SUBJECT

SAWDUST BRIQUETTE CHARCOAL, a unique HYGIENIC cooking fuel so different from others is the product of carbonized compressed SAWDUST , a WOOD-WASTE and will play a vital role in the preservation of a valuable forest resource and at the same time enhance the taste of barbecue meat, thanks to its formidable quality, durability and steady emission of evenly distributed heat which is ENVIROMENTALLY FRIENDLY.

With a firm commitment in the preservation of a clean environment, the proposed industry helps to positively dispose off SAWDUST , which has been a nagging headache to the sawmillers, thus preventing indiscriminate burning and dumping resulting in pollution endangering our lives.

Bearing in mind that this is an EXPORT ORIENTATED INDUSTRY, it will help to generate FOREIGN EXCHANGE in Malaysia's favor.

This project is carefully and systematically designed on the basis of a proven and competent technology (from our partner who have successfully designed and constructed two similar plants in the peninsular), with available supply of raw materials, a demanding and explosive market.

2) PRODUCT

"SAWDUST BRIQUETTE CHARCOAL" is charcoal bar of either hexagonal or square cross section with a center hole. Size and shape of charcoal are manufactured to the general requirement of each country. Generally, square charcoal is in great demand in Japan whereas most buyers in Korea generally accept the hexagonal shape.

"SAWDUST BRIQUETTE CHARCOAL" is a pure natural, manufactured devoid of binders or other chemicals, with twice the burning time and higher energy of its best kind. Again, it is economical with reduced service cost such as trucking and storing. "SAWDUST BRIQUETTE CHARCOAL" is a new barbecue charcoal improving traits of "WHITE CHARCOAL" and minimizing its shortfalls. It rids off sparks and odors, reduce smoke and gasses, and prolong its burning. "SAWDUST BRIQUETTE CHARCOAL" comes with standard sizes and packing which will offer greater convenience to transportation, storing and delivery sales.

3) PRODUCTION PROCESS

a) Sawdust is collected from sawmills either directly from SILOS or loading by means of Payloader onto lorries.

b) Sawdust of various types is well mixed prior to storage or charging into the HOPPER for immediate production requirement.

c) Controlled amount of sawdust is delivered to ROTARY SCREEN from the HOPPER by means of a CONVEYOR underneath the HOPPER and an INCLINED BELT CONVEYOR.

d) Suitably sized sawdust is sifted and collected from the ROTARY SCREEN and the rest will be considered as rejects (3 - 5%).

e) Sifted sawdust in item "d" will be stored in a SILO under the ROTARY SCREEN.

f) Controlled amount of sifted sawdust is delivered for drying by means of the following :-

A SCREW CONVEYOR (variable speed ) under the SILO.

An INCLINED BELT CONVEYOR.

A FEEDER SCREW CONVEYOR.

g) Drying process is carried out with the following equipment :-

A hot air furnace

Suitable to handle approx. 20 - 25 M3/Hr of raw sawdust at an initial moisture content of 45% to approx. 7 - 10%.

A PNEUMATIC CONVEYOR SYSTEM comprising :-

A BLOWER FAN

JET DUCTING

CYCLONE

h) Dry sawdust ( 7 - 10% MC ) is stored in a SILO(DRY SILO).

Dry sawdust is delivered to the production line by means of the following :-

A SCREW CONVEYOR (variable speed) under the DRY SILO.

An INCLINED SCREW CONVEYOR feeding the main production line.

A HORIZONTAL DISTRIBUTION CONVEYOR with dropper chutes to each and every forming machine.

