FPRDI
PROCEEDINGSOF fl vf0-3 INTERNATIONALCONFERENCE ON COCOWOODUllLIZATIONTECHNOLOGIES FOREWORD
The third International Conference on Cocowood Utilization, organized principally by the Forest Products Research and Development Institute (FPRDI) in coordination with the International Tropical Timber Organization (ITTO) and the Common Fund for Commodities (CFC), was successfully conducted on 26-29 October at Holiday Inn, Manila, Philippines.
Held 18 years after the second meeting in Zamboanga, Philippines in 1979, the organizers underscored the importance of the 1997 conference as the crucial link in the 18-year gap between the last two international gatherings on cocowood utilization ever convened.
This Proceeding presents the highlights of the conference, the papers presented in each session, as well as the discussions after each session.
The conference could not have been successfully conducted had it not been for the moral support of the ITTO and CFC. Also, many ITTO-3 Project Staff and FPRDI Staff who made up the conference committees worked very hard to make the affair a success. Space is not enough to thank all of them individually. To all those who helped towards the successful conclusion of the conference, we thank you from the bottom of our hearts.
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,/' /1~tf ~.~~llf{~ J,lOMULO C. EA LA project Leader, ITTO-3 Project {Convener of the Conference I /
CONFERENCElWORKSHOP OBJECTIVES
The International Conference on Cocowood Utilization is a part of a Project entitled "Technology Transfer/Commercialization of Selected Cocowood Utilization Technologies" sponsored and managed by the International Tropical Timber Organization (lTTO), Common Fund for Commodities (CFC) and the Forest Products Research and Development Institute (FPRDI). It is one of six (6) sub-projects being implemented by FPRDI.
The workshop is a critical part of the project to regionalize or disseminate the research results io a wider audience.
The main objective ofthe conference is to provide a forum for the exchange of information, consultation and cooperation between the Asia-Pacific cocowood producers and consumers particularly in the field of:
• Sustainability of cocowood resources and processing facilities • Supply and demand outlook • Improved market access • Processing and quality improvement, waste reduction • Improvement of technology transfer & structural conditions in markets for cocowood experts • Greater cooperation among those involved with tropical cocowood production and trade in the Asia-Pacific region • Improved statistical data collecting and reporting • Coordinated efforts for promotion, pIarketing and dissemination of technologies • Research and development including pUblication of conference proceedings containing technical papers and the results of exp"erts consultations and discussions. 1
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1 Table of Contents
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Opening Ceremonies 3
li~~~q!!~:·::·I_::.!.lilfi:l':quiq~·:ftt:'!«~:·:II~lIJlI~~:::...':.:::::.:::::: :::::::::'::::·:::::··t~·.: Utilization of Coconut Wood, Husk and other Cellulosic Materials 11 R&D on Coconut Utilization 13
:l':ii~~ql¥1II_~if$in~rl~~·:rill~Mml9.l~q:li£l!~Rlq~~~~.:····,:.::,::::m:·:·IW: Commercialization of the High Pressure Sap Displacement (HPSD) Treatment of Coconut Trunk for Utility Poles 19 Chainsaw-Tablesaw Cocolumbering System 22 Composing Jig for the Production of Cocopanels for Furniture 23 Utilization of Coconut Coir Dust for Waste Water Treatment 25 Cocowood: Alternative Raw Material for Industrial Pallets 29 Furniture and Wares from Cocowood 33 Utilization of Co co wood for Briquettes 35 Open Forum 36
~~$$rqullqqgmqg~·rg~l~_ql!·IYIJffiII~!~~Qiqf~lqpll~r.lgr.$·:qjlllll~~ Pole Treatment by High Pressure Sap Displacement 41 Cocowood Faced Veneer 43 Cocowood Furniture 45 Cocowood Wares 47 Composing Jig for Edge Gluing 47 Open Forum 49
~~~§[qn~~cq(l«P~lg~fg;9Y~illlqptl.~~~$impnt:.5$ Properties of Cocowood and its Uses 55 Secondary Processing of Coconut Palm Wood 59 Coconut Wood: The Quest for Better Value Added Utilization 61 Cocowood Carvings in Tanzania: Challenges and Options 62 Economic and International Trade Perspectives of Coconut Production and Coconut Wood Utilization: International Trade Assessment 63 Open Forum 65
~««$fqn~9tqn~t.I,:·mY~I~~I··~!!·I~Bqr¥,(qg.···::::::::{:::·:~9 Coconut Wood Utilization in Tonga: Products, Design and Market Opportunities 71 Networking/Information Dissemination of Technologies Developed for the Coconut Industry 72 Open Forum 74 Closing Ceremonies 75
Coco Veneer Laminated Panels 81 Utilization of Coconut Coir Dust for Waste Water Treatment 91 Use of Coconut Timber as Electric Distribution Pole 96 Coconut Wood Utilization Products Design and Market Opportunities 102 Commercialization of Cocowood Pallet Technology 106 A Furniture Company's Experience with Coco Lumber and the FPRDI-Designed Composing Jig 117 Economic and International Trade Perspectives of Coconut Production and Coconut Wood Utilization 121 Cocowood Wares 125 Secondary Processing of Coconut Palm Wood 129 Composing Jig for the Production of Cocopanels for Furniture 136 Cocowood Furniture 142 Coco-Charcoal Briquetting 146 Chainsaw-Tablesaw Cocolumber Processing System 153 Coconut Wood: The Quest for Better Value Added Utilization 163 Cocowood Carvings in Tanzania: Challenges and Options 170 Production and Coconut Wood Utilization R&D in the Philippines 181 Secondary Process ing of Coconut Palm Wood 189 Networking/Information Dissemination on Technologies Developed for Cocowood Industry 196 Raw Material Source and Acquisition 202 Z INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION OPENING CEREMONIES Engineer Romulo C. Eala, the Project Leader, welcomed the participants to the Conference ofthe Technology Transfer/ Commercialization of Selected Cocowood Utilization Technologies. The 1997 conference on cocowood utilization was held under the auspices of this project which was being funded by the International Tropical Timber Organization (lTTO) and the Common Funds for Commodities (CFC). Engineer Eala underscored the importance of the 1997 conference as the crucial link in the 18-year gap between the only two international gatherings on cocowood utilization ever convened. The first was held on Oct. 25-29,1967 in the Kingdom of Tonga. The Tonga seminar made available benchmark information on coconut stem utilization. It enabled participants to arrive at a consensus as to the directions of research and development (R&D) activities regarding the development of cocowood based industries in coconut growing countries. 3 OPENING CEREMONIES Three years later, on Oct. 22-27, 1979, the second meeting was held in Zamboanga, Philippines to determine the current state of knowledge and practice on cocowood properties, processing, and utilization. Consequently, participants were able to identify areas for further research aimed at fully utilizing the coconut stem towards economic viability and full commercialization. More importantly, it was during this meeting when the potential of felled over mature coconut trees was established. These trees were no longer seen simply as agricultural wastes but as renewable resource to support energy production in particular and the development of the cocowood industry in the Philippines and other coconut-growing countries in general. The 1997 conference was envisioned to accomplish the following objectives: • To provide opportunities for updating developments in processing, products, resource base, market situation and prospects, and dissemination and transfer of cocowood utilization technologies; and • To serve as a forum for the exchange of ideas and information among technology generators, policymakers, and cocowood producers and consumers with varied interests, concerns, and roles in promoting the wise utilization of coconut wood. Messages were delivered by Dr. Dominique Lelievre, project manager of the Common Fund for Commodities, and Dr. Douglas Pattie, project manager for the forest industry of the International Tropical Timber Organization. Dr. Dominique Lelievre, the Common Fund for Commodities' project manager, in his message outlined CFC's mandate, strategy, and operations. He explained the nature of CFC as an intergovernmental organization open to all member states ofthe United Nations and its specialized agencies or to intergovernmental organizations of regional economic integration. At the time of the conference, CFC had 104 members, including 103 member states and the European Commission. CFC adheres to a twofold objective: to serve as a key instrument in attaining the agreed objectives of the Integrated Programme for Commodities; and to facilitate the conclusion and functioning of International Commodity Agreements, particularly those concerning commodities of special interest to developing countries. 4 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Dr. Lelievre stressed the significance of the Technology Transfer/Commercialization of Selected Co co wood Utilization Technologies as fitting into the ITTO's general strategy of sustainable timber management. He added that the Fund also saw the project as useful to coconut growers and traders, thus a welcome addition to the other projects on coconut it was either funding or assessing for support. Dr. Douglas Pattie, on the other hand, gave credit to the Government of the Philippines for being the first to realize the potential of cocowood as a processed commodity in the tropical forest economy. He maintained that the Philippines stood as a testimony to development based on a judicious balance between enlightened self-interest and international cooperation. Likewise, he emphasized the importance of the 1997 conference in the light ofITTO's commitment to the International Tropical Timber Agreement which calls for international cooperation for industrial development as an essential part of overall tropical forest development and conservation. The conference serves as a venue for ITTO's unique role in providing a framework for consultation, cooperation, and consensus. Through this conference, ITTO and the CFC could forge both strong cooperation to ensure the efficient use of resources and dialogue among all partners on how cocowood utilization and commercialization should go forward. Mr. Carlos B. Carpio, deputy administrator of the Philippine Coconut Authority (PCA), delivered the message on behalf of PCA Administrator Virgilio David. Mr. Carpio emphasized the need for member countries of the World Trade Organization, the Philippines included, to keep in pace with developments in the General Agreement on Tariff and Trade (GATT) environment where the name of the game is competition. Sadly cocowood is used only for the construction industry. Preferably, export-quality cocowood products must be produced and processed by farmers' cooperatives in the Philippines in response to demands of the GATT environment. 5 OPENING CEREMONIES Mr. David, through Mr. Carpio assured the delegates of PCA's support towards technology generation, transfer, and commercialization of co.cowood. Dr. Emmanuel Bello, FPRDI director, introduced the keynote speaker, Dr. William G. Padolina, secretary of Department of Science and Technology. Dr. Bello described the Secretary as young, dynamic, multi-talented scholar, academician, scientist, and administrator. The Secretary's career, Dr. Bello explained, is distinguished by his successful balancing of the equally demanding tasks of teaching, research as well as academic and bureaucratic administration. In DOST alone, Secretary Padolina served at one time as Undersecretary of Science and Technology Services, Undersecretary of Research and Development, Chair of the ASEAN Committee on Rice Biotechnology Network, and Chair of the ASEAN Committee on Science and Technology. The keynote speech of Secretary William G. Padolina focused on the breakthroughs achieved so far in cocowood utilization and the concomitant challenges the industry faces. Some of the major breakthroughs achieved by FPRDI (then Forest Products Research and Development Commission or FORPRIDECOM) and the Philippine Coconut Authority were: /6 7 poles viable and of forward CEREMONIES proven items be put Philippines. 1997 traditional species. treatment as the been developing transmission the would in tree in novelty in OPENING has Padolina as lumber. power least purpose uses at well into like preservative as discussed conference Secretary fully, stem be and uses the same export-quality this to gymnospermous higher-end penetration; and that potential, tapped for and need serves coconut be of seasoning, higher-end such that hopes to market pallets, developments, resource; outlook; wood yet for the these cocolumber of has realizing improve demand of expressed Conversion challenges Machining, cocolumber. Coconut angiospermous in to cocowood's this material improvement; use and • • • for reduction; but line withline raw The In secretary as following Sustainability Supply Strategies Waste Quality Processing; already, The instrumental markets, and furniture. the conference: • • • • • • 8 • • • • ." Marketing; Expansion Improvement for in Greater the cocowood Asia-Pacific cooperation of other of exports; techno-transfer region parts among and of . co cocowood-producing co and biomass; OPENING structural CEREMONIES conditions countries \ -CD z --CO ..c '- ...... Cl) o 2cCl.) '" -- C Cl) \U CD -- Cl) ~u2: :> '-- w COo..c>::::J== Cl) et:cna. -- - - - " ...... o Raw Material Source in the Philippines UTILIZATION OF COCONUT WOOD, HUSK, AND OTHER CELLULOSIC MATERIALS Dr. Rolendio N. Palomar Division Chief III Philippine Coconut Authority, Zamboanga In Asia, Indonesia has the largest area devoted to coconut (3,712,000 ha), followed by the Philippines (3,080,000 ha), India (1, 669,000 ha), Sri Lanka (419,000 ha), Thailand (412,000 ha) and Malaysia (290,000 ha). The following tables present details about world raw material sources in terms of coconut area, ageing palms, millable logs, and sawn lumber. Table 1. Asia and the Pacific Countries COUNTRY COCONUT AGEING MILLABLE SAWN AREA (HA) PALMS LOGS (HA) LUMBER (%) (CU.M) INDONESIA 3,712,000 25 69,600,000 20,880,000 PHILIPPINES 3,080,000 30 69,300,000 20,790,000 INDIA 1,669,000 10 12,517,500 3,755,250 SRI LANKA 419,000 20 6,285,000 1,885,500 THAILAND 412,000 35 10,815,000 3,244,500 MALAYSIA 290,000 40 8,700,000 2,610,000 PAPUANEW 260,000 30 5,850,000 1,755,000 GUINEA i VIETNAM 186,000 25 3,487,500 1,046,250 VANUATU 96,000 45 3,240,000 972,000 I WESTERN 75,000 45 2,531,250 759,380 I SAMOA FIn 64,000 35 1,680,000 504,000 I SOLOMON 59,000 40 1,770,000 531,000 I ISLANDS I 1 1 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Table 2. World (Regions) AREA COCONUT AGEING MILLABLE SAWN AREA (HA) PALMS LOGS LUMBER (%) (CU.M) (CU.M) WORLD 11,177,000 30.90 214,282,500 64,284,760 TOTAL APPC* 10,353,000 31.79 196,526,250 58,957,880 MEMBERS OTHER 824,000 30 17,756,250 5,326,880 COUNTRIES AFRICA 461,000 30 10,372,500 3,111,750 AMERICA 254,000 25 4,762,500 1,428,750 ASIA 64,000 30 1,440,000 432,000 PACIFIC 45,000 45 1,181,250 354,380 F.S. 17,000 30 382,500 114,750 MICRONESIA PALAU 14,000 35 367,500 110,250 ~- -- - ~~------~- _ ... _----- * Asia Pacific Coconut Community Table 3. Philippines (Regions) AREA COCONUT MILLABLE SAWN AREA (HA) LOGS (CU.M) LUMBER (CU.M) SOUTHERN 517,360 11,640,590 3,492,180 TAGALOG SOUTHERN 501,310 11,279,470 3,383,830 MINDANAO BICOL 372,570 8,382,820 ~2,514,850 WESTERN 371,080 8,349,300 2,504,790 MINDANAO EASTERN VISA Y AS 323,540 7,279,650 2,183,900 CARAGA 225,600 5,076,000 1,522,800 NORTHERN 211,620 4,761,450 1,428,440 I MINDANAO AUTONOMOUS 187,760 4,224,600 1,267,380 I MUSLIM , . MINDANAO CENTRAL VISA Y AS 135,310 3,044,480 913,340 I WESTERN VISAYAS 112,160 2,523,600 757,080 1 CENTRAL 98,440 2,214,900 664,470 I MINDANAO ILOCOS 13,390 301,280 90,380 I CAGA Y AN V ALLEY 7,340 165,150 49,550 CENTRALLUZ~ 2,270 51,080 15,320 CORDILLERA 250 5,630 1,690 AUTONOMOUS REGION· 12 Raw Material Source in the Philippines JR&D ON COCONUT UTILIZATION Mr. Carlos B. Carpio Deputy Administrator for Research Philippine Coconut Authority The following topics were tackled briefly: situationer on coconut production; production statistics; problems ofthe coconut industry; industry forecast; research and development (R&D) programs; and conclusion and recommendation . Prospects of CNO •in the Lauric Oil Market 1. There is a need to produce the following: • 2.3 million MT (present) • 3.0 million MT (Y2000) • 3.5 million MT (Y2005) 2. There is available market for domestic and foreign consumption. 3. There is an increasing market globally due to shift of industrial users to organic raw materials. 