. For itsmanagement, the following structure is recommended :

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7.2.1 Personnel4For this type of seasoning kiln, one boiler is needed for the production of steam which provides bothheat and humidification to the kiln. There will be boiler man for this purpose.There will be electricmotors, compressor, other electric accessories, etc which will necessitate an el

ectrician. Above all,there will be kiln operators to run the seasoning plant. Considering the economyof the forum, thefollowing employees are suggested :

a) Kiln operator/Foreman -One : Regularb) Kiln operator/cum Electrician -One : Regularc) Boilerman -One : Regulard) Boilerman Associate -One : Regulare) Kiln operator Associate -One : Regular

d)Labourer - Four : Occasional

7.2.2 Qualification, salary and other facilitiesa)The Kiln operator/ Foreman should be at least SSC and Trade Certificate holder inmechanical works and should have some experience in the line. His salary may befixed upaccording to his experience, but it may be around Tk 5,000 - 8,000.

b)The Kiln operator cum Electrician should preferably be SSC and Trade Certificate

holder inElectrical works and some experience in the line. His salary may be fixed up atTk 4,000 6,000.

c) The Boilerman should preferably be SSC and Trade Certificate holder in boilerworks withsome experience in the line. His salary may be fixed up at Taka 4,000 - 6,000.d) The Boilerman Associate should be Trade Certificate holder in boiler works who has readupto at least class VIII. His salary may be fixed up at Tk 3,000- 5,000.e) The Kiln operator Associate should be Trade Certificate holder in mechanical/electricalworks who has read upto at least class VIII. His salary may be fixed up at Tk 3,000- 5,000.

The seasoning plant will run 24-hour a day till the end of seasoning of timber which may take 7 15days. For this, the employees have to work on two- three shifts basis. Two employees, one kilnoperator and another boilerman, can do this job at a time. The Associates will also work as Kilnoperator and Boilerman. It will be convenient for both the employees and the employer if there is aprovision for residential accommodation for at least two persons. Then, they can

be summoned asand when needed.



7.2.3 Practical training on operation4 This number of personnel is not required to run the kiln drying. The owner canrun it with less number ofpeople efficiently

15



These employees will have basic vocational training on specific fields, but willnot have experience onkiln operation. So, a thorough practical training need to be imparted to all ofthem. The Kiln operatorsand Assiciates are also required to be trained on boiler operation. It means, inthe absence of some

one, other employee should be able to do the job properly.

7.2.4 Maintenance of machineriesThe operational and maintenance guidelines will be provided by the manufacturersfor the seasoningkilns and boiler. These guidelines should be followed properly. Maintenance of these machineries willinvolve mechanical, electrical and boiler works for which one of them will be able to perform theparticular job. Once they are accustomed to these, there will be no problem to do the regularmaintenance work. It is also expected that the manufacturer will provide some in

itial maintenancetraining.

8.0 ALTERNATIVE OPTION FOR STEAM HEATED SEASONING8.1 Solar seasoningIt is already mentioned that the members of the Forum are very keen to establisha seasoning plantfor seasoning timbers. But if it takes a long time to raise the required amountof fund for the steamheated kilns, then an alternative option may be considered. For the interim period, solar seasoning isthat option. It has been discussed earlier (Section 3.2.2) that commercial solarkilns were installed

by public and private enterprises because of good performance, easy operation and low cost ofconstruction. It may also be mentioned here that solar kilns can be constructedusing all localmaterials (Sattar,1991).

8.2 Economic aspects of solar seasoningThe most advantage of the solar kiln is its economic aspects. The cost of construction of two 200 ft³capacity solar kiln is estimated at Tk 160,000 (Annex- 20). The cost of seasoning of 1.0-inch and1.5-inch Teak/Chapalish timbers has also been estimated. It is presented in Table-6. The details ofthe calculation are shown in Annex-21.

16



If the economic aspects are considered, solar drying is very lucrative. The costof seasoning per ft³ isonly Tk 37.4 for 1.0-inch timber and Tk 52 for 1.5-inch timber. So, it is the cheapest one. Moreinteresting is its pay back period. It is found that the investment of Tk 160,000 for two solar kilns can

be paid back in only 6.3 months for combined drying. It may be mentioned that the life of a solar kilnis 10 years.

Table- 6:Seasoning cost of Teak and Chapalish timbers and other economic aspectsusing 200 ft³ capacity solar kilns

Sl.No.Particulars Timber of 1.0- inchthick

Timber of 1.5inchthick1 Output of seasoned timber per annum 3,600 ft³18 charges:(18 days/charge)2,400 ft³(12 charges:28 days/ charge)2 Total recurring expenditure(land rent+ electricity+ operation+ loading &unloading)111,600 101,9403 Total capital investment

(initial investment+ working capital)107,900 105,4854 Total cost(recurring exp+ interest on total capitalinvestment + depreciation)134,706 124,7085 Solar seasoning cost/ ft³ = Total cost/output Tk 37.4 Tk 52.06 Return on investment (%) 281.7% 144.0%6 Pay back period 4.3 months months

8.3 Other aspects of solar seasoningFrom the past experience it is found that solar drying is technically sound andeconomically viabletechnology (Sattar, 1987, 1991). But its only drawback is its drying time compared to conventionalsteam heated drying. It takes a long time to fully season the timber round the year. Normally, it takesabout double time during the winter and pre-/post- winter periods (Sattar 1994).During rainy season,solar kiln absorbs whatever solar radiation available, and dries timber, but very slowly. This is why theaverage drying time is long.

9.0 WOODWORKING MACHINERIESWoodworking machineries are used for preparing the sawn planks into different sh

apes and sizesprior to manufacture products. There are various types of them, but the main machineries include



planer, circular saw, jointer, moulder, mortiser, rip saw, turning lathe, router, etc. Each machine has

17



its own specific function. So, these machines are used for making furniture andrelated products inmedium to big furniture enterprises.The Forum has fund constraint at this initial stage and thus cannot afford to procure all of theminvolving quite a substantial amount of money. So, their acquisition of machiner

ies is considered to be

restricted to basic ones. These are as follows :

1) Circular saw, 2) Thickness planer, 3) Jointer and 4) Moulder

9.1 Quotations of woodworking machineriesThe specifications of these four types of machineries were prepared. The local suppliers as well asforeign suppliers and manufacturers were contacted. They were requested to submit the quotations inrespect of these machineries within the scheduled time. Initially there were man

y responses, butfinally the following local and foreign suppliers/manufacturer have submitted quotations :

a) Galaxy Electro Power Ltd, 119- 200 Nawabpur Road, Dhaka has submitted two price lists, one ofJapan and another of Italy made various machineries (Quotations- 4). These are small woodworkingtools suitable for the individual purposes or small individual enterprises. Forcollective use, heavy dutymachineries are needed. So, none of these are suitable one, and as such are notincluded in thecomparative statement.

b) Abedin Equipment Ltd, B-52 Kemal Ataturk Avenue, Banani, Dhaka has quoted differentwoodworking machineries (Quotation-5). Except one model of circular saw , othersare also smalltools, and are not meant for heavy works. These are available from the ready stock. The offer ofcircular saw is included in the comparison.

c) Aziz Machinery & Tools, 64 Nawabpur Road, Dhaka has quoted for different combinedwoodworking machineries (Quotation- 6). All these are available from the ready stock. These areincluded in the comparison.

d) Luna Enterprise, 91 Nawabpur Road, Dhaka has submitted a quotation of four basic woodworkingmachineries (Quotation- 7). These are included in the comparative statement.

e) One leading manufacturer from India, namely Jai Industries, Ahmedabad has quoted for fourbasic wood working machineries (Quotation- 8). These are included in the comparative statement.

f) Another supplier from India, namely Gangotri Impex has quoted for some machiner

ies (Quotation-9). The relevant machineries are included.



