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Match manufacture
Alex.K.GeorgeBSF-10-002
FSC 301 Logging,utilization of timber and non timber forest products (2+1)
Contents Match production in IndiaSpecies used in IndiaTypes of matchesMatch manufacturing processUtilization of waste wood and residues.
MatchA match is a small stick of wood with a
solidified mixture of flammable chemicals deposited on one end.
When that end is struck on a rough surface, the friction generates enough heat to ignite the chemicals and produce a small flame.
History
The first known use of matches was in 577 AD northern China.
1826 AD, John Walker of England invented the first friction matches.
In 1831, Charles Sauria of France developed a match that used white phosphorus.
These matches were strike-anywhere matches and were much easier to ignite.
.In 1844, Gustaf Pasch of Sweden proposed
placing some of the match's combustion ingredients on a separate striking surface.
J. E. Lundstrom of Sweden to introduce safety matches in 1855.
First automatic match machine was patented by Ebenezer Beecher in 1888.
Match in IndiaAround 1910 immigrant Japanese families
who settled in Calcutta began making matches with simple hand- and power-operated machines.
Import matches from Sweden and Japan. The first sulphur match that would produced
in South India in 1923, and the first safety match in the form we know today, in 1932.
.Mechanization came to the Indian match
industry in 1924 .First mechanized large scale sector in India
started by wimco.There are now 17,000 units in India from
that 12,000 in Southern India,75% to 90% are situated in Southern India.
Match in Tamil naduP. IyaNadar and A. ShanmugaNadar who went to
Calcutta to learn the process from Purna Chandra Ray, a local businessman, who had learned the trade in Germany.
where a combination of the dry climate, cheap labour and availability of raw materials from Kerala created ideal conditions for match production.
80% of match wood from kerala.5,500 units in Tamil nadu.7,500 match works in Sivakashi and Sattur(55-60%
of India’s requirement).
Wooden match production in India is split into three sector,
1. Mechanized large-scale sector
2. Handmade small-scale sector
3. Cottage sector
Handmade small-scale (67%) and cottage (15%) sectors, Mechanized large-scale sector(18%)
-Tandon (1991)
Raw materialWood(splints)Potassium chlorate- match headRed phosphorous – Side mountCardboards – Inner and outer boxesTissue paper and wax – wax matches.
Qualities of a MatchwoodStraightness of the grainGood fissilityStrength and toughnessGood white colourFreedom from knotsEasily peelableCapacity to absorb paraffinRoundLight weight
Major species.. Ailanthus excelsa (yellow mutty) Ailanthus triphysa, (white mutty) Ailanthus malabarica (mysore mutty), Populus deltoides (cotton wood), Populus tremula (Aspen), Populus balsamifera (balsam poplar) Albizia falcataria, Boswallia serrata, Alnus nephalensis, Erithrina indica, Pinus, Havea brasillensis
Alternate species.. Lania coromandelia Ceiba pendandra Melia dubia Bamboo Simarouba glauca Sterculia vilosa Gmelina arborea.
For box making..Bombax ceibaHavea brasillensisPopulus deltaitus
Types of matches1. Early matches2. Friction matches( John Walker in 1826)
3. Noiseless matches( János Irinyi in 1836)
4. Safety matches(Johan Edvard Lundström)
5. Strike anywhere matches6. Special purpose matches
1. Storm matches2. bengal matches
Size of the matches:Standard=40-43 mmHouse hold=47-55 mmLongest matches=90-200 mm
Raw material needs
manufacturing ProcessEconomics
Industrial processing
manufacturing process
Production of match splints
Wooden logs
Billets
Debarking
Peeling(2.2 mm thickness,280 mm length)
Chopping
Drying a day
Wax coating or polishing
grading
Smoking with hydrogen peroxide & sulphur (3 hours)
Splints production
Billeting Peeling
waxcoating&
Grading Carbonizing &Drying
Chopping
Debarking
BilletingThe logs are converted into small billets,the
size of which ranges from 25-40 cm/1ft length.
Debarking:The billets are manually debarked.