13 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION R & D Productivity Programs A. SCFDP Planting and Replanting Project • 50,000 ha/year (project target) • 1,000,000 ha (to be planted in 20 years) B. SCFDP Rehabilitation • Through fertilizer application • Increased production with reduced hectarage Constraints to CNO Production Low supply and production are due to: • senility of present fruit-bearing trees; • poor quality planting materials; • indiscriminate cutting; • natural calamities; and • some government policies. Research Advances in the Philippines • Development of coconut specific fertilizer grades and compound feJ,1ilizer • Development of PCA's nine local coconut hybrids Potentials of increasing fatty acid content through cloning technique • Development of synthetic variety • Application of molecular techniques Research Studies of peA's Timber Utilization Division • Wood quality evaluation of different varieties of coconut • Cocowood drying and treatment • Cocowood preservation • Glue-laminated timber • Design and fabrication of cocowood furniture component • Cocowood residues and husk utilization 14 Raw Material Source in the Philippines Recommendations • PlantinglReplanting using promising hybrids • Strict enforcement of the Act Providing for the Regulation of the Cutting of Coconut Trees, Its Replenishment, Providing penalties Therefore and for Other Purposes • R & D technology transfer • Policy amendments • Support from all coconut sectors Issues for the 1997 International Cocowood Conference • Many countries need to replenish the aging coconut palms. • Palm stem utilization is secondary to replanting and replenishment. • Small owners' attitude not to fell overmature palm must be given serious consideration in terms of incentive schemes from the government. • In some countries cocowood offers advantages in overseas exchange expenditure. . • Countries with abundant resources of traditional timbers will have problems in changing preferences for timber uses. • There is a great range in the interest and activities on cocowood utilization from country to country. • The diffused, duplicated, and wasteful efforts oftoo many agencies need to be addressed. Slides depicting various facets of the coconut industry were shown: indiscriminate cutting of coconut trees; rhinoceros beetle, the most destructive pest of coconut; poor quality of planting materials; hybrids; seed garden in Cotabato; synthetic variety; c10nillg of coconut; macapuno; fertilized versus unfertilized palm; coconut utilization; sawmilling; dyeing; and preservation. 15 ...... -c ...... ,ID N CO L.. -C en CD CD CD, Z c c..- o CD 0 0) <.9 - 0 I CD '0 en -0 > c en Q)..c w fl: 0_ u CL L. CD en U.OI- INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION COMMERCIALIZATION OF THE HIGH PRESSURE SAP DISPLACEMENT (HPSD) TREATMENT OF COCONUT TRUNK FOR UTILITY POLES Forester Catalino A. Pabuayon Senior Science Research Specialist Forest Products Research and Development Institute Current ProgramslPlans ofthe National Government focus on two major areas: • Total energization /electrification of the country, including the remotest barangays at considerably lower cost; and • Agro-industrializationlrural industrialization (development of industries using agri-based and forest-based raw materials). To be able to implement the various government programs/plans, the following needs are paramount: • Infrastructure development; • Construction of roads; • Improvement of communication facilities ; and • Electrification of rural villages. Electrification started in the early 1960s with the creation of the National Electrification Administration (NEA) and electric cooperatives. However, efforts in this area were hampered by problems like high cost of wooden poles, high transport cost, and difficulty in delivering poles from sources to site. One solution is the utilization of coconut trunk for use as transmission poles using the HIGH PRESSURE SAP DISPLACEMENT METHOD (HPSD). HPSD is a preservation method using a portable-treating machine [5 gal/min piston pump, 113 horsepower electric motor, and 5-10 caps/treating cylinder (350- mm dia. X 530-mm length)]. HPSD-treated poles are comparable in quality :with commercially treated poles. Retention is 18-24 kg/cu.m. HPSD has several advantages: • cheaper than conventional treating plant; • portable, easy to transport from one site to another; • low maintenance cost; • easy to operate; • possible treatment of poles right after felling (in-situ treatment) • shorter time of treatment; . • deeper preservative penetration; and • reduced transport cost of poles. 19 FPRDI Generated and Developed Technologies Furthermore, the HPSD treatment: provides income.to small coconut plantation owners; contributes to forest conservation; has low investment requirement; alleviates poverty in remote areas; and generates employment. The use of HPSD-treated poles is further reinforced by the following factors: • use of senile coconut trees to be replaced by Early Maturing (EM) and High Yielding (HY) varieties; • logging ban in dipterocarp forests for poles; • availability of coconut trunks in villages; and • cheaper cost of poles. Possible objections to this strategy are the products' durability, its appearance, its strength, and the current depletion of coconut plantations and reduction in coco oil production and export. Waste disposal also poses serious problems. An econOI~icanalysis showing the possible savings in using HPSD technology. Two case analyses -- QUEZELCO of Pito go, Quezon and ORMECO of Calapan, Oriental Mindoro -- which highlighted the savings generated from the use ofHPSD- treated Coco trunks, are as follows: Economic Analysis SCALE OF OPERATION: 200 POLES/MONTH CASH COSTS: Chemical CCA, 100 kg/drum, 5 drums@P12,500/drum P 62,500 Labor (contract) @ P250/pole 50,000 Pails @ P100/pc, 12 pes, usable for 2 mos 600 Containers @ P300/pc, 3 pes, usable for 2 mos 450 Tent @ PlOO/pc, 1 pc, usable for 10 mos 100 Supervision @ P4,500/mo, 1 supervisor 4,500 Repairs 1,000 Coconut trunks @ P650/pole, 200 poles 130,000 Subtotal 249,150 NONCASH COSTS: Depreciation (cost of equipment is P 160,000, useful·' P2,667 life is 5 years) Interest on capital (1 % per month) 4,092 Subtotal 6,759 TOTAL COSTS PER MONTH PER 200 POLES P255,909 TOTAL COST PER POLE P1,280 COST OF COMMERCIALLY (CCA) TREATED P5,600 POLE SAVINGS PER POLE FROM USE OF HPSD P4,320 20 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION CASE Energization of the Different Barangays Covered by Quezon Electric Cooperative I (QUEZELCO), Pitogo, Quezon, Philippines Total no. of potential barangay consumers 807 Total no. of baran gays already energized 517 Total no. of baran gays to be energized 290 Current needs (pole demand) of QUEZELCO (a) Maintenance (existing) 2,000 poles/year Est. Cost of wooden CCA treated Pll,200,000/year poles @ P5,600/pole Cost ofHPSD-treated coco poles 2,000 poles x Pl,280/pole P2,560,000/year SAVINGS FROM USE OF HPSD-TREATED CO CO TRUNKS P8,640,000/year (b) Remaining barangays (290 barangays) 8,700 poles Approximately 30 poles/barangay Est. Cost of wooden CCA treated poles @ P5,600/pole x 8,700 poles p48,no,000 Cost of HPSD-treated Coco Poles @ PI ,280/pole x 8,700 poles Pll,136,000 SAVINGS FROM USE OF HPSD-TREATED 'coco TRUNKS . P37,584,000 CASE 2 Energization of the Different Barangays Covered by Oriental Mindoro Electric Cooperative I (ORMECO), Calapan, Oriental Mindoro, Philippines Total no. of consumers 102,954 Total no. Of towns , 15 Total no. of villages 398 Percent energized 68% No. Of villages to be energized 127 Total demand for poles: 30 poles/village x 127 villages 3,810 poles Cost of wooden CCA treated poles @P5,600/pole x 3,810 poles P21,336,000 Cost of HPSD-treated Co co poles @Pl,280/pole x 3,810 poles P4,876,800 SAVINGS FROM USE OF HPSD TREATED COCO TRUNKS P16,459,200 2 1 FPRDI Generated and Developed Technologies Forester Robert A. Natividad Supervising Science Research Specialist Forest Products Research and Development Institute The peA coconut replanting program entails cutting millions of overmature or unproductive coconut palms (estimated usable volume = 0.80 cu.m per trunk), however, felled trunks stored or left to rot in cutting areas serve as breeding sites for pests, particularly beetles. Furthermore, timber supply from forests are inadequate for the increasing timber demand in the wood industry/needs of the growing population. Solution to the Problem I One solution to the foregoing problem is the use of coconut logs as alternative raw materials for lumber production. This can be facilitated by the use of the chainsaw-tablesaw cocolumber processing system. 22 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION This technology involves a single process and equally simple equipment. It requires relatively unskilled labor; operation is not capital intensive; and operation system conforms well with the rural setting. The technology looks promising considering the fact that traditional sawmills require skilled manpower and high investment, and mechairized logging is difficult and expensive. Sources oflogs are dispersed and long-term supply , from particular areas is Uncertain. Lastly, cocolumber processing by chainsaw is commonly used but lumber recovery is low and lumber quality is poor. Limitations of the Technology There are certain limitations or drawbacks of this technology. One, it is designed for small-scale operation. And two, facilities for sharpening and retipping the table saw blade are available only in urban centers. COMPOSING JIG FOR THE PRODUCTION OF COCOPANELS FOR FURNITURE Ms. Edna B. Bauza Senior Science Research Specialist Forest Products Research and Development Institute The wood-based industry is beset with the problems of dwindling raw materials and narrow sizes of cocolumber. One solution to these problems is the production of wide panels from cocolumber with the us~of composing jig. The composing jig includes the panel, board, hydraulic jack, pressure gauge, hydraulic pump with motor, pressure regulator, check valve, pressurized hose, and bolts. The light operations involved in the production of composed panels are planing, rip-sawing, cross-cut trimming, sorting, gluing, assembly, pressing, and cunng. 23 FPRDI Generated and Developed Technologies Features of the Technology The abundant supply of cocolumber is a plus factor. So are the facts that the equipment is easy to operate, inexpensive, and capable of producing wide panels from lumber. More importantly, the technology helps in the management of waste utilization. Benefits The process broadens new material base, generates employment, and helps in producing high value added products. Certain limitations of the technology include difficulty in machining and the ensuing dark-colored product. Financial Indicators Product capacity 400 slim chest/moo Initial investment cost P231,152 Production cost/slim!chest P164.37 Selling price P213.68 Financial evaluation • NPV - P167.742 • IRR - 34.7% • ROI - 39.4% 24 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION UTILIZATION OF COCONUT COIR DUST FOR WASTE WATER TREATMENT Ms. Ma. Salome R. Moran Senior Science Research Specialist Forest Products Research and Development Institute The production of cation exchange resin from coconut coir dust may offer a solution to two environmental problems: the disposal of this coir fib er waste product and the removal of heavy metal ions in industrial waste water. These two problems led the Forest Products Research and Development Institute (FPRDI) to develop a cation exchange resin from coir dust to treat c industrial waste water containing heavy metals. In doing so, coconut coir dust could be used for wastewater treatment. Production of cation exchange resin from coconut coir dust To produce the resin, the coir dust pass through a 1I4-inch screen to remove residual fiber and then dried. Add I part aqueous formaldehyde with 20 parts sulfuric acid (0.2N) to 2 parts coir dust. Heat the resulting mixture at 80°C for two hours. Add water to bring down the temperature and stop the reaction. Filter the mixture through a 200-mesh stainless steel screen. Wash with water, dry, and store in polyethylene bags. Resin yield is 89%. The process is shown in Fig.I. 25 FPRDIGenerated and Developed Technologies Coconut Coir Dust 1 Screecing -, t Drying J Formaldehyde llj Sulfuric Acid [~~c~1 ~ + + I Dryi~gI 1 COCONUT COIR DUST CATION EXCHANGE RESIN Figure 1. Production of Cation Exchange Resin from Coconut Coir Dust 26 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Waste water (from automotive battery manufacturer) 1 Coir dust resin TREATMENT COLUMN 1 l Coir dust resin TREATMENT COLUMN 2 1 Treated water (for disposal) Lead content within limits set by DENR Figure 2. Waste Water Treatment Using Coconut Coir Dust Cation Exchange Resin Treatment Of Waste Water Using Coco Coir Dust The cation exchange resin produced from coco coir dust was pilot tested at Constant Battery Manufacturing to remove l~ad ions from waste water (see Fig.2). The waste water's pH was adjusted to pH 8 with sodium hydroxide. Then the waste water containing 8 ppm (mg/L) oflead was pumped into the column containing coir dust resin at a low flow rate of95 Llhour. This reduced lead content of the waste water by 84 percent. The same water was passed through a second column at the same flow rate. This further reduced the lead content by 94 per cent. The final lead content of the treated water was 0.5 ppm---within the limit set by the Department of Environrnent and Natural Resources. The coir dust resin filtered out the heavy metal as well as particulate matter. 27 FPRDI Generated and Developed Technologies Equipment required The following equipment was used in the pilot test: Reactor (tightly closed stainless steel mixer with 15 kg capacity, heater, and thermometer); Stainless steel treatment column measuring 25.4 cm by 2.82 m: and Portable pH meter/scan. Features and Benefits Cation exchange resin from coir dust efficiently removes pollutants, is a cheaper method of water treatment, and a cheaper substitute for imported synthetic cation exchange resin. It is an environment-friendly technology. It adds value to coconut coir dust, generates employment, reduces importation of synthetic cation exchange resins, and helps minimize water pollution. Market potential The technology has much market potential, especially in the automotive battery manufacturing industry, gold mining industry, and boiler using industries. Furthermore, financial analysis indicates that coconut coir dust cation exchange resin costs less than the commercial cation exchange resin. However, coir dust resin is a bulky material that requires more space for storage and high treatment columns. 28 FPRDIGenerated and Developed Technologies COCOWOOD: ALTERNATIVE RAW MATERIAL FOR INDUSTRIAL PALLETS Ms. Lolita Villavelez Supervising Science Research Specialist Forest Products Research and Development Institute Pallets are platfonn devices used to hold or transfer products in a unit load system. They are important in handling, storage, and transport of commercial products. In the Philippines, the demand for wooden pallets is great. Table 1. Demand for wooden pallets USER AVERAGEDEMANDnMONTWCOMPANY DoleFil 2000 shipping pallets Del Monte 2000 shipping pallets Exports for Japan 2000 Soft drink companies 1000 B-Meg, San Miguel Corp 800 Pharmaceutical fIrm 500 Gasoline refmery 500 Ceramic manufacturing 500 corporation Chemical products 500 Despite the demand, there are constraints in the supply of pallets. These are caused by limited wood supply and the search for alternative raw materials. One solution to this would be the use of cocowood for pallet manufacture. Brief description of the technology A pallet made from coconut lumber has outstanding features. It is cheaper than ordinary lumber. Table 2 shows a comparison between different types of lumber and their costs. Table 2. Types of lumber and respective costs TYPE OF LUMBER COST (US $) Philippine Mahogany Group 0.75 Plantation species 0.47 Imported lumber 1.40 Coconut lumber 0.38 29 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Advantages of the technology The advantages of the technology include the following: 1. durability is comparable with traditional species; 2. production cost is lower; and 3. maintenance/replacement cost of component parts is lower. Results of an alternative comparison by benefit cost analysis using Equivalent Uniform Annual Cost (EUAL) Method illustrates this (Table 3). Table 3. Comparison by Benefit Cost Analysis ASSUMPTION TRADITIONAL (US$) COCOWOOD (US$) Price/cost per board 0.75 0.47 foot Selling price per pallet 18.00 11.25 Maintenance and repair of 200 pallets/month with average of2 deckboards to be repaired: 1.23 0.77 1 deckboard = 1.64 board feet cost! deckboard Replacement 1,000 pcs replaced every 2 1,000 pcs replaced every 6 months months ------_ .. _- The cocowood pallets fare better than the commercial wood pallets when other criteria are used for the comparison (Table 4). Table 4. Cocowood Pallets and Commercial Wood Pallets Compared CRITERIA COMMERCIAL WOOD COCOWOOD Pallet life 2 months 6 months Cost per pallet US$ 18.00 US$ 11.25 Initial investment .215M .135M ( 12, 000 pcs) Maintenance US$ 5,412.00 US$ 3,382.50 Replacement US$ 108,000.00 US$ 22,500.00 30 FPRDI Generated and Developed Technologies Resource Requirements Producers of cocowood pallets require the following resources: 1. Materials: coconut lumber; nails (commercial or special) 2. Labor (the cost oflabor is 30% of material cost) 3. Tools and equipment: hand tools (hammer drill); chainsaw; and plane Benefits of the Technology Several benefits of using cocowood pallets have been identified. These include the following: 1. expansion of raw material base for pallets; 2. contribution to conservation; 3. generation of employment in the countryside; 4. development of a high value added product from cocolumber; 5. lower cost of raw material for pallets; and 6. favorable economic feasibility indicators. The technology is financially feasible ifthe following assumptions are made: 1. Pallet size = 1000 mm x 1016 mm x 101.6 mm 2. Financial resources: • 70 per cent investment cost = loan US$34,081.53 • 30 per cent investment cost = equity of US$14, 606.37 3. Loan payable in 5 years with an interest rate of 18 % 4. Production program: 1sI year = 60% of production 2nd year = 80% of production 3rd year = 100% of production 5. Selling Price is based on mark-up of30% ofP.C. + unit cost + production cost 31 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Technical feasibility analysis A feasibility analysis showed the economic and technical feasibility of the use of cocowood for pallets. The analysis was based on US$ figures computed at lUS$ = P32. 