18



9.2 Assessment of the quotationsA comparative statement of all the woodworking machineries has been prepared inorder to assessthem. Table-7 contains the comparative statement.

Table- 7: Comparative statement of quotations of woodworking machineries

Sl Type of machineries AbedinEquipments(Dhaka)AzizMachinery(Dhaka)LunaEnterprise(DhakaJaiIndustries

(India)GangotriImpex(India)Total cost Total cost Total cost Total cost Benapole(from ready (from (import from (C&F + (C&F +stock) readystock)India) taxes+ costupto Dhaka)taxes+ costupto Dhaka)1. Circular saw

Work table size 36X24 5 HP (Heavy duty)-Tk 40,0002.38 HP(Germany)--Tk 65,000Size-36x19 Tk 57,880(ModelJ-535H)-2 Thickness planer18, 5 HP, complete(Heavy duty)--Tk 92,000 Tk 74,020(ModelJ-601Tk 119,947(ModelJ-601)3. Moulder3 HP, complete(Heavy duty)

--Tk 97,000 Tk 70,240ModelJ-504H



-4. Jointer/ Surface planer18, 3 HP, complete(Model J- 118)--Tk 68,000 Tk 66,280 -Tk 80,59510, 2 HP

(ModelJ-116)Sub-total Tk 3,22,000 Tk 2,68,4205. Combined woodworkingm/c : Circular saw,Thickness/ Surfaceplaner, Moulder, Scorer& Mortiser, (China)-Tk 2,20,000(Model-ML393C---6. Combined woodworking

m/c : Circular saw,Thickness/Surface planer,Moulder, Mortiser, 1.5HP-Tk 140,000(Model-ML392E)---7. Planer & Jointer12, 3HP (China)-Tk 65,000(ModelMJ300A)---

9.2.1 Technical aspectThe enterprises of the Forum need heavy duty type basic woodworking machineries.A singlemachine of each type should perform single function at a time continuously. Unlike combinedmachines, this machine will allow different technicians to work simultaneously with their works withoutwaiting for other to finish his work. With these specifications in mind, the machineries have beenevaluated.

19



a) The local supplier, Galaxy Electro Power Ltd, has supplied two price lists of different kinds oftools and machineries, including some woodworking machineries. These are made ofItaly and Japan(Quotation-4). These are also very small portable type equipments. Thus, none ofthese meet the

requirements of the Forum.

b) The local supplier, Abedin Equipments has offered for different machineries (Quotation- 5). Theseare all good quality machineries of German made. But these are small proto-typesand suitable forindividual or very small enterprises. Thus, these machines are not suitable forlarge scale commercialapplication. However, one medium sized circular saw has been shown in the comparison.

c) The local supplier named, Aziz Machinery& Tools has submitted a quotation for t

he combinedwoodworking machineries which consist of from circular saw, thickness planer, surface planer,moulder , mortiser, scorer and planer to jointer (Quotation- 6). These are madein China. These arenot as per requirements of the Forum.

d) The local supplier, Luna Enterprise, has quoted for four machineries which areneeded by theForum(Quotation- 7). The quality of these machineries cannot be adequately judged since no detailedspecifications have been provided.

e) One Indian manufacturer, Jai Industries has quoted for the circular saw, thickness planer,moulder and jointer (Quotation- 8). All of these are heavy duty type machines and meet therequirements of the Forum.

f) Another Indian supplier, Gangotri Impex, has quoted for some woodworking machineries(Quotation- 9). Two relevant machines may be considered.

9.2.2 Economic aspect(a) The price of one circular saw has been quoted for Tk 40,000 by Abedin Equipments. This is of2.38 HP capacity. The individual enterprise may consider this one, but not suitable for the Forum.(b) The price of each set of combined machines offered by Aziz Machinery rangesfrom Tk 2,20,000to Tk 65,000. Like other sets, the machine of the lowest price, i.e., Tk 65,000,is not heavy duty type(Table-7). These are not suitable for the Forum, but the individual enterprise may consider for its use.(c) The prices of machineries of Luna Enterprise are higher compared to those ofIndian supplier, JaiIndustries. The total cost is Tk 3,22,000 (Table-7).20



(d) Jai Industries has offered the lowest prices for all basic machineries. These are heavy duty andare meant for continuous use. The total price of these four machineries is Tk 2,68,420 inclusive oftaxes and transportation upto Dhaka (Table-7).(e) Gangotri Impex has mentioned the price of one Thickness planer as Tk 1,19,94

7 which is exactlythe same type and model of Jai Industries. Jai Industries has quoted Tk 74,020 for this machine. Theprice of a lower capacity Jointer (2 HP) has also been offered higher price thanthat of Jai Industries(Table-7).9.2.3 Overall evaluationConsidering technical and economic aspects, the tender submitted by Jai industries, Ahmedabad,India may be considered for purchase by the Forum. The machineries have met thetechnicalrequirements and also offered the lowest price. The cost of these machineries ha

s been detailed inAnnex-22.

10.0 RECOMMENDATIONSBased on the feasibility study, the following recommendations have been made forthe Forum offurniture enterprises, Rokeya Sarani Furniture Development Industries :

1(a) Two compartment type seasoning kilns of 500 ft³ each using gas in the boilerbe installed. Awater treatment plant should be procured along with the kilns to supply iron-free water to the boiler.Thus, the quotation submitted by Gangotri Impex, 20B Nimtala Ghat Street, Kolkat

a, India beaccepted.

(b) For these fixed type kilns, 5-katha land should preferably be owned by the Forum. If it is notpossible, then the land should be rented for a long term basis, at least for 10years. The pay backperiod of the initial investment is, however, less than three years.(c) If it takes a long time to raise sufficient fund for the steam heated kilns,then alternative optionshould be considered. It is recommended that at least two solar kilns of 200 ft³ capacity beconstructed. The initial investment of Tk 160,000 will be paid back in only 6.3months.2. The basic woodworking machineries quoted by Jai Industries, Ahmedabad, India arerecommended to be purchased. These are heavy duty machines, and are suitable forsimultaneousrunning for the member enterprises of the Forum.21



11. 0 REFERENCES1.Anon. 1991. Survey report on cottage industries of Bangladesh. BSCIC, Dhaka. 65pp2.Anon. 1978. Maximum permissible moisture content in timbers for making different

products.Bangladesh Standard and Testing Institute, GOB. 10 pp3.Ali, M.O. Sattar, M. A. and Talukdar, Y.A. 1980. Kiln drying studies on 1 ¼ -inchtimber species ofBangladesh. For. Res. Inst. Bull. 6, Chittagong. 10 pp4.Karim, B. 2004. Personal communication, Paris Furniture, Mirpur, Dhaka5.Kibria, M.G., Sarker, D. C., and Islam, S. S. Forest Statistics of Bangladesh.2001. Bulletin 4,Forest Economics Division, BFRI, Chittagong. 119 pp

6.Sattar, M. A. and Ali, M. A..1969. Air drying studies on 1" and 2" garjan timber. Forsetdale News.2(1): 29-427.Sattar, M. A. 1980. Kiln drying schedules for indigenous timbers of Bangladesh.Bulletin No. 4,Wood Seasoning Series, BFRI, Chittagong. 11 pp8.Sattar, M. A. 1982. Solar kiln for seasoning of timber in Bangladesh. For. Res.Inst. Bull. 8 (WoodSeasoning Series), Chittagong. 10 pp9.