Excess sawdust is channeled back to the DRY SILO in a RETURN CONVEYOR.

j) Compression of sawdust to form SAWDUST BRIQUETTE ( Approx. 10:1 ) by means of FORMING MACHINE. Dry and warm sawdust are compressed ( screw) through a predetermined mold ( square or hexagonal ) with regulated heat energy from a SUPER INDUCTION HEATER LIGNIN (resin within wood cells ) will melt at the preset temperature and form the natural binding agent to the compressed sawdust within the heated ( in channel form ) to form a hard and almost unbreakable wood mass ( SAWDUST BRIQUETTE ) . SAWDUST BRIQUETTE is the intermediate product in the production process for SAWDUST BRIQUETTE CHARCOAL.

k) "SAWDUST BRIQUETTE" is produced in a continuous form and cut into standard lengths in the CUTTING BOX by a rotary cutter. Smoke and gas emulsion from the "SAWDUST BRIQUETTE" production are also collected in the CUTTING BOX and expelled to the building external through an individual smoke stack.

l) All SAWDUST BRIQUETTE produced are collected and delivered through a long DELIVERY BELT for strapping and stacking in which the cooling process is taking place simultaneously.

m) SAWDUST BRIQUETTE are bunched and strapped in standard form ( or stacked in boogie )ready for charring carbonization process ).

n) Charring is carried out in a CARBONIZATION KILN. The whole process inclusive of cooling takes approximately 5 - 9 days before packing is permissible.

o) Packing method

Bulk quantity sales are usually packed in standard corrugated carton boxes of 8.5 and 10 Kgs for export with special printing requested by the buyers.

All rejects are packed in poly-bags for oversea markets specifically for agricultural uses. However, the same will establish its market in the local region in the foreseeable future.

4) WHY SAWDUST ?

It is of particular interest to know why sawdust is the only selected raw material in our proposal instead of abundant source of others such as off-cuts, wood barks, rejects from the sawmills as it is available at minimum or nominal cost.

It is the experience of most regular charcoal users and from the proven research report that soft wood charcoal will burn satisfactorily than hard wood charcoal in all forms ( charcoal in our local region is mostly half charred ) except it has a much shorter burning time for its light mass.

This proposal is to consolidate the superior quality or soft wood charcoal into a dense mass, which will supersede its only drawback for being the super charcoal.

From the various researches and practical experiences gained in the past, it is revealed that the light hardwood species such as MERANTI, JELUTONG which are readily available in this region are the most ideal raw material in sawdust form to produce the proposed "SAWDUST BRIQUETTE CHARCOAL" which complies to the internationally recognized quality for barbecue charcoal with the following characteristics :-

SMOKELESS

ODORLESS

SPARKLESS

MINIMUM GAS EMULSION

MINIMUM AS CONTENT ( 1.5 % and below )

HIGH HEAT VALUE ( KCAL/KG )

ABLE TO BURN IN SINGLE FORM.

MARKETING

The company shall export 100% of its production in the initial commercial operation to Korea, Japan and Taiwan. The company shall promote the same to countries like middle east, Europe as well as the local market so that the sales will eventually be balanced at a certain ratio which the company considers sound.

COMPETITION

There are a few companies, which produce a similar product in PHILIPPINES, THAILAND, INDONESIA and even in Malaysia. However, the competent technical know-how, expertise and the experience of the proposed factory will make its success through the tremendous savings both in capital investment and production cost.

UTILITY CONDITION

The proposed factory requires an electrical power of approximately 600KVA for its full operation.

PERSONNEL REQUIREMENT

Office	-	3 Persons
Factory	-	50 persons

POLLUTION & WASTE CONTROL

The main activity for the proposed factory is to produce charcoal from sawdust. Hence, the following are anticipated to escape from the manufacturing process :-

Water vapor are expected to escape from the drying process as detailed under header 3(g) in the preceding headers. This is harmless to human body, even that a dust pollution control is provided in our design to cater for any fine dust escape, should it be found in the vaporized water gasses.

The conventional carbonization process in charring kilns tend to produce considerable environmental damage, caused by the volatile pyroligneous products and a large quantity of carbon powder through the chimney. The intensive researches carried out has overcome this problem by burning away almost all gasses expelled from the chimney effectively, thus eliminating the problem of pollution.

Practically there is no disposal problem for the proposed factory. The intermediate rejects (stage of sawdust briquetting ) are reusable and the final rejects (charcoal ) are actually a saleable product for both agriculture usage and activated carbon production.

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Contents By PROCESS INTEGRATOR (M) SDN BHD All rights reserved