1. Investment Cost US$ 47,166.40 Fixed investment a. Land b. Buildings c. Plant machinery and equipment Total fixed investment 35,406.25 Pre-operating capital 2,343.25 Working capital 9,416.40 2. Production Capacity 500 pallets/month 3. Average production cost estimate 9.00/pallet 4. Selling price $11.78/pallet % mark-up 30% 5. New Present Value (NPV) $29,669.407 6. Return on Investment (ROI) 32% 7. Internal Rate of return (IRR) 33% Users and producers of coconut pallet in the Philippines Three companies produce coconut pallets in the Philippines. These are: 1. Philippine Pallet Resources PPR, PMR, 3rd Floor MMBC Building, 670 Edsa Cubao, Quezon City 2. Pasajol Woodcraft Brgy. San Vicente San Pablo City 3. CFB Philippines, Inc. 92 Maharlika Highway Brgy. San Francisco San Pablo City 4000 32 FPRDIGenerated and Developed Technologies There are at least 13 users of cocowood pallets. These are the following: 1. B-Meg, San Mig~elCorporation 2. Fractional Motors Corporation 3. Fujitsu ten Corporation 4. Energy Stewards 5. Resins Inc. 6. Ever Electrical Manufacturing Corp. 7. Ishida Phils. Grating Co. Inc. 8. Amkor/Anam Pilipinas 9. SC Johnson and Sons Inc. 10.PEMCO 11. BASF Coatings and Inks Inc. 12. Vita Color 13. RoGenerix Conclusion Based on the Philippine experience, cocowood for pallet manufacture is a feasible business venture, which could be adopted by coconut producing countries. FURNITURE AND WARES FROM COCOWOOD Mr. Victor G. Revilleza Senior Science Research Specialist Forest Products Research and Development Institute The furniture and wares industry is beset by problems such as inadequate supply oftraditional species, high cost of imported lumber, and strict competition in the export market. Cocowood is a potential substitute material for the traditionally used species for the manufacture of furnitures, wares, and other novelty products. It can be processed into value-added finished products such as furniture, housewares, and novelty items. It is also a potential export quality product because of its unique appearance and quality when finished) In recent years, it has gained wide acceptance. However, it remains a cheap raw material perceived fit for low-value products. It is still the cheapest construction material available for housing, especially in the rural areas. In the construction industry, it is used for formed lumber and scaffolding. 33 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Technology description The technology recommends the use of cocowood as a substitute material for commercial wood species in the manufacture of furniture, wares, and novelty products. Cocohard in combination with cocomedium can be used for furniture making while cocomedium and cocosoft can be used for laminated tabletops and various cocoware items. The technology has several outstanding features: 1. an existing abundant supply of cocowood; 2. lower cost than commercial wood; and 3. properties comparable with traditional wood. Its wood properties meet furniture and wares requirement. This is apparent in the data in Table 1. Table 1. Wood property requirements PROPERT FURNITURE WARES COCOWOO IES D Density Medium to Medium to High Moderately Moderately High High Volume Low to Medium Moderately Low to Low Shrinkage Medium Drying Easy to Easy to Easy Moderately Moderately Difficult to Dry Difficult to Dry Machining Good to Fair Very Good to Good Good Gluing and Good Good Good Finishing Texture Fine to Moderately Fine to Moderately Coarse Coarse Coarse Benefits The benefits of the technology include the following: 1. increases value of cocowood products, eventually making cocowood a prime species for lumber products; 2. sustainable operation; 3. market competitiveness (cocowood has unique features that will help it stand out in the search for new materials); and 4. helps in forest conservation. 34 FPRDIGenerated and Developed Technologies Problems in cocowood utilization Unfortunately, despite its great potential as raw material for furniture and wares, cocowood: 1. is hard to work with; 2. requires additional processes; 3. blunts tools (it is hard when dry); and 4. is usually unavailable as quality grade cocowood. Conclusion If the furniture and the gifts, toys, and housewares industries would accept and utilize cocowood, it could become a new premium raw material. And once the technical and economic viability of using cocowood in the manufacture of high value products has been determined, attention should be focused on promoting and marketing these products in both domestic and foreign markets. UTILIZATION OF COCOWOOD FOR BRIQUETTES Mr. Dante Pulmano Science Research SpecialistForest Products Research and Development Institute Charcoal briquetting is the process of converting ground charcoal or charcoal fines into a compact form of fuel with the addition of binder and application of pressure to produce the desired uniform-sized charcoal briquettes. The Forest Products Research and Development Institute (FPRDI) developed a two-ton, eight-hour charcoal briquetting system. It is composed of a mechanized rotary type charcoal briquettor, a charcoal binder mixer, and a briquette dryer. A hammermill or crusher is optional; but all the materials used in the fabrication of the equipment are locally available. This technology converts available charcoal fines generated by coconut shell granulating plants into a saleable product that provides an alternative source of energy. Other biomass wastes can also be used. Binders could be smokeless binders, such as cassava and cornstarch as smokey binders, such as tar, pitch, asphalt, sugarcane molasses, wood tar, and coal tar-pitch. 35 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Features of the technology The technology: • uses simple and locally-fabricated equipment; • uses briquettor that is comparable to more expensive imported briquetto,r of the same capacity; • can process other agro-forestry waste charcoal fines, such as sawdust, cofee bean hull, and corn cobs; • helps conserve use of wood charcoal for domestic and industrial fuel; and • produces quality coco-shell briquettes. There already exists a demand for charcoal briquettes overseas. For example, the demand in Germany is 52,800 mt/yr; Holland 8,500 mt/yr; Belgium 10,900 mt/yr; Korea 24,000 mt/yr; and Japan 12,000 mt/yr. Furthermore, there is sufficient local demand for charcoal briquettes since the poultry industry uses about 590 metric tons of charcoal briquettes each brooding season. FPRDI's priorities and commitments regarding the technology are as follows: • extend complete technical assistance concerning the fabrication/installation of the briquetting plant; • conduct seminars/training of operators on the operation and maintenance of the plant; and • exert all efforts to promote the use of the technology. OPEN FORUM Chairman: Forester Dominador S. Alonzo R. Palomar of the Philippine Coconut Authority (PCA) Zamboanga Research Center wanted to know if 18-24 kg/m was the preservative retention of the whole cross section of the trunk. He asked C. Pabuayon ifFPRDI analyzed preservative retention of every section of their coconut poles--from center to periphery of trunk. C.Pabuayon ofFPRDI explained that equal distribution of chemicals in the poles cannot be expected as the depth of chemical retention and penetration would not be the same throughout. Thus, streaking happens in some of the outer portions. 36 FPRDI Generated and Developed Technologies R. Palomar noted that they were able to attain an average service life of only 12 years in their cocowood poles. He wanted to know ifthis would still be economical in the long run. C. Pabuayon responded to this question by explaining that since coconut is a plantation species, use for at least 10 years would still be economical. D. Alonzo, also ofFPRDI noted that they would look more deeply into the distribution of preservative in coconut poles. K. Fa'anunu of Tonga was interested in the durability of coconut poles compared with the durability and strength of conventional wood. He explained that this was important because the commercial side of using coconut poles is attractive but he was not sure about the marketing side. c. Pabuayon explained that they recommend poles with maximum height of35 feet since the top portion is not as strong as the lower portion ofthe pole. R. Palomar said that when they inspected poles in Davao, they saw no reason to replace them for lack of durability. They did not have any defect but were replaced with longer poles. He said that they saw three or four poles that still had not been removed. They calculated that 85% of the poles set up in 1989 were still standing. A. Fruhwald of Germany was interested in the outside density of cocowood. He noted that in Malaysia, they found that transmission poles made of coconut was stronger than those made of pine. He wanted to know what the distribution of preservatives was throughout the whole length ofthe pole and how the sap was disposed. D. Alonzo also pointed out that targeting the battery manufacturers was easiest to do as they were the easiest to approach but FPRDI would be testing the resin's application in other industries. F. Torres asked V. Revilleza about the recommended age of coconut used for furniture. V. RevilIeza emphasized that the coconut must be 65 years or older in keeping with the peA rule. F. Torres then wanted to know how to determine the age ofthe coconut. V. RevilIeza explained that some have developed a formula for estimating the age of coconut tress but this is not foolproof. 37 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION D. Alonzo acknowledged the problem of determining age of coconut trees. At present, this is done by counting the number of leaves produced/year. He suggested that this would make a good thesis problem for the masteral graduate program. In summary, D. Alonzo noted that all seven technologies presented were developed by FPRDI as solutions to the problem of disposal of coco trunks. He noted that all the technologies were cheap, simple, efficient, environment-friendly, easy to operate, and rural based. He acknowledged the economic feasibilities presented. He also noted the limitations of each technology and the suggestions made regarding safety of workers involved in the processing of coconut; the need to improve sawmilling or conversion of coconut poles into cocolumber; and determining strength of poles specially at the top, and the distribution of preservative throughout the poles. 38 C") oz Cl) Cl) w Cl) INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Pole Treatment by High Pressure Sap Displacement Mr. Francisco Buhain Sr. Superintendent, Material Planning MERALCO, Pasig City MERALCO is a privately owned, publicly listed, electric power distribution company. It has a franchise area of9,283 sq. km covering 2.9 million customers for a total KWHR of20.3 B. Its distribution lines cover 9,391 circuit km. Already, it has installed 406,725 poles and requires another 45,000 poles each year. MERALCO uses coconut palms because the Philippines has 3.3 M ha with 438 M coconut trees. Each tree has an average height of 15-18m, sometimes reaching 30 m. The average diameter is 300 mm, its modulus of rupture is 38.7 Mpa, and its modulus of elasticity is 6,600 Mpa. Cocowood is equivalent to ANSI Class 4 wood pole. Creosote cocopole experiments The company has experimented with the use of coconut lumber. In the June 1997 Creosoted Cocopoles (MERALCO-Pacwood) Experiment, they used 27 pieces of coconut lumber that each measured 7.5 to 10.5 meters long .. These were debarked, treated with CCA prophylactic, and air-dried for three months. The poles underwent Creosote (oil-based) treatment for two hours and retention for four hours. Results included: • 124 kg/cu m (192kg/cu m) retention • 32 mm (25mm) penetration • 2,100 kg (1,000 kg) cantilever strength The February 1989 experiment used 40 coconut poles and were treated with Creosote up to refusal. Retention was 230-kg/cu m (192- kg/cu m) and penetration was 44 mm (25mm). Eventually, MERALCO installed 1,200 Creosoted cocQPoles that measured 7.5-12.0m long in residential subdivisions to replace rotten poles. They were placed in varying soil conditions and strung with secondary or single primary lines. 41 Cocowood Utilization by Private Sector/Cooperators of FPRDI HPSD-CCA treated cocopole experiment In July 1990, MERALCO and FPRDIjoined forces in a PHSD~ CCA-treated ,cocopole experiment. The experiment used six freshly cut coconut timer that measured 7.5 to 12.0 meters long. They were HPSD treated with 6 per cent concentration CCA (water-based) for five hours. After treatment, they were debarked and a CCA prophylactic was applied. Retention was 8.03 kg/cu m (9.6 kg/cu m) and penetration was throughout the entire trunk. It installed 2,188 HPSD-CCA cocopoles as part ofMERALCO's Rural Electrification Project. FPRDI experts trained workers and they worked under MERALCO supervision using 6-cap HPSD equipment purchased from FPRDI. - Results Cocowood is an acceptable substitute for wood as electric distribution pole. Ninety-one per cent (91 %) of creosoted cocopoles are still standing after eight years in service. Eighty-two per cent (82%) of CCA-HPSD-treated cocopoles are still standing after six years in servIce. 42' INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Mr. Jacinto Calolot Owner/Proprietor, FANCY PANELS ENTERPRISES, INC. Davao City FANCY PHILS manufactures plyboard and plywood products and fancy panels such as Gemilina laminated, ipil-ipillaminated, and co co veneer laminated panels. However, the eoco veneer paneJs almost always receive incredulous reactions, as most people cannot comprehend why some would want to turn coconut into a veneered and decorative panel. This company is relatively new and small with a net worth of about 20% that of conventional plywood establishments. It uses hot presses, boilers, bandmills, a sander, a composer, aJdln drier, lumber finishing equipment and other support equipment. Its production of coco veneer panels started. with the search for a substitute for narra plywood. In 1996, FPRDI and DOST introduced the company to the prospect of producing coco face veneer laminated panels. Impact on Coco Farmer Because the establishment is located in Region 11, the coconut industry is crucial to the region's economy. It buys coconut raw materials ata higher rate than coconut lumber processors. This benefits coconut farmers. However, FANCY is selective in its choice of raw materials. Production Processes Cook the co co flitches. Check tl~eflitches for nails (which housewives use to anchor clothesline) imbedded in the wood. Trim both ends squarely with a chainsaw. Use a Taihei Model V-34 slicer. After slicing, air dry the veneer strips for at least 30 minutes and then clip using a manual veneer clipper. Pair the strips lay up individually ove~the plywood or stitch or join into 4x8 panels before laying up. Manually size the laminated panel, sand with a sanding machine, grade, crate, and mark. 43 A Cocowood Utilization by Private Sector/Cooperators of FPRDI Production Cost Based on current costs and prices, cost of producing a 5.5 x 4 x 8mm co co veneer laminated panel is P252.50 (about $7.50) Cost of cocowood veneer is only 5% of the total cost while the processing cost accounts for 18% and the bulk of the amount is the cost of the regular plywood. Co co veneer panels are commercially sold and used as decorative panels in housing, for house and office furniture, and other personal accessories such as brief cases. More diversified uses of coco veneer panels are being tested by the company. Problems and Difficulties Although the co co veneer product is simple to manufacture, the company faces some major problems and difficulties as follows: 1. Quality of raw materials is difficult to establish as maturity and age of coconut trees cannot be ascertained. 2. Special care is needed to handle veneer strips which easily tear, shred, break, and split. 44 INTERNATIONALCONFERENCE ON COCOWOOD UTIUZATION 3. Nails embedded in the flitches impose unnecessary cost during slicing the flitches. A 25-centavo nail can extensively damage a P20,000 slicer knife. 4. Market resistance is due to consumer perception that coconut is good only for low cost products. Perhaps a marketing thrust aimed at developing a classy and elitist image for coco-panels will improve its image. 5. Financial return is low when viewed in the light of its difficult handling and problems manufacturers face. Recommendations Mr. Calolot suggested that commercial application of coco-veneer panels be diversified and expanded. The market base for coco-veneer panels must be strengthened by more participation in the manufacturing aspects. He further recommended for continuous technical study to improve different areas of co co panel manufacturing. He expressed the hope that FPRDI would always be in the forefront of searching for solutions to problems of the cocowood industry. COCOWOOD FURNITURE Mr. Florentino Torres President, FURNITUREVILLE INC. Pampanga The many problems faced by manufacturers of furniture from solid co co lumber include: • sourcing of good quality, high density cocolumber; • finding trees that are at least 60 years old; • needing to treat trees within 24 hours of cutting to avoid ending up with discolored wood; and • getting only the outside part of the coconut, resulting in a recovery rate of only 35%. If the outside part is used, the thickest portion is only about 1.5 inches. Thus, these must be laminated to make table tops, making joinery a problem. 