Sattar, M. A. 1983. Properties and uses of teak wood. Bulletin No. 8, Timber Physics Series,BFRI, Chittagong. 7 pp10.Sattar, M. A. 1987. Comparative studies on wood seasoning with a special reference to solardrying. Bano Biggyan Patrika. 16 (1&2) : 30-4211. Sattar, M. A. 1988a. Lumber stacking and drying. In: South Asiaworkshops on sawmillproductivity improvement. APFIDG., RAS/86/048, Chittagong, Bangladesh: 13-1-1212. Sattar, M.A. 1988b. Prospects of wood seasoning in Bangladesh. Bano Biggyan Patrika. 17(1&2) : 80-8813. Sattar, M. A. 1989. Construction and operation of solar kilns for seasoningtimber in Bangladesh.RERIC International Energy Jour. (Thailand). 11 (2) : 41-5014. Sattar, M. A. 1991. Seasoning of timber by using solar energy. In : 10th World Forestry Congress,Paris, French : 327-33215. Sattar, M. A., Sarkar, S.B.and Talukdar, Y.A.. 1991. Kiln drying of gamar (Gmelina arborea)using varying sticker thickness and drying schedule. Bangladesh Jour. of ForestScience. 20(1&2) : 49-5416. Sattar, M.A. 1994. Major energy saving by use of solar timber drying in deve

loping countries.Renewable Energy(England). 5(1) : 457-464.17.



Sattar, M. A. and Bhattacharjee, D. K. 1998. Physical and mechanical propertiesand uses oftimbers of Bangladesh. Booklet, Bangladesh Forest Research Institute, Chittagong. 64 pp18. Sattar, M. A. 2002. Review of marketing of wood in Bangladesh. Intercooperaion, SwedishAgency for Development and Cooperation. 65 pp

22



ANNEX - 1TERMS OF REFERENCE (TOR)

A.Background

KATALYST is mandated to enhance the private sector in Bangladesh by improving the capacity ofthe private sector to ameliorate its growth and competitiveness. Business-like interventions areneeded to lead to a sustainable result without negative side effects. KATALYST operates in severalproducts and business service sectors of which furniture sector is one.

The furniture industry is mostly concentrated in Mirpur area where about 400 small to medium scalefurniture and sawmill industries are clustered in one zone. But the most important processing

technology like seasoning is lacking in that area. As a result, either unseasoned or partially seasonedtimbers are used for making end products in almost all cases. Seasoning is considered to be a vitallyessential technology for the furniture industries, because it enhances the quality of the products byimparting improved physico-mechanical properties, increased service life and other favourableproperties. Because of these distinct advantages, there is a growing interest toadopt this technology,but the individual enterprise is handicapped due to a large investment involvedin adopting thetechnology.

As a part of the activities, a vision workshop was organized by the Industry andRural Servicescomponent of KATALYST where a tremendous enthusiasm was observed among the owners offurniture and sawmill industries to have seasoning plants on collective basis. They have alreadyformed a Forum and have started to raise fund for this purpose, and approached KATALYST to offerthe technical assistances right from the feasibility study to installation, operation, training and otherrelevant aspects of interest to improve the quality of timber and its products.The assignment aims atstrengthening the furniture and sawmill industries in this respect. Initially, the feasibility aspect will bedealt with and after completion of this first phase, subsequent activities willbe taken up. It is veryimportant that seasoning plant be a sustainable one despite the fact that the entrepreneurs areenthusiastic and find it profitable. Accurate information on demand and supply side would be properindicators for this purpose.

B.Objectives

1.Study the feasibility of installation of seasoning kilns through collective effort of the owners of



the furniture industries at Mirpur area; the feasibility must cover answer to the followingquestions along with other related issues : What is the current demand? How the demand is met at present? What would be the approximate increase in cost if seasoning is done? Are the

entrepreneurs ready to bear the cost? Would it be profitable enough for themanufacturers to use seasoned timber? What should be appropriate capacity of seasoning kiln to satisfy the collectivedemand? What if there are different types of timber or different sizes of planks? How long it may take to season to season a particular amount of planks? What may be a feasible type of kiln- electric, gas-fueled or solar?

What would be a preferable area for the installation of a seasoning plant? What would be a dependable management and maintenance structure for theseasoning kiln?2.Collect detailed information about the seasoning kilns from local and foreign sources withspecific information on the following aspects : What the different price-ranges offered by the suppliers for seasoning kilns ofdifferentcapacity?

Hong long it may take to install a seasoning kiln starting from placing an orderfor akiln? How many people are required to run, operate and maintain a seasoning kiln?23



Will the supplier provide any technical support in installation/ operation andmaintenance of the plant? What might be the best offer from the dealers?3.

Collect detailed information about basic woodworking machinery from local and foreignsources.C.Methodology and Activities1.A 4- 5 member team will be formed comprising the representatives of the entrepreneurs; theconsultant will work directly with them for the communication in the cluster;2. Representative furniture and sawmill industries will be visited at Mirpur andkey timber traders,sawmillers and furniture manufacturers will be consulted;

3.The right type, size and specifications of the seasoning kilns and basic woodworkingmachinery required for the Mirpur area will be identified;4.The mechanism and operation of different types of existing seasoning kilns at Savar/ andChittagong (BFRI and BFIDC complex) will be demonstrated to the members of the Forum(i.e. circular saw, jointer, thickness planer and moulder) will be collected from both local andthrough exposure visits;5. Details of manufacturers

and suppliers of the seasoning kilns and basic woodworkingmachinery foreign sources like India/China/Taiwan/Korea/Indonesia/other throughvisit tolocal agents and correspondences, and then proper specifications for seasoning kilns andwoodworking machinery will be finalized;D.Work PlanActivityNo.Details of the works Tentative dates No. ofdays1 Initial day-long discussion session with the key actors 25 July 2004 12. Formation of a core team, planning and discussion 2- 3 Aug 2004 23. Designing one set of interview guidelines for the furnitureand sawmill industries and for the suppliers of seasoningkiln6- 7 Aug 2004 25 Visit and interview with different types of furniture andsawmill industries at Mirpur and consult the key personsto collect requisite information9- 12 Aug 200414-17Aug 200444