Billeting and Debarking
Peeling:There are three types of peeling machine used
viz.1.Indian peeling machine-manual debarking2.sweden peeling machine-manual
debarking3.chinese peeling machine-no debarking is
neededThe moisture content is 40-50%
Peeling
Chopping:Here german made
chopper and Indian made chopper are used.
The capacity of the german chopper is 15 tonnes/day.
The blade has to be changed for every eight cut.
.Carbonizing:The chopped splints are carbonized by
setting up in a yard for 3 hours under the vapours of hydrogen peroxide & sulphur in order to enhance the color of the splints.
Drying :After carbonizing ,the splints are dried in
the presence of sunlight in courtyard for a period of eight hours. Incase of rainy days, the splints are dried using steam driers.
Drying
Wax coating : This is more important for any stick to get fire and keep up
the fire for a long time. The sticks are poured over a wax coating machine which
coats wax over the stick and also polishes the stick that gives quality cum attraction.
The sticks become more strength than the normal stick after this application.
Grading: After that the splints are grated by grading machine. In small scale industries graded by hand
CHEMICAL UNIT
Strike Anywhere matchesphosphorus sesquisulfidepotassium chloratzinc oxide
• MECHANICAL STIRRER
• POWDERING THE CHEMICALS
• CHEMICAL MIXING
The dried match sticks are poured over the stick holder where it fixes the sticks to a metal belt.
The metal belt with the attached sticks runs over the chemical liquid and dips it at the base level.
Then it runs continuously till the top storey where it gets completely dried by the fans provided by the side ways.
Then the dried sticks are collected and are passed on to the packing unit.
Dipping and filling unit
Outer box & inner box production unit In previous days, both boxes where
prepared out of wood viz., Ceiba pentendra
for outer box & rubber for inner box.
But due to non-availability, both boxes are
made of card boards.
In outer box production unit , a mixture of
phosphorus and varnish is used for side
mounting.
For inner box, the card board is cut in
different sizes, the cut card boards are made
as inner boxes manually and also is
mechanized.
Dried matches are collected and they are filled in appropriate boxes in 50’s or 70’s according to demand. This process is carried out manually.
Then these are finally packed in bundles of different sizes.
Box filling unit
Packing unit
Done manually.
Packing 10 boxes is one
unit and packing 6unit is
one bundle.
The filling quantity is
four types, 40s, 50s, 70s,
and 200s.
Production of wax match sleeks
Manufacturing process of match sticks
Economics.Annual requirement of wood in India is
200000 Cu.mFor the production of one bundle(i.e.600
match boxes) 2 kg of wood is required. Yellow mutty=Rs.5,200/tonneWhite mutty=1 cft=Rs.250-300
Current supply of match wood from Tamil Nadu 100-250 tonnes/month.
Sticks per kgAilanthus excelsa -13,227/kgAilanthus tryphysa-14,320/kgCeiba pentandra-13,297/kg
Nearly 80 per cent of the matchwood is now supplied by kerala
For making 2 to 2.5 lakh match bundles, nearly 4,000 tones of wood per month is required.
For producing one crore bundles per month, match wood requirement is around 10,000-12,000 tonnes
Process whereby biomass like straw, sawdust is concentrated by machines into small pellets or briquettes.
Moisture content of the compacted biomass between 7% and 14%.
Briquetting
Densification of biomass to produce homogeneous, uniformly sized solid pieces of high bulk density which can be conveniently used as a fuel.
Process
Two main high pressure technologies are in use 1. Ram or piston press 2. Screw extrusion machines
Technologies
ISSUES AND CONSTRAINTS
Shortages of raw materials, particularly match quality soft woods, chemicals, match wax and wax paper ( Samachar.in, 2008)
Geographical distribution of the industry in one region and resulting labour shortages
Monopoly of the 18 “Match Kings” Exploitation of women and child labour by these monopolists Failure of the cottage sector Introduction of new technology in the hand made sector Unique problems of the veneer and splint making industry. Mechanization and causes Excess production (ie 38% surplus
than demand).
ReferencesProject report on vason makwin –match industry Case study on the saftey match industries in India by:
J.C. Tandon T. Mehta, 1981. A Hand Book Of Forest Utilization.
International book distributors, Dehra Dun, India.http://en.Wikipedia.Org/wiki/match
Thanks