45 Cocowood UtUization by Private Sector/Cooperatot~of FPRDI Technically, cocowood users are not prepared to deal with problems like this~oughthey have had some assistance from various groups. Furthermore, they received a booking for five containers of furniture unfortunately, they were not able to source the wood and were unable-to meet the demand. Since most ofthe furniture produced are tables and chairs, technical assistance is needed to determine moisture content of the cocowood used for the tops of these tables and chairs. Processing coconut is difficult for the workers because they cannot use the ordinary high-speed steel on cocolumber. They had to use carbide-tipped blades, which are quite expensive. Also, workers could not tolerate the cocodust produced even with the use of masks eyes still water. As in any marketing strategy, producers must be in the right place at the right time. Based on experience, Mr. Torres felt that they were in the right place but not at the right time as far as cocolumber utilization is concerned. For example, Germans perceive coconut as low-end furniture. Thus, it cannot be priced high in the international market despite its high cost of processing. In conclusion, he felt that their experierice with cocolumber was a very good learning process as far as furniture making was concerned. But they were unable to continue experimenting on coconut furniture because of financial limitations. Nevertheless, he assured the group that once his company has made its mark in the world furniture industry, they would work with coconut again. This may happen sooner than expected because mahogany and other hardwoods are getting more difficult to find. He predicted that in a few years, cocowood will have a place in the furniture industry. Design is not a problem. It is the technical aspect that needs help. 46 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION COCOWOOD WARES Mr. Domingo H. Ladao Proprietor, DAVAO ETNOKRAFT DESIGN Davao City Mr. Ladao's family has been using ordinary wood as raw material. However, when the government banned the cutting of trees and mangroves, his family stopped their wood turning business. In 1983 the government started low cost housing programs. Coconut tress were used in constructing the houses and government soon faced the problem of how to dispose ofthe trees. His family used the trees despite the small capital. The equipment they used was fabricated. An electric motor was purchased to run their fabricated wood turning machines. In the beginning, they faced the problem of processing freshly cut wood. They turned this immediately and then dried the products without getting the moisture content ofthe wood. After weighing and turning, they would do the finishing. Because they did not apply preservatives, cracking and molding resulted. They consulted government agencies for advice, thus, and learned to apply preservatives in the drying process. They have learned to process the wood while it is moist. Once it has been turned, they then started the dry process. The company produces hand painted jars, vases, and ashtrays from cocowood. He feels that it is the hand painting and the wood texture that first attracted their buyers in trade fairs to their products. COMPOSING JIG FOR EDGE GLUING Mr. Benjamin Dimaano General Manager, JERMOND INTERNATIONAL INC. Zamboanga City Mr. Dimaano's brother established Jermond International Inc. in 1991 in Zamboanga City. It started out contracting school chairs but it soon ventured into the export business and now markets wooden furniture and home accessories to the US, Europe, and Australia. 47 Cocowood Utilization by Private Sector/Cooperators of FPRDI Using cocolumber for furniture is advantageous because it is readily available, cheap, and beautiful when varnished. However, using cocolumber is not without problems. The company has encountered several problems when working with cocolumber in furniture production, including its low tensile strength, coarse grain, and uneven hardness. Furthermore, it is difficult to nail, paint, and smoothen. Manual lamination, the A-frame composing jig, and the FPRDI designed jig were compared with results as follows: Manual composting is cheap, easy, and fast. However, the pressure applied on the wood cannot be measured and consistency cannot be maintained. Ifpieces of wood are nailed together, this leaves holes in the wood. If the pieces are left in the jig, then several jigs will be needed. The A-frame laminating jig is easy to use. The pressure applied is consistent, and long and short pieces of wood can be laminated. It has low capacity and is expensive. Lastly, the FPRDI-designed composing jig has high production capacity. Pressure can be accurately measured when this is used. Tightening of the nuts and clamps is a tedious process. It is expensive - about P50,OOO/unit. r 48 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION The following are recommended when cocolumber is used in furniture manufacturing: • combine coconut with wood with high tensile strength; • develop furniture designs in incorporating cocolumber; and • determine the market for cocolumber furniture. He further recommended FPRDI to improve the design of its hydraulic lamination composing jig to facilitate holding the wood together, loading and unloading, and clamping of wood. OPEN FORUM Session Chairman: Engineer Arnaldo P. Mosteiro Dr. F. Lauricio of FPRDI asked F. Buhain for any observation about the soundness ofthe poles. F. Buhain explained that the most common observation about the poles is that termites infest them. However, when the poles are no longer sound, MERALCO replaces them. F. Lauricio asked F. Torres what kind of research would be helpful in improving the cocowood manufactlJring industry. 49 Cocowood Utilization by Private Sector/Cooperators of FPRDI According to F. Torres who manufactures cocowood furniture, they need procedures that will allow them to properly kiln dry cocowood to 10'-12% moisture and enable them to properly source cocolumber that can be made into good furniture. F. Lauricio wanted to know what initiatives B. Dimaano had taken to promote their cocowood furniture. B. DimaanQ explained that the items their company produces are neither too bignor expected to carry too much weight. However, when they make furniture, they combine cocowood with better woods such as Philippine mahogany. A. Fruehwald asked J. Calolot for information on the recovery rate of the different inputs. For example, he asked about the chemical base of the hot melt glue and the composing method Calol<;>tuses. J.Calolot noted that net recovery is 30%. He said that they use Uris, a water-based glue used for ordinary plywood. They layout veneer. !fit is more than six inches thick, it is laid out in six-inch strips or stitched. They don't use composers, as they haven't tried to use co co strips as naked board for plyboard. He hopes to try this, however. Dr. M. Giron of FPRDI asked Buhain about any observed differences in damage between different pole treatments. F. Buhain said that different soil conditions do not affect unit performance. Termites attacked those installed in good environments perhaps an indication of the conservative treatment of the poles. Furthermore, not all the poles received a good preservative treatment, thus the early decay of the poles. He did not think that environment would be a factor in pole performance. M. Giroh asked, "Were the poles that were not completely treated located in a place where they were exposed to termite and fungal infection?" F. Buhain answered that when they established the poles, th~ydid not select the areas. However, they have on record the retention of these poles by batch. Some poles were down because of typhoons, which I. would down even conventional steel or concrete pO'les. M. Giron asked' hini why MERALCO has not gone into full blast production of cocopoles. 5(} INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION F. Buhain explained that MERALCO experimented with cocopoles as an alternative to wood poles, which are imported. However, they preferred the concrete poles which can be manufactured and whose availability can be forecast. The cocopoles were used in their piloting oftheir rural electrification project. Since results are not yet in, they are slowing down on the project. On projecting the service life of treated poles, Mr. Palomar explained that the problem was not due to termites but due to fungus. He noted that 12 years is the average service life of poles. Because Davao City has high, evenly distributed rainfall, he said that the ground is wet year round and it can be expected that the bottom of the poles are soft. Pabuayon also stated that the material is treated with CCA. A chart is being used to predict the servic,e life of treated poles. He suggested that factors which determine attack of treated poles be investigated. Palomar explained that they achieved the minimum requirement but moisture was a problem. He surmised that the chemical leached out into the soil. He suggested that this is why average service life was only 12 years. K. Fa'anunu then wanted to know where the decay starts. This was answered by R. Palomar who explained that in their experience, the decay starts in the soft portion. After 12 years, the soft portion is gone and the pole looks like a tube. K. Fa'anunu said that they had done a cross-section and sent it to New Zealand. He observed that treatment doesn't really penetrate to the pith. Thus, he recommended that the pith be taken out before treatment and four feet at the top. R. Palomar explained that treatment is not a problem. However, there was erratic preservative distribution and uneven penetration: of chemicals in the outer stem. c. Pabuayon added that if there is leaching, the conditioning and fixation processes might be contributory factors. N. Geron asked the group to consider effects of chemical leaching from treated poles. She noted the need for researchers to determine how soil and water can be detoxified of CCA. M. Giron asked the group to consider effects of chemical leaching from treated poles. She noted researchers should determine how soil and water can be detoxifie4 of CCA. 51 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ~ .-tn ... z Cl) ... c cCJCI) o ...., [E CJ tn en :1 E tn . en -c-CI) o -c tn w .... C tn en 'a.. ca INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION PROPERTIES OF COCOWOOD AND ITS USES Prof. Arno Fruehwald Germany The project was conceived to come up with a system which can sustain the management and utilization of cocowood as substitute for high priced commercial timbers. Its objectives are to test the: • quality of cocowood and to find appropriate products; eo manufacture of products; • the cocowood product; and .• market opportunities of the products. 55 PRODUCT DESIGN AND IMPACT ASSESSMENT The following points regarding the cocowood production process were given emphasis: 1. At the start, the density of timber varies across the stem and along the height. 2. In a typical sawing pattern, class 1 timber has high, class 2 has density, and class 3 has low densities. 3. In terms of sawing performance, a 2-2.5 m3 1kpu lumber can be processed using a bandsaw with one sawblade, stellite tipped, saw tooth pitched at 32 inm. 4. Class 3 timber has a density of719 kg! m3 and has the highest lumber yield (45%) among the three classes. 5. Air drying takes about 10-12 weeks. In kiln drying, there should be excessive surface checking in high density materials while the cells collapse in low density materials. Thus, pre-airseasoning is recommended. 6. In lumber grading, using the Pilodyn test device will result in a correlation with density of -0.98, which means that the timber has an extremely good density. The following products of cocowood were discussed,· their manufacturing processes, properties, product performance, and markets given emphasis: • top layer coco; • window frame; and • euro palettes. These products have excellent properties, but there are problems basically in terms of acceptance of the materials because of their dark color and heavy weight. Cocowood may be used as doors, window frames, chairs, beds, and sofa. 56 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION In conclusion, the highlights of the project results were presented: 1. Air-dried structural lumber has a good yield in strength classes compared with softwood lumber. 2. Gluelam, a product manufactured from medium and high-density cocowood, showed no gluing problems. It is strong. 3. Doors for interior and exterior use have a good appearance. 4. Windows with three (four)-layer window frames are very durable, but appear somewhat heavy. 5. The wall paneling material has a good overlaying behavior and nice appearance. 6. Laminated solid wood parquet flooring (3 layers) with high density top layer has a good appearance, excellent glueability overlaying and wear (taber test). 7. There are simple problems in machinability (quality) ,and acceptable treatment of simple furniture. 57 PRODUCT DESIGN AND IMPACT ASSESSMENT Project design. objectiVes--/ Coconut trees selected. harvested. processed into lumber in North Sulawesi. 53 trees from 3 sites processing of products in industry and testing of r~d~/ pioducts guelam products sawing performance and density lIumber yield I lIaminated flooring moisture Dip-treatment furniture components I fiber structure air seasoning household articles I 1 strength kiln drying windows. doors I glue joints wall paneling I grading lumber fire resistance I pallets structural lumber in buildings box and frame wood polymers corner joints I product manufacturing. general processing product properties. and properties market opportunities I basic information of coconut wood Fig. 1. Cocowood products production process 58 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION SECONDARY PROCESSING OF COCONUT PALM WOOD Prof. Dr. Dieter Fink APPLICATION TRAINING AND MANAGEMENT GmbH Reutlingen, Germany The presentation was based on the experience gained from the research programme "Utilization of Coconut Timber from North Sulawesi, Indonesia" which was conducted on behalf of the Federal Research Centre for Forestry and Forest Products in Hamburg,Germany. In addition, the findings presented in the report reflected practical experiences made in plants in Southeast Asia and in the Pacific region, where coconut wood is processed. Following are the reasons why cocowood processing is more cost-consuming than processing traditional species: • high tool wear; • an extremely low machining performance per unit of time and, consequently, low processing speeds and a low output; • high investments in highly dimensioned machinery, tools and extraction equipment; • relatively small log diameters/dimensions; • wooden parts of one raw density class featuring small cross sections; and • a lot of grading and sorting work. However, much lower harvesting and transport costs can make up for the high processing costs (the plantations are on relatively even ground and easily accessible, no forest roads are required since there are large distances between the trees). Regarding machining properties, the study revealed that the absolute value ofthe feed per tooth tZ, played an outstanding role, compared to the other parameters .. It is much more important than, cutting with feed or cutting against feed metQ.od, which plays a major role when processing conventional species, because of the pre-splitting effect, which is more or less strong when processing conventional speCIes. 59 PRODUCT DESIGN AND IMPACT ASSESSMENT The relevant results of the research are as follows: • There is high blade wear, even when using carbide-tipped tools, and, consequently high tool costs. • Due to relatively small feed per tooth rates, the output is smaller than with conventional species. • There is high cutting forces with Cocos HD. • There is a high amount of dust and fine particles, which pollute the environment and make tools dull. Thus, a good dust extraction equipment is necessary. • Machines, drives, bearings, and guides must be adequately dimensioned since industrial processing of cocowood requires the "best" machines and tools. • Wet cocowood is easier to machine than dry cocowood. All types of glue designed for gluing wood can be used to glue coconut palm wood. Examples are PV A adhesive, urea, melamine, phenol-formaldehyde adhesives, epoxide and polyurethane adhesives. However, the choice of the adhesives depends mainly on the conditions of use (interior/exterior use, climate resistance) and on the machining conditions Goint gluing, assembly gluing, fitting tolerance of the components, wood moisture content, etc.). In principle coconut wood has very good gluability. With regard to surface finishing, a well-sanded wood surface is a pre-condition for high surface quality. The fine sanding of cocowood should be carried out with 100/120 grit, parallel to the grain and at low pressure. Cocowood absorbs stain very well and the prime and top coating of cocowood can cause problems if the coating materials are not properly formulated. This problem can be avoided by using elastically formulated PU (polyurethane) paints. Industrial use of cocowood requires professional approach and processing. This already begins with the design of the end product because not all of the design and construction principles and methods, which are known from conventional species, are applicable to cocowood. Furthermore, potential wood processing companies must use this valuable and aesthetic raw material in an economically sensible way. Sufficient positive experience and know-how should be made available to help avoid mistakes and to enable manufacturers to process and market this material to gain profit. 