6. Assessment of the needs of the furniture and sawmillindustries in respect of seasoning kilns and basicwoodworking machinery



21-24Aug 2004 47 Testing the adequacy of the existing drying methodadopted by the furniture industries29-30Aug 2004 28. Collect relevant information, particulars and photographsof different types of seasoning kilns (electric, gas andsolar heated) from BFRI and BFIDC at Chittagong

7- 9 Sep 2004 39. Collection of detailed information about the kilns andmachinery from local and foreign sources through visitsand correspondences11-16Sep 200418-20Sep 20046310 Collect relevant information of gas-fired seasoning kilnfrom Hatil Complex at Savar/ Kashimpur23 Sep 2004 111. Identification of the proper specifications based on the

needs and capability of the industries25-28Sep 2004 412 Preparation of the final report covering the total activities/works10-12 Oct 2004 3Total 37

24



E. DeliverablesDeliverable Due date for submissionThe final report will contain details of survey findings on feasibilityof the seasoning plant and also include type, size, price and originof the machinery, and recommendation of proper specifications ofseasoning kilns and basic woodworking machinery for the Forum

20 Oct 2005Meeting minutes After each meeting onweekly basis

ANNEX- 2Rokeya Sarani Furniture Development Industries (RSFDI)

Sl. No. Member enterprises Owner Address1 Crystal MeublesFurniture ShopMr. M. Quamrul Huda

Convenor218/6, West Kafrul, BegumRokeya Sarani Road, Mirpur2 Paris Furniture Mr. M. Bazlul KarimSecretary607, Kazipara, Begum RokeyaSarani Road, Mirpur3 Rangamati Complex( 2 members)Mr. M. Jalilur Rahman 494, North Kazipara, BegumRokeya Sarani Road, Mirpur4 Hatil Complex Mr. Selim H. Rahman 1243, East Monipur, BegumRokeya Sarani Road, Mirpur

5 Dhaka Furniture Mr. S. M. A. Awal Plot # 13, Main Road, BegumRokeya Sarani Road, Mirpur6 Shital Complex Mr. M. Alamgir Prodhan 495/5, Monipur, Kazipara,Rokeya Sarani Road, Mirpur7 Sandwip Complex Mr. M. Mainur Rahman 613/1, North Kazipara, BegumRokeya Sarani Road, Mirpur8 Bhai Bhai Furniture Mr. M. Jalilur Rahman 494, North Kazipara, BegumRokeya Sarani Road, Mirpur9 Decorus Furniture Mr. M. Fazlul Hoque 615, North Kazipara, BegumRokeya Sarani Road, Mirpur10 Furniture Garden Mr. M. Mesbahuddin 220, Kazipara, Begum RokeyaSarani Road, Mirpur11 Mamata Furniture(2 members)Mr. Habibur Rahman 218/6,West kafrul, BegumRokeya Sarani, Mirpur12 Hazrat Shah ParanFurnitureMr. M. Tofazzol 20//2/A, West Kafrul, BegumRokeya Sarani Road, Mirpur13 Dorian Furniture Mr. Aminul Islam 205/5, West Kafrul, BegumRokeya Sarani Road, Mirpur14 Shawdagar Complex Mr. M. Nurul Islam 604, Kazipara, Begum RokeyaSarani Road, Mirpur15 Rawshon Complex Mr. N. Islam Salim 618, Kazipara, Begum Rokeya

Sarani Road, Mirpur16 Furnitech Furniture Mr. Azazur RahmanShuva



622, Kazipara, Begum RokeyaSarani Road, Mirpur17 Aleef Furniture(2 members)Mr. A. K. Azad 613/1, Kazipara, BegumRokeya Sarani Road, Mirpur

25



18 Madina Furniture Mr. M. A. Hakim Sarkar 50, Sheorapara, BegumRokeya Sarani Road, Mirpur19 Khaleda Furniture Mr. M. A. Khair Molla 586/2, Sheorapara, BegumRokeya Sarani Road, Mirpur

ANNEX 3

Enterprises/ organizations visited and personnel met

Sl. Personnel Enterprises/ organizations Address(a) Furniture Enterprises1 Mr. M. Quamrul HudaProprietorCrystal Meubles Furniture Shop 218/6, West Kafrul, Begum RokeyaSarani Road, Mirpur2 Mr. M. Bazlul KarimManaging DirectirParis Furniture 607, Kazipara, Begum Rokeya

Sarani Road, Mirpur3 Mr. M. Jalilur RahmanDirector Business Dev.Rangamati Complex 494, North Kazipara, BegumRokeya Sarani Road, Mirpur4 Mr. N. M. S. AlamDirectorYa Rab Complex 217/1, West Kafrul, BegumRokeya Sarani Road, Mirpur5 Mr. Selim H. RahmanManaging DirectorHatil Complex 1243, East Monipur, BegumRokeya Sarani Road, Mirpur

6 Mr. M. Mainur RahmanProprietorSandwip Complex 613/1 North Kazipara,BegumRokeya Sarani Road, Mirpur7 Mr. M. Israil MiahDirectorBhai Bhai Furniture 494, North Kazipara, BegumRokeya Sarani Road, Mirpur8 Mr. M. Fazlul HoqueProprietorDecorus Furniture 615, North Kazipara, BegumRokeya Sarani Road, Mirpur9 Mr. M. SolaimanProprietorThe National Furniture 315, East Monipur, BegumRokeya Sarani Road, Mirpur10 Mr. M. K. Akhtar KhanProprietorFurniture Express 632, Kazipara, Begum RokeyaSarani Road, Mirpur11 Mr. Habibur RahmanProprietorMamata Furniture 218/6,West Kafrul, BegumRokeya Sarani, Mirpur12 Mr. M. Tofazzol

ProprietorHazrat Shah Paran Furniture 20/d/2/A, West Kafrul,BegumRokeya Sarani Road, Mirpur



13 Mr. Aminul IslamProprietorDorian Furniture 205/5, West Kafrul, BegumRokeya Sarani Road, Mirpur14 Mr. M. Nurul IslamProprietorShawdagar Complex 604, Kazipara, Begum Rokeya

Sarani Road, Mirpur15 Mr. N. Islam SalimProprietorRawshon Complex 618, Kazipara, Begum RokeyaSarani Road, Mirpur16 Mr. M. MesbahuddinProprietorFurniture Garden 220, Kazipara, Begum RokeyaSarani Road, Mirpur17 Mr. Azazur RahmanProprietorFurnitech Furniture 622, Kazipara, Begum Rokeya

Sarani Road, Mirpur18 Mr. A. K. AzadProprietorAleef Furniture 613/1, Kazipara, Begum RokeyaSarani Road, Mirpur19 Mr. Shahjahan KabirDirector Business DevModern Furniture Complex 6, North Kazipara, BegumRokeya Sarani Road, Mirpur20 Mr. Arifur RahmanProprietorVienna Furniture 752/1, Sheorapara, BegumRokeya Sarani Road, Mirpur21 Mr. M. M. Alam

ProprietorWoodman Furniture 1038, Sheorapara, BegumRokeya Sarani Road, Mirpur22 Mr. M. Zahirul Islam Baghdad Furniture 752, Sheorapara, Begum