60 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION COCONUT WOOD: THE QUEST FOR BETTER VALUE ADDED UTILIZATION Mr. Sugath Dissanayake Assistant Director Market Development and Research Coconut Development Authority Sri Lanka The potential for the utilization of cocowood is great. International markets take quality coconut wood exclusively. Coconut wood can be used more widely in manufacturing a variety of products like furniture, composite woods, layered construction material and particleboard, laminated and finger-jointed products, and molded products. The marketing structure for coconut wood products tends to be well established. There are two major kinds of outlets in marketing wood products: traditional furniture retail shops that market solid, high priced cocowood-based products; and large retail outlets that offer value added articles made of cocowood. The best prospects appear to lie in the marketing of furniture articles made of cocowood. The market requires consistent quality, acceptable prices, guaranteed delivery schedules, continuity of supplies, and readiness to accept customer design as well as products manufactured to customer specification. To successfully promote cocowood-based products and cocowood as timber, the respective governments of coconut growing countries have to institute support programs for the progress of their coconut wood industries. Promoting cocowood utilization provides considerable added value to a widely available resource, generates employment, and creates export opportunities for cocowood, and eventually for other items produced by other industries. Integration of the coconut growing and coconut wood processing industries are going to be the order ofthe future, if we continue to grow coconut as a crop at current scales; and accept coconut wood processing as an integral part of its operations. The demand for coconut wood is likely to outstrip supply in the future. Therefore, producing cocowood articles appears to offer profitable prospects for coconut producing countries. 61 PRODUCT DESIGN AND IMPACT ASSESSMENT COCOWOOD CARVINGS IN TANZANIA: CHALLENGES AND OPTIONS Mr. Joseph J. Mpagalile Ministry of Agriculture Tanzania In Tanzania, coconut is used for food and non-food purposes. However, as a result of the pressure put upon the black African wood or ebony, using cocowood as a substitute was given importance. This is because the price of ebony is increasing while that of old palm remains low; conventional trees have limited uses while cocowood has more benefits; and the quality wood needed by carvers is readily available. Despite the advantages of cocowood, carvers encounter a number of problems. There is no accurate system to determine the age of palm; some products crack due to improper seasoning; coco farmers, policy makers, and researchers lack awareness about the possibility of substituting cocowood for ebony; it is difficult to use tools because of the hard cocowood; people working on cocowood have limited training and experience; and there is limited managerial skills on the part of the leader of the group. 62 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Since majority of the carvers lacked knowledge of the basic business and products promotional issues, pUblicity activities were conducted. They participated in farmers' field days, world food days, 'local trade fairs, and special exhibitions. Likewise, local workshops and seminars were conducted for artisans, carvers, and extension personnel involved in the promotion of cocowood. Promotional activities are expected to continue in the future in the form of business training, involvement in media (radio and television), intensified training for carvers on finishing, and special training for leaders on certain aspects of coconut wood carving. ECONOMIC AND INTERNATIONAL TRADE PERSPECTIVES OF COCONUT PRODUCTION AND COCONUT WOOD UTILIZATION: INTERNATIONAL TRADE ASSESSMENT Dr. Achilles C. Costales College of Economics and Management UP Los Baiios The coconut industry was considered as a sunset industry because of its sluggish economic performance in terms ·of physical productivity and contribution to gross value-added in agriculture (GV A). Despite this situation, farmers still engaged on widescale cutting of coconut trees. This prompted the enactment of the "Coconut Preservation Act of 1995" which proposed that a coconut tree shall not be cut unless it has reached 60 years old. However, productivity at this age is lower. 63 PRODUCT DESIGN AND IMPACT ASSESSMENT In tenns of export perfonnance of cocowood, the following points were given emphasis: • The aggregate export perfonnance of cocowood has fallen short of the "balanced trade" standard. • Shares of coconut in total exports fell from about 10% in 1986 to only about 4 % of total export value by 1996. • Traditional products continue to be the major export earners while co co-chemicals show a declining importance as export revenue source. • There is no assigned commodity number for coconut lumber, coconut wooden pallette, and coconut-based handicrafts. In the last three years, the aggregate contributions of coconut to the economy increased but individual contribution per tree has remained small. Is there a case then for cutting coconut trees, transfonning them into coco-Iumber or processing them into higher-value products, and exporting them, too? Thus, the issue of "to cut or not to cut" was established. Coconuts should be cut at the optimal cutting age, i.e., when expected additional earnings for that year have fallen to match the maintenance cost for that year. The optimal cutting age is detennined by the export prices of the final output and the reflected farmgate prices of coconut, and the foreign exchange rate. From the economics viewpoint, considering the opportunities of generating export earning, there should be no irreconcilable conflict between cutting and not cutting a fruit-bearing tree. The coconut tree has value, both as export earner and as cocowood, and all its potential uses. It is simply a matter of timing. Timing takes advantage of both the height of the productivity of the tree and its expected value as cocowood at cutting time. Therefore, following the "optimal cutting age" rule has these implications: 1. Coconut trees may have to be cut much earlier. 2. At optimal cutting age, physical productivity may still be higher than current averages. 3. Value of cocowood may be significantly higher than when the tree is attacked by pest and diseases. 64 INTERNATIONALCDNFERENCE ON COCOWOOD UTILIZATION Open Forum Session Chairman: Dr. Wilfredo M. America C. Carpio of the Philippine Coconut Authority (PCA) asked A. Costales ofUPLB about the exact optimal age for cutting coconut trees. Because of its other emerging uses like exporting it as coconut husk, aside from using it for lumber. He further stressed that his answer to the question "to cut or not to cut" is "to cut and plant." A. Costales, on the other hand, admitted that he was not definite. , about the exact optimal age. He agreed, however, that when the optimal age comes, one could always plant and replace the tree with another high yielding variety. Therefore, there will be no loss. R. Plum, wanted to know about the effect of the peso devaluation on the coconut wood industry as far as manufacturing and exports were concerned. Specifically, he asked whether export earnings would be translated to copra. A. Costales responded that h~was not certain whether the increase in the peso prices of export earnings would instantaneously be translated into copra prices. They have not yet investigated the co fluctuation of farm gate prices with the depreciation, thus he cannot predict the effect of such situation. Another question about import substitution was addressed to A. Costales. He was asked for the amount of locally produced coconut import, significant to the country's total timber requirement and consumption. A. Costales explained that the kinds of lumber imported for construction would have a different specification from cocolumber. Thus, there might be no direct substitutes. However, he stressed that if the Philippines imports wood, then there is a chance that cocolumber can also come in to supplement the need for wood in the construction system or for some other ~estheticbusinesses. J. Calolot asked D. Fink if it was possible to produce machine composed naked lumber core from cocowood and allow the production of S4S lumber first by using the hotmelt glue and then composing it into 4x8 panels. 65 PRODUCT DESIGN AND IMPACT ASSESSMENT D. Fink mentioned that he had not tested the method yet. However, he explained that in Germany, upon delivery of about a cubic meter-and-a-half of lumber, these are manufactured into beach and softwood machine composed lumber, with a length of2.5 meters or 8 feet long. These are done according the different density classes. A. Fruehwald stated that they did not have any problem using a specific lumber substitute. However, they need to increase the amount of glue by 20 per cent to avoid fast penetration into the wood. Adjustments were also necessary when applying pressure to very soft cocowood lumber and high density lumber. A problem was encountered using the high density machine composing because the MOE of the high density material had weak surface finishing. The company, however, believed that if they produced on a huge basis, they would certainly overcome these problems. To A. Fruehwald of Germany, he asked if it was necessary for cocolumber to be dip-treated prior to kiln drying. A. Fruehwald explained that if a time frame was arranged between processing of logs into lumber and bringing them into the kiln for at least 10 days, there shouldn't be any need for dip treatment. For testing the machining properties of cocowood considering the abrasiveness of the raw material, M. Mosteiro asked D. Fink how the dulling of the knives and cutters was determined and how the quality of the machine services was evaluated. To J. Mpagalile of Tanzania, M. Mosteiro inquired about the stage when the carving process starts. Is it when cocowood is freshly cut or when it is partially dried or in season condition? Evaluating the surface quality means checking if there are splinters or tom out muscular bundles. These are compared with timbers darker Maranti and copra. Tool wares are evaluated by surface quality. The method is according to the American Standard Association method---the STM. To J. Mpagalile of Tanzania, M. Mosteiro inquired about the stage when the carving process starts. Is it when cocowood is freshly cut or when it is partially dried or in season tondition? J. Mpagalile explained that after cutting, the logs are transported to the place where the carvers are situated. It takes 1 to 3 weeks to get the log to the site and by then, the log is partially dried. Sometimes, it takes up to two months before the logs are cut while they are left outside under the shed. Carving one piece of log takes a week to finish. Therefore, in 2 12 months the logs are already partially dried. 66 INTERNATIONALCONFERENCE ON COCO'vvOOD UTILIZATION On the issue of processing cocowood using expensive materials and resources, J. Calolot clarified with D. Fink if the high cost offset the cheap price of cocowood so that ultimately, expensive finished products could be manufactured. D. Fink confirmed that it is possible since the harvesting and the transport costs for cocostem are much lower than for commercial timbers. Thus, the cheaper harvesting and transport costs can cover the higher production cost and the machining cost. There was a comment on the issue.of cost and availability and resulting cost of the material which must be considered for cocowood production. Problems may arise if cocowood is always compared with common timber species. Another comment was made regarding finding the right products for the right market for cocolumber. It was clarified that cocowood is not considered a cheap material. In fact, because of its color and appearance, it is much more accepted in Southern Europe than in Central ·or Northern Europe. The products must have a special design because a good design and an appropriate marketing system can increase the value ofthe final product, which can cover the production cost. R. Palomar inquired from D. Fink about the current cost of the complete woodworking machinery for secondary processing of cocowood. D. Fink said that the cost of the equipment depended on the type of machine. However, even second hand machinery can be combined if they are very well maintained and if the motors and the guides are still in excellent condition. They are using 30- year-old machines, which cost 5,000 German marks, and they are still good enough for processing cocowood. He admitted too that he couldn't say if an Italian machine is better than a Taiwanese machine or vice versa. He emphasized however, that the machines should be heavily designed, because it would be necessary for the machines and for the tools. A question on how to blow away the dust during the chipping process was raised. D. Fink explained that it normally depends on the chipping process. He strongly recommends a good exhaust system for the tools and for the workers. Moreover, for work accuracy, work pieces are also necessary. 67 PRODUCT DESIGN AND IMPACT ASSESSMENT K. Fa'anunu of Tonga shared his experience about a heavy-duty planer with 5 cutters that he bought from Germany. The technology in Germany is changed every year and this machine is only one year old. The tool costs US$25,000, and he believes it is a good buy. J. Mpagalile was asked about the kind of process they employed in drying the carved articles, and how the moisture content in the export site was determined. Is it by kiln drying or conventional airdrying? J. Mpagalile answered that carvers used the conventional drying method. They work, keep their carvings and dry them under the shed. One disadvantage is that when these products are exported to Europe, they start to crack specially in the sharp edges ofthe carvings a problem, which they still need to address. R. Palomar clarified from A. Fruehwald the schedule to follow when airdrying is used in combination with kiln drying. A. Fruehwald recommended that one could go directly from prelumber to kiln although pre-airdrying could be done also. In three months, moisture content is between 30% and 90% (not 50% to 250- 380%) for green lumber. This affords souring in energy and time. For the kila, there are 10-15 schedules for pre-airdrying of green lumber. For timber tools, of between 55 and 65-70 degrees Centigrade, it is generally 5 tasted with a degree MC of 15%. If a 12% final MC is required at the end of the kiln schedule, then 6% moisture content is applied. Likewise, temperature is reduced and there is a rise in the degree of moisture content equilibrium when green lumber is used. 68 en (0 ~ .-CD en Lt) ~.5 Z >CD~ .... 0° 0I en ..,CD~! r::Z en ::l-c W o r:: en Om INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION COCONUT WOOD UTILIZATION IN TONGA: PRODUCTS, DESIGN, AND MARKET OPPORTUNITIES Mr. Kaveinga Fa'anunu Chief Executive Officer Tonga Timber Limited Tonga It is important to know one's product and its market. A knowledgeable partner or agent can help in determining market, prices, and support services. For 22 years, cocowood utilization in Tonga has been concentrated on lumber, furniture, and wares needs of their domestic market. Tonga Timber and its US manufacturing partner studied coconut wood under different ronditions. Available technical information on cocowood was collected, the tradename for the cocowood products was selected, and a brochure ofthe new wood was prepared. Potential markets for cocowood can be categorized into wholesalers, retailers, manufacturers, and consumers. Products that could be made and teste4 include floor tiles, interior panels, serving trays, and cutting boards. 71 Country Overview And Networking In the Tongan experience, matching of wholesalers and suppliers is important because: • big wholesalers are not good partners for small time suppliers; • retailers are after smaller volume; and • manufacturers of furniture demand the lowest prices because they buy crude resources and process them. Building up a local market for cocowood products requires much time and local initiative. NETWORKING/INFORMATION DISSEMINATION Of TECHNOLOGIES DEVELOPED FOR THE COCONUT INDUSTRY Josephine C. Suharto Publication Office Asia and Pacific Coconut Community Jakarta, Indonesia The Asia and Pacific Coconut Community (APCC) has realized the important role of information in boosting the coconut industry. Thus, APCC has two information functions as follows: 1. provides a forum for promoting friendship, exchanging expertise and information, identifying common problems; and 2. collects, analyzes, and packages information on all aspects of coconut and related products and disseminates such information as necessary to meet the various needs of the industry. 