26



2323252629(b)

303132333435(c)3637383940

41424344ProprietorMr. M. A. Hakim SarkarProprietorMr. M. A. KaderProprietorMr. M. A. Khair MollaProprietorMr. S. M. A AwalProprietor

Mr. S.H. RahmanProprietorSawmills/ TimbertradersMr. B.M Jahurul HoqueProprietorMr. Siddiqur RahmanProprietorMr. Abu Bakar SiddiqueProprietorMr. M. Aminul IslamDirectorMr. Rafiqul IslamProprietorMr. M. Nurul IslamProprietorOther organizationsDr. M. Ashraful HaqueDirectorDr. N. A. SiddiquiDivision HeadDr. M. Nazrul IslamDivision HeadMr. M. A. KhalequeDivision Head

Mr. S. M. A. RahmanAsst General ManagerMr. S. M. A. Latif



Manager, ProductionMr. M. Shakil AhmedAsst General ManagerMr. M. Saiful IslamAsst General ManagerMr. Nurul Alam SikdarManager, Marketing

Madina FurnitureLong Life FurnitureKhaleda FurnitureDhaka FurnitureShital ComplexSonali Timber Trade SawmillAl Makka SawmillNesarabad TimberPopular Timber TradersNational Timber ComplexUzzal TimberBangladesh Forest Research

InstitutedododoBangladesh Forest IndustriesDevelopment CorporationdodododoRokeya Sarani Road, Mirpur50, Sheorapara, Rokeya SaraniRoad, Mirpur

49, Sheorapara, Begum RokeyaSarani Road, Mirpur586/2, Sheorapara, BegumRokeya Sarani Road, MirpurPlot # 13. Main Road, BegumRokeya Sarani Road, Mirpur495/5, Monipur, Kazipara,Rokeya Sarani Road, Mirpur168, Senpara, Begum RokeyaSarani Road, Mirpur?, Senpara, Begum RokeyaSarani Road, Mirpur152, Senpara, Begum RokeyaSarani Road, Mirpur? Senpara Begum RokeyaSarani Road, Mirpur? Begum Rokeya Sarani Road,Mirpur167, Senpara, Begum RokeyaSarani Road, MirpurSholashahar, ChittagongdododoCabinet Manufacturing Plant,

Section- 2, Mirpurdo-BFIDC Complex, Kalurghat



Dodo

27



ANNEX- 4QUESTIONNAIRE REGARDING FURNITURE INDUSTRY INMIRPUR ZONE

1. GENERAL INFORMATION

a) Name of the industry :b) Address :c) Year of establishment :d) Owner/designation :e) Phone/e-mail address :

2. TYPE OF INDUSTRYa) Fully mechanized/ Semi-mechanized/ Manual : (Tick)b) Medium/ Small/ Other : (Tick)c) Total number of employees :

3. MACHINERYa) Mention the major machinery and equipments :

b) Mention the origin of the machinery/equipments : Local/ Foreign (India/ China/ UK/ Germany/Italy/ Other (mention ) : (Tick)c) If foreign products, how these were procured? : Local market/ Imported : (Tick)

4. RAW MATERIALSa) What type of raw materials are used ? : Sawn timber/ Plywood/ Particle board

: (Tick)

-% of sawn timber used :b) Name the major timber species: Teak/ Chapalish/ Gamar/ Garjan/ Other (mention): Tick)c) Price of sawn timber/cft: (Tk): Teak- , Chapalish- , Gamar-

Garjan-, Other (mention) -

d) Why the particular timber species are used ? : Easy availability/Cheaper/ Better quality/Preferred by the customers/ Other (mention) : (Tick)

e) Mention the total amount of sawn timber used per month (in cft) :f) Indicate the amount of sawn timber actually be for seasoning (cft) :g) From what sources timbers are procured ? : Local market /Imported/ Both : (Tick)h) If imported, mention % of the total :

i) Mention the country of origin : Myanmar/ Malaysia/ Nepal/Bhutan/ Indonesia/Singapore/ Nigeria/Other (mention) : (Tick)

28



5.SIZES OF TIMBER useda)Mention the sizes of timber which are commonly used (in inch) ? : 0.50/ 0.75/ 1.00/ 1.25/

1.50/ 1.75/ 2.00 : (Tick)b) What are the sizes used mostly ? :c) How these sizes are obtained ? : Converted from logs/squares in own sawmill/In other

sawmill/ Purchased required sizes from local market/ Purchased sizes from foreign market:(Tick)

6.PROCESSING TECHNOLOGY

a)What processing technology is adopted for timber prior to manufacture of products ? :Seasoning/ Chemical treating / Other (mention)/ None : (Tick)

b)If seasoning technology is adopted, what method is used ? Kiln drying/ Air drying/ Solar drying :(Tick)

-Do you think that your adopted method is adequate for proper seasoning ?Yes/ No: (Tick)

c)If you are not adopting proper seasoning , do you think it is due to the following one or morereasons? : (Tick)

-Lack of seasoning facility-Unable to install own seasoning plant-Increased seasoning cost involved-Lack of technical knowledge-Dont know about seasoning-Other (mention) :d) Do you know t hatthe quality of timber and its products can be improved throughseasoning? : Yes/ No : (Tick)

e) Are you confident that better price and market can be fetched if products aremade fromseasoned timber? : Yes/ No : (Tick)

f) Do you know that customers are increasingly interested in purchasing productsmanufacturedfrom seasoned timber? : Yes/ No : (Tick)

g) If yes, mention the percent of customers who are interested even with reasonably higher cost :(%)



g)Do you know that it is pre-requisite condition to manufacture products from seasoned timber, incase of export ? : Yes/ No : (Tick)

h) If ( d, e, f, g ) are yes, will you be interested in adopting the seasoning t

echnology presently/ inthe future? : Yes/ No : (Tick)

29



i) If yes, will you be ready to bear the additional cost involved in seasoning?:Yes/ No: (Tick)

7. MANUFACTURED PRODUCTSa)Name the major products :

b)In what markets these are sold ? : Local market/ Foreign market/ Both : (Tick)

c)Name the products which are exported, if any :

-% of the total products :d) Name the products which are imported, if any :-% of the total products :e) If not exporting now, is there any planning for export in the future ? : Yes/No : (Tick)

f)Mention the problems /bottlenecks for not exporting the products presently:

(i) Technical :(ii)Financial :(iii)Policy level :(iv)Other :8.DESIGN OF PRODUCTSa)

What designs of products are used : Local /Foreign/ Both : (Tick)

b)If any foreign design is used, mention the reason :

c) Mention the total foreign designs used (%) :

d)How the foreign designs were obtained : Catalogues/ Foreign visit/ Imported items/ / Other(mention) : (Tick)

e) Are you interested in developing/obtaining improved designs ? : Yes/ No : (Tick)

30



9.COST OF PRODUCTSa)Mention the approximate cost of the manufactured products per month (in lakh) :(Optional)

10.SUGGESTIONS/ FURTHER NEEDSa)After completion of the feasibility study, do you need further technical assistance ?: Yes/ No :(Tick)

b)If yes, what specific assistance are needed ? : (Tick)

(i)

Full guidance/technical assistances including procurement, installation, training, operationand developing proper seasoning schedules(ii)Training, operation and developing seasoning schedules(iii)Operation and developing proper seasoning schedules(iv)Only training of the operators(v)Only developing seasoning schedules(vi)None of these

c)You have formed a forum specifically for installing a seasoning plant on collaborative basis,what is your idea about ?

(i)Management of the forum to run it on sustainable basis :(ii)Management of the seasoning plants to run it on sustainable basis :31



ANNEX- 5General information about the member furniture enterprises at Mirpur area

Sl.No.

Particulars Frequency Percent Cumulativepercenta) Nature of industries: i) Mechanized 1 4.5 4.5ii) Semi-mechanized 6 27.3 31.8iii) Manual 15 68.2 100Total number of industries 22 100b) Size if industries : i) Big1 4.5 4.5ii) Medium 12 54.6 59.1iii) Small 9 40.9 100Total number of industries 22 100c) Type of machinery : i) Fully mechanized0 0 0ii) Only hand tools 14 63.6 63.6

iii) Both hand/ machine 8 36.4 100d)Place of procurement of machineryi) Localii) ForeignTotal number of industries using machinery3710307010030

100

ANNEX 6

Information regarding raw materials, particularly timbers used by the furnitureenterprises

Sl. Type of raw material Average RangeNo. Percent Min. Max.a) i) Sawn timber 80.8 70 90ii) Plywood 10.7 10 20iii) Particle board 8.5 2 10b). Type of timber species Av. Percent Rangeof useFrequencyof industriesPercenti) Teak 70.8 41 100 22 100ii) Chapalish 11.5 6 30 21 95.5iii) Gamar 8.6 8 20 18 81.8iv) Garjan 9.1 9 30 22 100c) Price of timber species Average RangePrice/cft (Tk) Min. Maxi) Teak 1300 1000 1500ii) Chapalish 877 800 1000

iii) Gamar 785 700 850iv) Garjan 836 750 900



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ANNEX - 7Information about thickness of timber mostly used and how these are obtained

Sl. No. Mostly used thickness ofplanks (inch)

Percent Timbers are obtained fromOwn sawmill Other sawmilli)ii)iii)iv)v)vi)vii)0.751.001.25

1.501.752.00Other thicknessTotal industries : 2246.220.26.515.45.44.12.2100

8 14(36.4%) (63.6%)

ANNEX- 8Information regarding reason/s and amount of use of these timbers

Sl. No. Why these particular timbers are used Frequency Percenta) i) Easy availableii) Cheaperiii) Better qualityiv) Preferred by customersTotal industries2202222221000100100100b) Amount of sawn timber and its requirement forseasoning/month

Averageamount (cft)i) Total amount used



ii) Amount needed for seasoningiii) Source of procurementTotal industries (excluding one big industry- Hatil Complex)230120Local21

ANNEX- 9Information about the processing technology used by the enterprises

Sl. No. Type of technology Frequency Percent Cumulativepercenta) i) Seasoningii) Chemical treatmentiii) Other (Improper seasoning)Total industries4

-182218.2-81.810018.218.2100b) What method seasoning Frequency Percent Cumulativepercenti) Kiln seasoning

ii) Solar seasoningiii) Air seasoningTotal industries40182218.2081.810018.218.2100c) How they assess their method ofseasoningProper Inadequate Dont knowCommentsTotal industries : 224 18 -

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ANNEX - 10Specific reasons for not adopting seasoning and awareness about it

Sl. No. Reasons for not adopting proper seasoning method a No. of ind. repliedYes (%) No (%)

1. i) Lack of seasoning facility 21 (95.5) 1 (4.5)ii) Unable to install own seasoning kiln 21 (95.5) 1 (4.5)iii) Increased seasoning cost 1 (4.5) 21(95.5)iv) Lack of technical knowledge 21(95.5) 1 (4.5)v) Dont know about seasoning 0 22Total number industries 22 (100)2. i) Do they know/ think that by seasoning-Quality of timber and products can be increased 22(100) 0-Better price can be fetchedii) Do they know/ think that :22(100) 0- Customers are increasingly interested 22(100) 0

-Customers are interested even with higher costiii) Are the industries ready to :22(53) 0- Bear the cost for seasoning kiln/s 22(100) 0Total number of industries 22(100)

ANNEX- 11Information regarding manufactured products

Sl. No. Manufactured products/Marketing/Planning Frequency Percent1.2.

3.Products : i) Usual furniture itemsii) Usual items with some special onesMarketing : i) Local marketii) Foreign marketiii) Both marketsPlanning for export : i) Presentlyii) In the futureTotal number of industries2222200020221009.010000090.9100

ANNEX- 12Problems/ bottlenecks hindering the present export potentials



Sl. No. Different aspects/ bottleneck Frequency Percent1.2.3.4.

Technical : i) Lack of woodworking machineryii) Lack of seasoning facilityiii) Cannot cope up with local demandFinancial : i) Financially not so solvent to expand andmodernize the factoryPolicy : i) Not declared as an industry like garmentindustryii) Bank loan not given without mortgaging anylandOther : i) Not allotted any govt. plot like cottageindustryTotal number of industries

21211212121212295.595.54.595.595.5

2495.5100

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ANNEX - 13Needs of the furniture industries regarding installation of seasoning plant

Sl. No. Type of specific assistance needed Frequency Percent1.

2.3.4.5.6.-Full guidance including procurement, installation,training, operation and developing drying schedules-Training, operation and developing drying schedules-Operation and developing drying schedules-Only training of the operators-Only developing drying schedules- None of these

Total number of industries 2222-----100-----

ANNEX - 14

Suggestions regarding management of the Forum and the seasoning plant to makethem sustainable

Sl. No. Type of suggestions offered by the key actors Frequency Percent(a) 1 -Run through a management committee/ council 22 100

2 -Select active and capable persons 14 63.63 -Select sincere and honest persons 11 504 -Select sincere and committed persons 8 36.45 -Monthly regular meeting 18 81.86 -Decision after taking consent of each member 3 13.67 -Subscription be regular 10 45.58 -Increase subscription, if necessary 4 18.29 -Financial transaction be fair and transparent 4 18.210 - 10% extra seasoning charge be paid 3 13.611 -Three trusted members for financial operation 3 13.612 -Arrange bank loan after forming Ltd Co. 4 18.213 -No withdrawal of fund within 12 months 3 13.614 -Target installation within 9-12 months 4 18.2Total number of industries 22 100Suggestions offered by the key actors for the Plant(b) 1 -Run by a separate set of staff and supervised directlyby the Forum5 22.72 -Appoint technical staff for the plant 4 18.23 -Appoint a set of employees and train them properly 7 31.84 -Consultant will suggest the structure 11 50.0Total number of industries 22 100

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ANNEX - 15Major commercial wood species with their origin and major uses

SlNo.