72 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION APCC networkinglinformation dissemination strategies used on technologies developed for cocowood are publications and video documentary, training, fora, and a coconut information network. Some of the APCC activities related to the transfer of technology on cocowood include: • PCAlFAO/GTZ Seminar on Coconut Waste Utilization; • UNIDO collaboration to draw up project proposal on Coconut Wood Utilization; • Palmwood Utilization Project; • Regional Experts Meeting on Cocowood Utilization; and • Use of developed infrastructure through print and electronic media. She described the following APCC regular publications: • COCOMUNITY • Statistical Yearbook • CORD • COCOINFO International 73 Country Overview And Networking OPEN FORUM Session Chairman: Dr. Magdalena Y. Giron Y. Robillos asked J. Suharto how FPRDI could avail itself of the video documentary on coconut wood processing. J. Suharto informed the group that the videotape is for sale at $100.00. But she added that it is normally given for free to the liaison offices. She mentioned that PCA has a copy of the videotape. Therefore they can have it copied from PCA, provided they specify the video system they are using in their own countries. K. Fa'anunu was asked about the product line being exported by Tonga. K. Fa'anunu explained that the cocowood timber is cut and exported from Tonga. It is sent to Hawaii for fabrication and duplication. In terms of product development, they think of little things, which may be useful for housewives like kitchen utensils. He was proud to say that their products were US made since they were manufactured in Hawaii, although the raw material came from Tonga. 74 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION CLOSING CEREMONIES Dr. Douglas Pattie, Dr. Dominique Lelievre, Dr. Emmanuel Bello and Engr. Romulo Eala presented the token to the presentors. The following were given tokens of appreciation: Dr. Rolendio Palomar (PCA) Mr. Carlos Carpio, Deputy Administrator (PCA) Forester Catalino Pabuayon (FPRDI) Forester Robert Natividad (FPRDI) Ms. Edna Bauza (FPRDI) Ms. Ma' Salome Moran (FPRDI) Ms. Lolita Villavelez (FPRDI) Mr. Victor Revilleza (FPRDI) Mr. Dante Pulmano (FPRDI). Mr. Francisco Buhain (MERALCO) Mr. Juanito Calolot (Fancy Philippines, Davao City) Mr. Florentino Torres (Furnitureville, Pampanga) Mr. Domingo Ladao (Davao Etnokraft Design, Davao City) Mr. Benjamin Dimaano (German International, Zamboanga City) Professor-Doctor Amo Fruchwald (Germany) Professor-Doctor Dieter Fink (Germany) Mr. D. M. Sugath Dissayanake (Sri Lanka) Mr. Joseph Mpagalile (Tanzania) Dr. Achilles Costales (University ofthe Philippines Los Bafios) Mr. Kaveirga Fa'anunu (Tonga) Ms. Josephine Suharto (APCC Indonesia) Dr. Bello expressed his gratitude for the participants' attendance in the conference. He hoped that the lessons they have learned and the tips given will be of help to them when they go back to their own countries. He also commended the quality presentations done by the speakers. He further expressed hope that it will not take another 18 years to have another conference for an important product like cocowood. 75 Closing Ceremonies He emphasized the importance of cocowood as a commercial commodity stating that it could have its own niche in the world market. He hoped that cocowood product manufacturers would intensify their activities in promoting the use of cocowood. He related the initiatives of FPRDI in conducting researches on cocowood utilization as substitute for traditIonal wood species which is becoming a scarce resource, thus making it more expensive for furniture makers. As cost of raw materials increases, the more difficult it is to compete in the world market. He thanked the ITTO for funding the project on the utilization of the lesser known species or "commercially less accepted species" so that it -can be introduced to wood product manufacturers in the Philippines and abroad. Finally, he wished that all those who attended has attained their objectives incoming to the conference and hoped that their stay in the hotel as well as in the Philippines was pleasant. Ms. Robillos formally declared the conference closed and thanked the participants for their time. Lastly, she wished the participants a safe and happy trip to their destinations. 76 en w u c z w a.. a.. ID t) C ID en IDL- L- 'I ID co.. oc..o ca Q) o INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION COCO VENEER LAMINATED PANELS (Making money from Coco without the Nut) by Mr. Jacinto Calolot Owner/Proprietor, Fancy Philippines Davao City I. Introduction Whenever I am asked about the nature of my business, my usual reply is: "The manufacturing of plyboard and plywood products; and fancy panels such as Gemilina laminated, ipil-ipillaminated, and co co veneer laminated panels." The coco veneer panel almost always receives incredulous reactions such as: Is your business not doing good? Can you not find other things to do? What for? Are you nuts? Have you gone coco? I have accepted such wild reactions considering that very few people have heard of the coco veneer laminating process. While all Filipinos can claim to be experts on coconut because the coconut tree is found all over the country, people feel uncomfortable in knowing that there is an aspect ofthe coconut that they never heard about -- that the coconut can be veneered and turned into a decorative panel. Company Background My company is named Fancy Panels Enterprises, Inc. We are a very young company incorporated only last May 1996. We have been in operation for only one and a half years and are in the business of manufacturing and marketing: 3/4 Plyboard Panels 3/4 & 112 Plywood Panels MDF Laminated Boards Decorative Panels - Gemelina Laminated Ipil-ipil Laminated Coco Veneer Laminated 81 APPENDICES We are a small company with a networth of only 1/5 conventional plywood establishments. We operate almost like a single proprietorship with a very simple management set-up and working teams. We have an employment force of 130 personnels and contractual force of 65 workers. Our machinery and equipment are exactly that of a plywood line-up except that the capacities are small. Our major machines are the:hot press 8 openings, boilers, bandmills, sander, sizer, composer, kiln dryers, lumber finishing equipment and other support equipment. The equipment which is not common to regular plywood plants is our Horizontal Veneer Slicer. Business Philosophy Considering our small size, our business philosophy is focused on the principles of flexibility, creativity, and tight organization. Our philosophy is premised in putting higher value on less valued indigenous raw materials. The thrust is to find diverse commercial applications for abundant and cheap raw materials in our region. By this philosophy, we hope to establish a niche that can be regarded as artificially exclusive, which the major plywood mills do not bother with because it is too small, trivial, and meticulous. And which the small processors will also find technically difficult and financially demanding. H. coca VENEERING Initial Involvement Our Fancy Panels lines started with our desire to produce a substitute for the renowned Narra Plywood. Everybody knows that the Philippine Narra has gained a reputation for its hardness, color, texture, and consistency. The Narra veneer laminated panels have become classy decors for luxurious establishments. However, due to its disappearing supply, the market demand could not be satisfied. Thus, we produced the Ipil-ipil veneer laminated panels as substitute for the Narra panel. We then included the Gemelina Veneer, Bamboo Veneer, and Mahogany Veneer in our product lines. It was fortunate that late last year, we were introduced to the prospect of producing Coco Face Veneer laminated panels by Forest Product Research and Development Institute (FPRDI) and Department of Science and Technology (DOST). Considering this product's conformity with our business philosophy and the good supply of coconut trunks, we found the prospects of the coco veneer panels very promising. 82 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Rational of the Product We viewed the coco face veneer laminated panels almost as a pioneer product since this has never been produced and sold in commercial scale. The first and only production incident that I can remember was when the progressive company Aras-asan Timber produced 300 pieces of coco laminated plywood to satisfy the request of a Malacafiang personality sometime in 1973. We expected that this could be marketed easily even in our region. Moreover, the nearest competing product would be the S4S cocolumber which had not gained ground in the market. Impact to the Coco Farmer Our establishments are located in Region 11 of the Philippines, one of the 13 regions in the country. As in other regions, the coconut industry is very important to our region's agriculture and economy. With 70,000 coconut farmers registered in our region, one can already relate the impact of putting higher value to any aspect of the coconut. With our current buying prices of coconut raw materials at.p 7.00 per bd ft in contrast to the buying price of coconut lumber processors at.p 5.00, the coconut farmers enjoy a much higher premium. Moreover, with our processing plant in regular production, the coconut farmer finds a sure market for his felled coconut trunks, thereby eliminating the risk that the felled trees may not be sold at all. Impact to Coco Dealers The harvesting and marketing of felled coconut trees or coconut trunk materials are done in two (2) ways: a. The coconut farmers cut the mature non-bearing coconut trees and directly sell these to cocowood processors; and b. Coconut farmers allow a trader to contract the standing trees and the latter handles the felling, the hauling, and the selling of coconut fletches. With our plant becoming an outlet for coconut fletches, the traders find it more profitable to sell the qualified coco fletches to us. They sell the remaining parts at a lower price to the bandmills. 83 APPENDICES Impact to End Uses The finished products are mainly used as decorative panels to be installed in the living rooms and kitchens of medium and socialized housing units. Considering the low prices and the aesthetic value of the coconut veneer panels, the homeowners find it a good substitute. At present, the end user has these choices: Narra Plywood P. 550 per 5 mm panel Imported decorative panel p. 440 Co co Veneer Laminated Panel P. 340 Ill. MANUFACTURING PROCESS 1. Product Line The finished product of co co veneer panels are two (2) kinds namely: Regular size - 5.5mm x 4 x 8 Others - 4.5mm x 4 x 8 The product features are: Grade -LC Type - Type Il ordinary glue Finish - Sanded 2 sides Crating - 125 panels per crate Marking - Registered PS Mark The basic manufacturing processes are: Preparation and cooking of co co fletches Slicing of coco veneer Lamination over regular plywood Sanding and Finishing 2. Raw Materials The coconut flitch materials that can be processed require proper selection and classi'fication. Basically, we only select the mature and large fletches. We experienced that only the first and the second butts are ideal for veneering as these will yield lesser defects in terms of breakages, splits, and tearing. Our selections are usually guided by the following criteria: Variety - tall variety (Laguna, Tagnanan, Hijo, ,San Ramon) 84 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Age - mature, preferably 40 years and older (estimated life of coco tree is 50 to 60 years) Length - 15 meters and up Acceptable portion - first and second butts of 8' per bolt The scaling of the Coco fletches are based on the following: Coco Tree - minimum dia. is 8" - minimum length is 8' Coco fletch - minimum size is 7" x 7" x 8' - average of 12" x 12" x 8' The normal allowances for width and thickness is 112" and length is 6". It is interesting to emphasize that the coconut farmer's wife is the most feared nemesis of coco veneer processors. In the pursuit of her household chores, she uses the coconut trees as posts for her clotheslines. She nails the clotheslines on the coconut trees and leaves these nails embedded in the fletches. In most cases, these cannot be detected and coco fletches bearing 3" - 4" nails cause extensive damage to our expensive Slicer knives. 3. Coco Tree Supply in the Region There is an abundant supply of coconut trunks for veneering as well as for lumber in our region. With a large base of coconut plantations, the annual felling rate of non-bearing coconut trees is more than sufficient to meet our raw material requirements. The regional profile relevant to our product line is:- Total,land aras Region 11 - 3.2 million ha CoconlJt Planted area - 0.6 million ha Coconut bearing trees - 59.6 million trees Non-bearing trees - 4.4 million trees % of coconut tall variety '-99% Coco trees felled in 1990-95 -7,000 ha Felled in 1990-95 - 0.7 million trees Coco trees' felled rate 1996-97 - 2,000 ha Felled trees 1996-97 - 0.2 million trees 4. Raw MateriaLCost To ensure an adequate supply of coconlJt fletches for selection, we'have set a premium on the buying price of coco fletches. Likewise, we have offered the farmers and the fletch traders a scheme where we can buy the first and second butts while they 85 APPENDICES can sell to the lumber processors the remaining butts. Should the coconut farmer choose to sell his standing tree instead of fletching it himself, we also offer a buying price ofP 350.00 per standing tree-- much higher than the lumber processor's price of P 200.00 per standing tree. 5. Treatment of Coco Fletchers There is a need for the coco fletches to be cooked to soften the material. After the coco fletches are selected form the suppliers, these are physically checked for embedded nails or metals. Both ends of the fletches are also squarely trimmed with a chainsaw. There is no need to straighten any side of the fletch as the slicer can clean this. With the steam vat and water heated through the return steam condensate of our Hot Press and Composer, the coconut fletches are cooked between six to eight hours at temperatures ranging from 70°C to 80°e. In some cases, when the fletches prove to be very hard and unsliceable, we put some caustic soda in the vat. We slice the coco fletches immediately after unloading from the vat. 6. Veneer Slicing Our Slicer is a Taihei Model V -34 unit. It is capable of slicing at a thickness of 0.1 mm to 4 mm and a maximum length of 12 feet. In the case of coco fletches, we slice at a thickness of 0.5 mm. The Slicer is set at a knife angle of 18 degrees and nose bar angle of20 degrees. We normally obtain a recovery rate of60% to 75% of green veneer and leave behind a last board that is 1-3/4 mm thick. The most common problem is our difficulty in establishing the right cooking quality of the fletches which is ideal for slicing. A half-cooked fletch will be too hard for the Slicer while an overcooked fletch may yield more shredded veneers. 7. Veneer Clipping and Pairing After slicing, the veneer strips are air dried for at least 30 minutes and then clipped through our manual type of veneer clipper. We then pair and lay-up the veneer strips either individually over the plywood or stitch or join the strips into 4 x 8 pieces before laying-up. 8. Veneer Glueing The glue is spread on the plywood core panel from which the veneer strips are laid-up. The normal glue spread per panel is .6 kg per glue line and we generate 44 panels per glue mix. Our glue mix composition is as follows: Ures glue - 17 kilos per mix Flour - 3.5 " 86 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Coco shell 1.5 " Catalyst 0.5 " Water - 4.0 " Total - 26.5 " 9. Hot Press We have an 8-opening Kitagawa Hot Press. The laid-up coco veneer plywood is pressed for 5 minutes at a pressure of 160 kg/cm2 and a platten temperature of 120 D C. Our pressing cycle is approximately 8 minutes. 10. Finishing The laminated panel is manually sized. Putty is applied to open joints. The panels are then sanded with a machine sander with grit 240 sandpaper. The panels are subsequently graded, crated, and marked. From this manufacturing process, our wood recovery rates are: Slicer - 60% to 70% Clipping -90% Lamination and Finishing - 95% Net wood recovery - 51% to 60% 11. Production Cost Based on current cost and price, our cost of producing a 5.5rnrn x 4 x 8 co co veneer laminated panel is P 252.50 (approximately $ 7.50). The cost of cocowood veneer is only 5 per cent ofthe total cost while the processing cost accounts for 18% and the bulk is the cost of regular plywood. Production Cost Profile: Coco veneer cost - P 13.00 Regular plywood (5mm) - 195.00 Glue 6.50 Labor 15.00 Depreciation 13.50 Overhead 10.00 Total Cost -P 252.50 12. Financial Return We find the coco veneer laminated panels to be as profitable as our other product lines. The contribution margin averages 21 %; the return on investment at 23% investment payback should hit by 4.5 years. The investment cost ofthe 87 APPENDICES machines, equipment and infrastructure directly related mainly to the co co veneer product line is approximately 12 12 million. IV. MARKET Commercial Application The coco veneer laminated panels are commercially sold and used as decorative panels in housing, decorative materials for house and office furniture and personal accessories such as brief cases. In the long run, there should be more diversified uses of coco veneer panels. Housing Market The market outlets of our company are primarily concentrated in Region 11. The target markets are the medium cost and socialized cost housing units. As popUlation increases in the region, the high demand for housing and the significant backlog in house construction present a very promising market for this product. Specifically, Region 11's population increases by 3% each year. Davao City has a population rate of3.5% per year. Housing needs are also increasing by 4 per cent per year. Housing Needs and Backlogs of Region 11 Housing Needs Backlol! 