CommonnameScientific name Occurance Major uses1. Teak Tectona grandis Hill forests Furniture, construction, other2. Garjan Dipterocarpus spp. do Construction, sleepers, other3. Champa Michelia champaca do Furniture, cabinets, other4. Chapalish Artocarpus chaplasha do Furniture, cabinets, other5. Chickrassi Chickrassia tabularis do Furniture, construction6. Gamar Gmelina arborea do Furniture, construction, other7. Jarul Legerstroemia speciosa do Industrial, other8. Sal Shorea robusta do Construction, other8 Civit Swintonia floribunda do Plywood, other

10. Dhakijam Syzygium grandis do Construction, other11. Telsur Hopea odorata do Construction, other12. Batna Quercus sp. do Construction, other13. Goda Vitex peduncularis do Construction, other14. Sundri Heriteria fomes Mangrove Construction,hardboard, other15. Gewa Exocaria agalocha do Newsprint, other16. Kankra Brugera conjugata do Construction, other17. Passur Xylocarpus mollocensis do Construction, other18. Raintree Samanea saman All regions Furniture, light work, packing19. Mango Mangifera indica do Furniture, packing, other20 Mahogany Swentonia mahogoni Rajshahi region Furniture, construction21 Silkorai Albizia procera All regions Matches, light work, packing22 Babla Acacia nilotica North-west Machine formats, sp. work

23 Sissoo Dalbergia sissoo do Construction, other24 Tentul Tamarindus indica All regions Construction, other25 Jam Syzygium cumini do Furniture, doors/frames, boat26 Kanthal Artocarpus heterophylllu do Furniture, construction, other

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ANNEX- 16(a)

Estimated cost of construction of two 500 cft capacity steam heated seasoning kilnsas quoted by Gangotri Impex, India

Sl.No. Particulars CFR BenapoleTaxes and transportcharge fromBenapole toDhaka, etcTotal cost1(a) Kiln equipmentsComplete with 2 sets of blowerfans, heating batteries, pipe line,top damper, motor, etc (withoutkiln chambers)

*US $ 5,527x 2= Tk 6,63,240(b) Insulated door - 2 Nos. US $ 869= Tk 52,1403 (a) Boiler (Model BSPG-3)Complete packageUS $ 11,051= Tk 6,63,060(b) Interconnectivity from boiler to 2kilnsUS $ 581= Tk 34,8604 (a) Chimney

MS self/Guy wire supportedUS $ 2,381= Tk 1,42,860(b) Interconnectivity ducting from fanto chimneyUS $ 581= Tk 34,860© Pipeline from boiler to 2 kilns US $ 1,521= Tk 91,260Sub-total US $28,038= Tk 16,82,280 Tk16,82,2805 Construction of 2 kiln chambers-Civil works & other costs(approx.)- local--Tk5,50,000Sub-total --Tk22,32,2806 Water treatment plantComplete with booster pump,materials, etc. excluding civilwork, electrical, etcUS $ 3,227= Tk 1,93,620

Sub-total US $ 3,227= Tk 1,93,620 Tk 1,93,620Sub-total -Tk 2,00,000 Tk 2,00,000



7 Other civil works, electric, etc. -local--Tk 50,000Sub-total Tk26,75,9008 Installation & commissioningcharge

Including board & lodgingTk 60,000Grand total Tk27,35,900

* 1 US $ = Tk 6037



ANNEX- 16(b)

Estimated cost of construction of two 750 ft³ capacity steam heated seasoning kilnsas quoted by Gangotri Impex, India

Sl.No. Particulars CFR BenapoleTaxes andtransportcharge fromBenapole toDhaka, etcTotal cost1(a) Kiln equipmentsComplete with 2 sets of blower fans,heating batteries, pipe line, topdamper, motor, etc (without kiln

chambers)*US $ 6,751x 2= Tk 8,10,120(b) Insulated door 2 Nos. US $ 869= Tk 52,1403 (a) Boiler (Model BSPG-3)Complete packageUS $ 12,987= Tk 7,79,220(b) Interconnectivity from boiler to 2 kilns US $ 581= Tk 34,8604 (a) ChimneyMS self/Guy wire supported

US $ 2,381= Tk 1,42,860(b) Interconnectivity ducting from fan tochimneyUS $ 581= Tk 34,860© Pipeline from boiler to 2 kilns US $ 1,521= Tk 91,260Sub-total US $32,422= Tk 19,45,320 Tk19,45,4225 Construction of 2 kiln chambers- Civilworks & other costs (approx.)- local--Tk6,00,000Sub-total --Tk25,45,4226 Water treatment plantComplete with booster pump,materials, etc. excluding civil work,electrical, etcUS $ 3,227= Tk 1,93,620Sub-total US $ 3,227= Tk 1,93,620 Tk 1,93,620

Sub-total - Tk 2,30,000 Tk 2,30,0007 Other civil works, electric, etc. - local --Tk 50,000Sub-total Tk



30,19,0428 Installation & commissioning chargeIncluding board & lodgingTk 60,000Grand total Tk30,79,042

* 1 US $ = Tk 6038



ANNEX- 17

Estimated cost of construction of two 500 ft³ capacity fixed type seasoning kilnsasoffered by Aditya Casting Udyog, India

Sl.No. Particulars Cost only-PunjabTaxes and transportcharge fromBenapole to Dhaka,etcTotal cost1 Kiln equipments US $ 16106Tk 9,66,360 Tk 2,00,0002 Boiler, complete set US $ 14990Tk 8,99,400

3 Freight charge from Punjab toBenapole(not included)- approxUS $ 834Tk 50,0004 Construction of 2 kiln chambers+ boiler room+ office room -Tk 7,00,0005 Other works & materials Tk 50,0006 Installation & commissioningcharge Including board &lodging-

Tk 60,000Total Tk 27,25,760 Tk 2,00,000 Tk 29,25,760

* US $ = Taka 60ANNEX- 18

Estimated cost of two steam heated seasoning kilns of 500 ft³ capacity as offeredby Incoplan srl, Italy

Sl. No. Particulars *Price: US $ Price : Taka1 Kiln with necessary equipments (ex-factory): 550 cft x 2 38,888 23,33,2802 Control room 1,458 86,8803 Inverter for the kiln 3,358 2,01,4804 Boiler (without electrical hydraulic & connections) 5,513 3,30,780Sub-total 29,52,4205 Freight for the kilns and boiler (Italy to Chittagong port) 2,000 1,20,000Taxes & transport from Chittagong to Dhaka -3,90,0006 Electrical, hydraulic connections, pump, etc -90,0007 Masonary, electrical & others materials & works -3,00,0008 Computer and printer -75,0009 Installation & test by the supplier+ Board & lodging5,114-3,06,840

30,000Total 42,64,260



= 1.225 US$* = 1 Euro = Taka 60

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ANNEX- 19(a)

Details of cost of seasoning of Teak and Chapalish timber using 500 ft³ capacitysteam heated kilns based on Gangotri Impex offer

Sl. . Items 2 units of 500 ft³

1.0-inch timbers2 units of 500 ft³1.5-inch timbers1 Output of seasoned timber per annum 44,000 ft³( 44 charges:7 days/charge)28,000 ft³( 28 charges:12 days/charge)2 Recurring expenditure per annuma) Land rent (Tk 30,000/month)b) Fuel : Gas