1993 - 47,574 units 75,138 units 1994 - 48,954 86,031 1995 - 50,379 92,839 1996 - 51,895 103,766 1997 - 53,337 NA 1998 - 59,885 NA The quality of coco panels use varies by type of housing unit. On the medium cost housing units, coco veneer panels use ranges from 10 - 20 panels per unit. In socialized housing, the usage varies from 5 - 8 panels. Price of Coco Panels The retail price of the coco veneer laminated panels ranges from 12350 - 12370. The dealer price is pegged at 12 320. Compared to competing decorative panels such as Narra plywood and imported decorative panels, the price range ofthe coco veneer panels is attractive and very affordable. 88 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION v. PROBLEMS AND DIFFICULTIES The coco veneer product though simple to manufacture is not without some major problems and difficulties. Foremost ofthese are: 1. Quality of Raw Material While the overall raw material supply is not a major concern, the type, quality, and grade of the co co fletch material is still a problem. The consistency of grain texture and color (tiger suit) ofthe co co veneer cannot be formally established as the maturity and age level of the coconut trees batch. Thus, the final product cannot have consistent, uniform color and texture. Moreover, the quality of the second butt will yield low recovery as this is relatively softer. 2. Extra Tender Care The coco veneer materials require extreme care in handling. They are highly susceptible to tearing, shredding, breakages, and splits. The handling of the veneer materials requires extra care from workers who are used to casual handling of the other product lines such as plyboard and plywood. 3. Coco Farmer Wife Problem Another problem is the farmers' wives practice of using nails to anchor clotheslines. This results in the high risk of nails embedded in the fletches. These impose unnecessary cost in slicing the coco fletches. It is ironic that a 25-centavo nail can extensively damage a P. 20,000 Slicer knife. 4. Market Resistance The coco panels bear some product image problems. This is understandable considering that the coconut is associated with ordinary materials such as charcoal, cocolumber, and the ordinary "walis tingting". Low income consumers aspire for products associated with the rich, famous, and classy. High income consumers never aspire to be associated with a poor man's products. Hence, in the long run, the marketing thrust should either project a classy and elitist image for the cocopanels or create a fad for "pang masa" products. 5. Average Financial Returns The financial returns of the cocopanel can be rated as average or normal for a product of its kind. This, however, cannot be rated as attractive enough to warrant 89 APPENDICES stronger business interests that can compensate for the extra difficulties and problems that a manufacturer will face. Since the profitability of the less demanding and easier product lines such as plyboard and plywoods are almost equal to the cocopanels, one can easily understand what the businessmans preference would be. VI. RECOMMENDATIONS AND PROSPECTS Overall, the business opportunities and prospects for cocoveneer laminated panels are favorable. The abundance of raw material, the respectable profit returns, and the presence of a large market greatly support this contention. To enhance the manufacturing capabilities and commercial application of cocoveneer panels, it is noteworthy to consider some recommendations: 1. There is a need to diversify the commercial application of co co-veneer panels. A more creative approach must be made to expand usage beyond traditional hose decorative panels. More so, to allow the recovery of odd sizes of coco-veneers, new applications for other panel sizes -- 2' x 4', 4' x 4', 3' x 6', 3' x 3' -- must also be found. 2. Popular Usage. To strengthen the market base for co co-veneer panels, there is a need to push for more participation in the manufacturing aspects, preferably those with existing capabilities like existing plywood mills. Product popularity can be enhanced through higher product usage which is also related to having more manufacturers. The most ideal is enticing one plywood mill per region to include cocoveneer panels among its ,product lines. 3. Need for continuous technical study. There are plenty of areas in the manufacturing of co co panels which need improvement and innovation; more so, in the training of plant workers and the best processing methods. FPRDI and peA have significant roles to play in these aspects. Conclusion In conclusion, adding value to electronics, computer chips, and other traded imported materials may be "high tech" but low in social virtues. Adding value to indigenous products like the coconut, may be high or low in technology but definitely great in social virtues. To all of you who are engaged in any way to enhance the value and importance of the coconut for the benefit of the coconut farmer, I say to you: blessed are those who give value to the coconut, for you shall, definitely pole-vault to heaven. 90 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION UTILIZATION OF COCONUT COIR DUST FOR WASTE WATER TREATMENT by M. S. R. Moran, C. P. Estudillo, C. C. Garcia and G. A. Eusebio ABSTRACT Coconut coir dust, a waste product from the coir fiber industry, was found to be an effective scavenger of toxic heavy metal ions. Coconut coir dust was converted to cation exchange resin by condensation reaction with formaldehyde with heat and acid. The yield of resin obtained was 89 per cent. Coir dust resin was used to remove lead ions from waste water of CONSTANT BATTERY MANUFACTURING. The pH of waste water (PH 2-3) was adjusted to pH 8 with sodium hydroxide. Waste water having 8 ppm (mgIL) oflead was pumped into the first column containing coir dust resin with a flow rate of95 Llhour. The same water was again passed through the second column with the same flow rate. The lead content was reduced to 0.5 ppm which is within the limits set by the Department of Environment and Natural Resources. Financial analysis indicated that the coconut coir dust cation exchange resin cost less than the commercial cation exchange resin. Keywords: cococoir dust cation resin, water treatment, waste water treatment, cation resin 1 Paper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 2 Researchers, Forest Products Research and Development Institute, College, Laguna, Philippines 91 APPENDICES 11. INTRODUCTION The disposal of coconut coir dust is becoming an increasingly difficult problem for the coir fiber industry. While there is a big market for coir fib er, coir dust has very little commercial value. Only 5 per cent of the total available coir dust from the coir fiber industry is used as soil conditioner. Ninety-five percent is considered waste. Studies conducted at the Forest Products Research and Development Institute (FPRDI) found that coir dust could effectively remove heavy metal ions from solutions. The presence of toxic heavy metal ions in water has become a serious problem. Discharge of waste water containing heavy metals that exceed the limits set by the Department of Environment and Natural Resources (DENR) is prohibited. Big industries spend millions of pesos for water treatment facilities, but small scale industries are another matter. They often dump their waste in different bodies of water because they cannot afford treatment facilities. The problems of coir dust disposal and industrial waste water containing heavy metals led FPRDI to develop a cation exchange resin from coir dust. Cation exchange resins are insoluble materials capable of exchanging positive ions from solutions. Ill. TECHNOLOGY DESCRIPTION Technical Aspect Outstanding Features of the Technology The technology offers a method of removing pollutants from coir fiber industry and automotive battery manufacturing industry. A cheaper method of water treatment, this technology requires a lower initial capital investment than the system currently used by big industries. It is also a cheaper substitute to imported synthetic cation exchange resin - coir dust costs US$3/kg while commercial resin costs US$l O/kg. Process Flow The production of coir dust resin involves screening, drying, chemical treatment, washing and drying (Figure 1). The coir dust is passed through a one-fourth-inch screen to remove residual fibers then dried. A mixture of one part aqueous formaldehyde and 20 parts sulfuric acid (0.2 N) is added to two parts coir dust. The resulting mixture is heated at 80°C for two hours. After 92 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION heating for two hours, water is added to the mixture to bring down the temperature and eventually stop the reaction. The mixture is then filtered through a 200-mesh stainless screen, washed with water, dried, and stored in polyethylene bags. The coir dust is used for water treatment (Figure 2.) Seven kilograms of coconut coir dust was placed into each of the treatment columns. Waste water containing 8 ppm of lead was passed through the first column with the flow rate of95 Llhour. The lead content ofthe waste water was reduced by 84 percent. The same water was again passed through the 2nd column where the lead content was reduced further by 94 per cent. The final lead content ofthe treated water is 0.5 ppm - well within DENR limits. Resource Requirement Raw Materials Coconut coir dust is available from the coir fib er industry. Formaldehyde and sulfuric acid are available from local manufacturers. Equipment The major equipment needed in the production of coir dust cation exchange resin is a stainless steel mixer with a IS-kilogram capacity and equipped with heater and thermometer. Other accessories include pH meter, weighing scale, screened bottom box, jute sacks, and polyethylene bags. The column used in water treatment is a cylindrical stainless steel column with a diameter of25.4 cm and a height of2.82 m. Manpower The production requires two daily wage workers, a general manager, a consultant chemist, and a consultant engineer. The two workers will be involved in the actual production process. The general manager will be trained on the production of the resin and will be responsible for selling the product and the water treatment system. The consultant chemist will monitor the quality ofthe resin and waste water while the consultant engineer will oversee the installation of the water treatment system. 93 APPENDICES Economic Aspect Market Potential The cation exchange resin from coir dust is initially targetted for the automotive battery manufacturing industry which generates lead-contaminated waste water. Other potential markets for the cation exchange resin are the leather tanning industry, gold mining industry, and boiler-using industry. Advantages/Benefits • This is an environment friendly technology because it will utilize coir dust which is a waste material and potential health hazard. • It gives added value to coir dust which is currently used as soil conditioner and sold at US$0.10/kg. • Employment is generated through establishment of enterprises. This means creation of additional jobs for people in the rural areas. • The importation of cation exchange resins is reduced, resulting in a savings on foreign exchange reserves. • Environmental pollutants are reduced by utilizing a waste from the fiber industry to remove heavy metals from industrial waste water. Limitations of the Technology The coir dust resin is a bulky material which requires more space for storage and higher treatment column. IV. CONCLUSION Coconut coir dust was found to be very effective in removing lead ions from waste water of an automotive battery manufacturer. The per cent removal of the lead ions was 94 per cent. The final lead content was 0.5 ppm from an initial lead concentration of 8 ppm. 94 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION The number of treatment columns through which the waste water must pass would depend on the initial concentration of lead ions in the waste water. The higher the concentration of lead ions, the more treatment columns are needed and the slower the flow rate required to increase residence time of the water in the coir dust. This will reduce the concentration oflead ions to the li!ll~trequired by DENR. Pilot experiments have shown that the co co coir dust resin was effective in removing lead ions. However, installation of additional water pumps is necessary to facilitate the treatment process. Burning of the used or saturated coir dust in a close circuit incinerator is recommended to recover the lead. The gas that will evolve from this process is trapped in a condenser, where the condensate is collected for possible use as wood preservative. Based on the economic analysis on the production of coir dust resin, the project is financially viable. REFERENCES 1. Manas, Adelina, M. S. S. Romana, A. S. Torres. 1992. Utilization of Coconut Coir Dust for Water Treatment and Removing Heavy Metal Ions from Solutions. Terminal Report. FPRDI Library. 2. DENR Administrative Order No. 35. Revised Effluent Regulations of 1990. 16p. 95 USE OF COCONUT TIMBER AS ELECTRIC DISTRIBUTION POLE (The Meralco Experience) by F. A. Buhain Manager and Head, Materials Planning/Engineering, Meralco ABSTRACT In 1987, Meralco experienced an acute shortage of wood pole supply that seriously disrupted implementation of its numerous electric distribution projects. At that time, the Philippine Coconut Authority (PCA) set up a coconut tree replanting program that provided huge and continuous supply pf coconut timber. Initial studies conducted by the PCA, Forest Products Research ancl'Development Institute (FPRDI), and Philippine . Council for Agriculture and Resources Research and Development (PCARRD) showed the potential of coconut timber for use as utility pole. With this background. Meralco launched a pilot project on the use of coconut timber poles in its distribution lines. Meralco sought the assistance of a timber treating company, Pacwood, Inc., to determine the proper method in preserving the coconut trunks. After a series of experimental treatments and tests conducted on several samples, an appropriate method of pressure treatment with creosote preservative was developed. Breakload tests were also performed on some samples and these yielded positive results. In mid-1989, wide scale acquisition, treatment, and installation of creosoted cocopoles was implemented in the company's southern provincial areas. Field performance ofthose cocopoles was monitored every year and no premature decay was noticed. The high cost of pressure treating the cocopoles with creosote preservative, however, prompted Meralco to search for an alternative method in preserving the cocopoles. The high pressure sap displacement (HPSD)developed by FPRDI in treating freshly cut timbers with chromated-copper-arsenate (CCA) solution was considered. The experiment jointly undertaken by Meralco and FPRDI in mid-1990 revealed that this method was applicable to coconut timber. In view of this, Meralco embarked on a wide scale use ofHPSD-CCA treated cocopoles in its Rural Electrification Projects. This paper presents Meralco's experience in the use of coconut timber as electric distribution pole. IPaper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Boliday Inn, Manila, Philippines 96 The Company Manila Electric Company (Meralco) is an electric power distributor established in 1903. It is a privately owned, publicly listed corporation, the country's second widely held, with over 88,000 investors. It was the Philippine's second biggest company in 1996 with gross revenues ofP57.91B and the country's highest Taxpayer in:l996. It was named the Philippine's Best Managed Company in 1996 by Asiamoney Magazine. Mera1co's company philosophy is "Service with Integrity". Its vision is to be a "World Class Company by Year 2000." Meralco Electric Distribution System Mera1co's franchise area covers 9,238 square kilometers encompassing 16 cities and 100 municipalities in Metropolitan Manila and nearby provinces. It serves about 2.9 million customers with electric energy sales amounting to 20.3 billion kilowatt hours - or roughly 53 per cent of the country's electricity consumption. Its electric facilities consist of 9,319 circuit kilometers of distribution lines installed on over 400,000 poles, 73 per cent which are wood. The annual pole requirement is 45,000 pieces. Wood pole Shortage Traditionally, Meralco procures its wood poles from domestic sources, the Philippines having been once abundant in timber forests. In 1987, the country's acute shortage of wood poles seriously disrupted the construction of the company's numerous distribution projects. This was mainly due to rapid deforestation and a government enforced log ban that tightened supply sources and weakened the quality of the few available poles. To remedy the situation, the company resorted to importations and the increased use of concrete poles. But these were costly alternatives. Furthermore, importing wood poles required huge US dollar allocations that could have been used for more essential importations. Coconut Palm In its search for economical and locally available supplements to wood poles, Meralco looked into the possibility of utilizing non-traditional or indigenous materials, one of which is coconut timber. Initial studies made by government research organizations such as the Philippine Coconut Authority (PCA), Forest Products Research and Development Institute (FPRDI), and the Philippine Council for Agriculture Resources Research and Development (PCARRD) have indicated the potential of coconut timber for use as utility pole. Coconut palm (Cocos nucifera L) is mainly distributed in the tropical coastal regions between latitude 20 degrees North and 20 degrees South, where Southeast Asia is located. The Philippines is rich in coconut palm: an area of about 3.3 million hectares is planted with 438 million coconut trees. A great number of these have become over mature (over 60 years) and incapable of producing the expected number of nuts per year. Since there is a need to maintain and expand production, the PCA has set up a program to replace the old and unproductive palms with early bearing and high yielding varieties. 