(25 m³/hr: 110,880 m³ for 1.0-inch &120,960 m³for 1.5-inch @ Tk 5/unit)c) Electricity(2.2 kw for 22 hrs/day: 29,832 units for 1.0-inch &31,528 units for 1.5-inch timbers @ Tk 4.5/,unitd) Loading and unloading(8 man-day/charge @ Tk 120/labour)e) Operation2 Operators, 1 Boilerman, 2 Associates)f) Waterg) Maintenance(Taka)3,60,000

5,54,4001,34,24442,2402,88,00050,00020,000(Taka)3,60,0006,04,8001,41,87626,8802,88,00050,0020,00Total recurring expenditure 14,48,884 14,91,5563 Capital investmenta) Initial installation :Kiln chamber, equipment,boiler, water treatment plant, etcb) Working capital(¼ of the total recurring expenditure)27,35,9003,62,22127,35,9003,72,889Total capital investment 30,98,121 31,08,789

4 Economic aspectsa) Recurring expenditure per annumb) Interest on the total capital investment



(@ 14%)c) Depreciation(on initial investment @ 2%)14,48,8844,51,93754,71814,91,556

4,53,43054,718Total expenditure 19,55,539 19,99,7045 Kiln seasoning cost per ft³ Tk 19,55,53944,000 ft³= Tk 44.4Tk 19,99,70428,000 ft³= Tk 71.46 Return on investment(assuming seasoning charge of Tk 100/ ft³)*Profit x 100

Investment= 89.4 %Profit x 100Investment= 29.3 %7 Pay back period 18.4 months 56.0 months

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ANNEX- 19(b)

Details of cost of seasoning of Teak and Chapalish timber using 750 ft³ capacitysteam heated kilns based on Gangotri Impex offer

Sl. . Items 2 units of 750 ft³

1.0-inch timbers2 units of 750 ft³1.5-inch timbers1 Output of seasoned timber per annum 66,000 ft³( 44 charges:7 days/charge)42,000 ft³( 28 charges:12 days/charge)2 Recurring expenditure per annuma) Land rent (Tk 30,000/month)b) Fuel : Gas

(35 m³/hr: 155,232 m³ for 1.0-inch & 169,344 m³for 1.5-inch @ Tk 5/unit )c) Electricity(3 kw for 22 hrs/day: 40,656 units for 1.0-inch &31,528 units for 1.5-inch timbers @ Tk 4.5/,unitd) Loading and unloading(12 man-day/charge @ Tk 120/labour)e) Operation2 Operators, 1 Boilerman, 2 Associates)f) Waterg) Maintenance(Taka)3,60,000

7,76,1601,82,95263,3602,88,00070,00020,000(Taka)3,60,0008,46,7202,99,37640,3202,88,00070,0020,00Total recurring expenditure 17,60,472 19,24,4163 Capital investmenta) Initial installation :Kiln chamber, equipment,boiler, water treatment plant, etcb) Working capital(¼ of the total recurring expenditure)30,79,0424,40,11830,79,0424,81,104Total capital investment 35,19,160 35,60,146

4 Economic aspectsa) Recurring expenditure per annumb) Interest on the total capital investment



(@ 14%)c) Depreciation(on initial investment @ 2%)17,60,4724,92,68261,58119,24,416

4,98,42061,581Total expenditure 23,14,735 24,84,4175 Kiln seasoning cost per ft³ Tk 23,14,73566,000 ft³= Tk 35.1Tk 24,84,41742,000 ft³= Tk 59.26 Return on investment(assuming seasoning charge of Tk 100/ ft³)*Profit x 100

Investment= 139.1%Profit x 100Investment= 52.4 %7 Pay back period 8.5 months 19.5 months

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ANNEX- 20Estimated cost of construction of one 200 ft³ capacity solar seasoning kilnbased on BFRI design

Sl. Items Materials Cost(Taka)

1 Swan timber for the superstructure 35 cft, garjan 29,0002 Plywood for partition wall 6 pieces, 3-ply 2,0003 Glass sheet : 5 mm for roofGlass sheet : 3 mm for walls140 sft240 sft5,8005,2004 Blower fan, Aluminium, 24 dia 2 sets 14,0005 Motor, 1 HP, 600- 700 rpm 2 Nos. 8,0006 Carpenter and helpers (10 + 12) Nos. 3,2007 Masonary work: making 6-inch high floor 13ft x 17ft x 0.5ft 8,000

8 Corrugated iron sheet, enamel paint, etc -4,800Total 80,000

ANNEX 21Details of cost of seasoning of Teak and Chapalish using two 200 ft³ solar kilns

Sl.No.Items Size/quantity/other Timber of 1.0inchthickTimber of 1.5inchthick

1 Output of seasoned timber perannum-3,600 cft18 charges:(18days/charge)2,400 cft(12 charges:28 days/ charge)Recurring expenditure/annuma) Land rentb) Fuelc) Electricity for blower fansd) Loading-unloading of timbere) Operation of the kilnf) Waterg) MaintenanceTk5,000/month-5,000 [email protected]/unit6 manday/charge6 manday/charge--Tk60,000

22,50012,96016,200



--Tk60,00022,5008,64010,800--

Total recurring expenditure 111,660 101,9403 Capital investmenta) Initial investmentb) Working capital-(¼ of total recurringexp.)80,00027,90080,00025,485Total of capital expenditure 107,900 105,485

4 Economic aspectsa) Recurringexpenditure/annumb) Interest on total capitalinvestmentc) Depreciation on initial invest-14%@ 10%111,66015,1068,000101,940

14,7688,000Total expenditure 134,766 124,7085 Solar seasoning cost/cft Total costoutputTk 134,7663,600 cft= Tk 37.4Tk 124,7082,400 cft= Tk 52 .06 Return on investment (%)(assuming seasoning chargeof Tk 100/cft)Profit x 100Investment281% 144%7 Payback period 4.3 months 8.3 months

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ANNEX- 22Details of cost of woodworking machineries and other particulars of Jai Industries

Sl. Description of the

machinePriceone uniteachSea freight plusterminal handlingcharge fromAhmedabad toBenapoleTaxes &transport, etcfrom

Benapole toMirpur(approx.)Totalcost1 Circular Saw MachineModel J-535HHeavy Duty, 18 raiseand fall tilting, completewith motor, starter andV-beltsUS $ 720=Tk 43,200

US $ 128= Tk 7,680 = Tk 7,000 Tk 57,8802 Thickness PlanerModel J-60118, complete with 5HP,3 phase electric motor,starter and V-beltsUS $ 975=Tk 58,500Us $ 142=Tk 8,520 = Tk 7,000 Tk 74,0203 MoulderModel J- 504HHeavy duty, completewith 3 HP 3 phaseelectric motor, starter &V-beltsUS $ 942=Tk 56,520US $ 112= Tk 6,720 = Tk 7,000 Tk 70,2404 Jointer /Surface planerModel J-11818Heavy duty, completewith 3HP, 3 phase

electric motor, starterand V-beltsUS $ 815



=Tk 48,900US $ 173= Tk 10,380 = Tk 7,000 Tk 66,280Total US$ 3,452Tk 207,120US $ 555Tk 33,300 Tk 28,000 Tk268,420

1 US $ = Taka 60

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KATALYST on MirpurFurniturePlant

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