97 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION This will provide a huge and continuous supply of coconut timber. In the Southern Tagalog Region alone, where 63 per cent ofMeralco's franchise area is located, an estimated 1.6 million senile coconut trees are felled every year. Unless processed into usable products, these will deteriorate and finally go to waste. Structure and Properties Coconut palm, being a mono cotyledon, has no growth rings. It has an average height of 15 to 18 meters and its stem commonly grows to an average diameter of 300 mm. When cross-cut, the trunk is made ofthree distinct zones: (a) the dermal zone - the outer layer of about 13 mm is of dark brown fibrous tissue resembling the bark, (b) the subdermal zone - the transistory zone about 50 mm wide is composed chiefly of horny cardiovascular strands set closely together in soft tissue, and (c ) the central zone or core, consisting of scattered bundles of vascular strands with soft or ground tissue. The strength properties of full-sized coconut trunks are comparable with that of conventional timber species. Its average modulus of rupture (MOR) of38.7 Mpa and modulus of elasticity (MOB) of 6,660 Mpa may be classified under ANSI Class 4 timber and, therefore, suitable for electric distribution application. The moisture content of freshly cut or felled coconut timber varies c<;msiderably from tip to butt and from central to dermal zones. Air drying of round, debarked coconut trunk under shed may take 4 to 5 months. The tangential and radial shrinkage rates may range from green to oven dry and indicate positively that coconut wood is almost a check and split-free species, making conditioning by Boultonizing or by steaming-and-vacuum possible. Coconut Timber Preservation Coconut timber, being organic in origin, is subject to deterioration by termites, beetles, and fungi especially if left in contact with the ground. Conventional wood pole preservation methods like hot-and-cold bath, sap displacement and vacuum-pressure with creosote-bunker oil solution or chromated-copper-arsenate (CCA) are effective in prolonging the service life of coconut timber. I;':xcept for those to be treated by sap displacement, coconut trunks must be debarked immediately after felling. The debarked trunks must receive a prophylactic treatment to prevent incipient deterioration prior to final treatment. The degree of protection will depend on the preservative retention and depth of penetration. Meralco-Pacwood Experiment In June 1988, Mera1co started its formal experimentation on coconut poles or "cocopoles. The assistance of a local wood preserving company, Pacwood, Inc., was sought to determine the most appropriate method of preserving the coconut trunks. Vacuum-pressure by full-cell process with 70/30 creosote-bunker oil solution was chosen since it is Pacwood's standard method of treating conventional wood poles for Meralco. A first batch of27 cocopoles cut to lengths of7.5 to 10.5 meters was selected from reasonably-straight and overmature coconut trees. The poles were debarked and brushed with CCA Type-C propylactic treatment immediately after felling to prevent fungi attack. ,98 APPENDICES Only one reasonably straight pole was taken from one coconut tree. After drying for 3 months and having an average moisture content of 29.73 per cent, it was treated to a final pressure of 14.29 kg/cm for two hours. The resulting creosote retention was a low 117 kg/m3 as against the 192 kg/m3 minimum requirement. However, the resulting creosote penetration was 32 mm, exceeding the 25 mm minimum requirement. This batch was retreated for four hours but retention improved to only 124 kg/m3. Cantilever breaking strength test was conducted on three 9-meter samples which all met the 1000 kg minimum requirement fqr ANSI Class 4 poles. Actually, the samples did not break but the test was stopped at loads of 1,900 kg, 2,100 kg, and 2,400 kg to prevent damage to the test equipment. In February 1989, a second batch of 40 cocopoles was again treated. To determine if the 192 kg/m3 creosote retention was attainable, the poles were treated for four hours up to refusal, which means that the pressure cylinder was flooded with creosote solution until the cocopoles refused to absorb. The resulting retention was 230 kg/cu m, already above the minimum requirement. The average creosote penetration was 44 mm. This batch was air seasoned for five months and the average moisture content was 18.43 per cent. Creosoted Cocopole Installations With this encouraging result, mass treatment of about 1,200 coc'opoles was pursued. Typical lengths were 9.0 m, 10.5 m and 12.0 m, the optimum standard lengths extractable from each palm. These were installed in various distribution projects in the southern provincial areas. Some were installed in residential subdivisions while others were used to replace rotted wood poles on existing lines. These poles carry light loads (e.g., secondary and/or single primary line). Very few have distribution transformer attachment that is limited to 50 Kva capacity. The cocopoles stand on different environmental conditions: majority on soily areas, some in rice fields, some near canals, others in termite-infested areas. The installed cocopoles are inspected eveiy year by a team to monitor their condition and evaluate field performance. ", ~eralco-FPRDIExperiment While technically feasible, the cost of creosote-treated cocopoles became more expensive than conventional wood poles due to the volume of creosote solution consumed. To bring down the cost of cocopole, Meralco consulted Forest Products and Research Development Institute (FPRDI) for an alternate treating method that is economical yet effective. FPRDI recommended the high pressure sap displacement method that they developed. This involved the application of water-borne CCA preservative solution on the butt end of a freshly felled undebarked log by means of a high pressure pump that pushes or displaces. the sap in the log and discharges it through the tip end. After complete treatment, the log is then debarked and liberaliy bf)lshed with high concentration CCA preservative solution all over the surface. FPRDI has developed a portable HPSD equipment and supplied this to 14 electric cooperatives in the Philippines who have used the equipment to treat conventional wood poles since 1983. The equipment consists of 99 cylinder caps where pressure is built-up, a reciprocating pump driven by a 113 HP motor, a 5-kw generator, a pressure gauge, hoses, pipes and fittings. Treatment can be done simultaneously depending on the number of cylinder caps. The pump can generate enough pressure for 12 cylinder caps. To determine its applicability on coconut timber, Meralco and FPRDI conducted a joint experiment on CCA-HPSD treatment of cocopoles to observe the treatment behavior of coconut trunks and to establish treatment parameters. Mera1co provided the logistical support while FPRDI provided the technical expertise. In July 1990, six freshly cut coconut trunks with lengths of7.5 to 12.0 meters were brought to the Mera1co Abello Center in Laguna. A 450mm portion from the butt end was debarked, tapered, shaved, and fitted into the cylinder cap with a 3mm thick rubber seaL A 6 per cent concentration CCA Type C preservative solution having a specific gravity of 1.05 was injected into the cylinder cap at a pressure of 1.05 kg/cm2. After 15 to 180 seconds depending on the freshness of the specimen, sap started to flow at the tip end. After 30 to 75 minutes, again depending on freshness and length of specimen, CCA effluents started to appear at the tip. Treatment was completed as the specific gravity of the effluent matched that of the CCA solution, This took from 4 to 5 hours. Average CCA retention attained was 8.03 kg/m3 as against the 9.6 kg/m3 minimum requirement. Since the solution was infused through the natural pathways or tracheads, the penetration was not confined to the outer portion but was spread throughout the entire trunk. The experiment showed that coconut timber reacts favorably to the high pressure sap displacement method using CCA preservative with a strong possiblity that the minimum required CCA retention of 9.6 kg/m3 can be attained. It also showed that the retention at the butt and groundline portions is heavy and gradually decreasing going to the tip. This is acceptable since the degree of protection is concentrated at the portions that are in contact with the ground and most susceptible to termite and fungi attack. CCA-HPSD Cocopole Installations To further test the applicability of the process and to be able to collect more data for continuing evaluation, mass treatment of 2, 188 units cocopoles using the HPSD process was pursued. Incidentally, Mera1co launched a Rural Electrification Project to electrify the whole franchise area. This 5-year program requires the extension of primary and secondary lines even to the remotest countrysides. Since the project was already in the implementation stage, it became an opportunity to utilize CCA-HPSD treated cocopoles. Quezon Province was chosen as the pilot project site for its abundance of coconut palms in the area. Meralco purchased a 6-cap HPSD equipment set-up from FPRDI. A contractor who was doing maintenance treatment of standing wood poles for Mera1co was hired to do the treatment. The workers were trained by FPRDI experts before they were allowed to treat. Treatment was done at the project site with supervision from a Mera1co engineer. Initially, CCA retention was below the requirement but as the treatment progressed it began to improve and eventually exceeded the 9.6 kg/m3 minimum requirement. With continuous technical assistance from FPRDI and practical suggestions from the contractor, 100 the initial problems encountered during the treatment were eliminated and the process was improved. Observations and Conclusion Periodic inspection of cocopole installations revealed that so far, 91 percent of the creosoted cocopoles are still standing after eight years in service while there are still 82 percent of the CCA-HPSD treated cocopoles installations after six years. Majority of the replaced cocopoles were those downed by typhoons while a small portion was damaged by termites, particularly those with low creosote or CCA retention. After careful evaluation of the experiments and pilot installations, it can be concluded that cocopole is an acceptable substitute for wood pole as electric distribution pole. Meralco took the bold step of using coconut timber in its distribution system but this does not mean that cocopoles will replace conventional wood poles. In fact, in line with the vision ofa "World Class Meralco", the company decided to shift to the use of concrete poles as early as four years ago. However, Meralco believes its experimentation on the use of coconut timber as electric distribution pole will not go to waste. Other electric utilities, especially rural cooperatives, can pick up from what was started and use cocopoles in their distribution system. 101 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION COCONUT WOOD UTILIZATION PRODUCTS DESIGN AND MARKET OPPORTUNITIES by Kaveinga F. Fa'anunu Chief Executive Officer, Tonga Lumber Limited, Nuku'alofa, Tonga, South Pacific ABSTRACT For 22 years, utilization of cocowood in Tonga has been concentrated on lumbering and manufacturing of furniture and wares for the domestic market. In May 1997, one month after the commissioning of the FPRDI's designed kiln in Tonga, the Company (Tonga Timber) exported its first container load of kiln dried lumber to its manufacturing partner in the United States of America. To date, the kiln is operating in full capacity, (36m3 per month), all of which are exported to the USA. It took Tonga Timber and its manufacturing parlner in the USA two-and-a-halfyears to study the behavior of coconut wood in the different environments that they were now exposed to in USA; carry out product designing and testing; and to thoroughly study the behavior and the general response ofthis huge and rather complex market towards coconut wood. Comprehensive study of the wood, end products, market, and technologies have' enabled the partners to determine the appropriate combination of conditions for the business to thrive. Once the environmental concerns and the growing demand for handmade and non toxic products relative to our technological and financial capacity have been addressed, it was decided that the patterns settled on the mass production of handmade household accessories using a completely non toxic and organic proprietary process invented by the partners. From lumbering through to seasoning, manufacturing, and finishing of the final product, no chemicals of any kind are involved. Use ofUS$14 portable solar dryer prior to kiln drying can totally eliminate fungal attack if the right procedures are followed. The invented finishing process, however, turn, sapstain into an asset, not a liability. ' lPaper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 102 For small to medium size manufacturer of cocowood products who are interested in finding and/or creating a niche within very large and dynamic markets, such as the USA and Europe, it is advisable to spend a reasonable amount of time in exploring the potentials and weaknesses of our wood at the market place before making commitments towards the processing side. Truly, no other wood in the world has the look of cocowood. However, it I not enough to bank on its look alone without presenting it in a way that appropriately expresses a perfect balance between the functional beauty of modern designs and the human need for natural beauty. Because of geographical isolation from the major markets, we are left behind in terms of market development and technological advancement. This widening gap often discourages us from exploring export potentials especially when we start considering the costs. To make such investment lasting and worthwhile, it is worth having a long term antenna at the market place either on agentship or partnership arrangements. No one will give us a clearer picture of the market that we are about to operate in but a member ofthat market. INTRODUCTION Until recently, the utilization of cocowood in Tonga has been confined to lumbering and manufacturing of furniture for the local market. The government has envisioned a nationwide replanting program to replace the felled senile palms with high yielding varieties or in some circumstances, with other timber trees and foodcrops. Unfortunately, the program has not been implemented primarily due to economic reasons brought about by the low prices of copra and coconut oil in the world market. In 1979 coconut plantations in Tonga totaled 35,600 ha. (Proceedings of Coconut Wood Utilization Seminar, 1979). In 1996 Landcare equated the decline in palm density to a loss of some 600 hectares per year (120 stems/ha). ("Inventory of the Coconut Palm Resources - Landcare Research NZ Limited). This indicates that if we start replanting at the same rate of cutting (600 ha/annum) the existing stock will disappear in 42 years' time. The new stock will not be ready for harvest until 60 years from now. To bridge this 18-year gap, the Company adopted a new policy reducing the cutting rate by 30 per cent while increasing our net return from 14.7 per cent to 21 per cent. The new shift in policy has been the major driving force behind our development as a responsible corporate citizen in the past few years. Instead of running two shifts to produce and sell framing timber (3200mlannum) we are now running only one shift at an increased output level of 2240m3 per annum. Only 22 per cent (500m3) are sold as roughs awn framing lumber. The remaining 78 per cent (1740m3) will be kiln dried and further processed into furniture and joinery for the domestic market. On the other hand, floor tiles, interior panels, cutting boards, serving trays, and business card holders, are being made for the export market. In order for the Company to maximize returns from the 1740m3 of lumber set aside for downstream processing, it invested a lot of money on identifying and pursuing export potentials. It invested over US$46,000 in placing wood samples all over the USA, monitoring their performance, studying customers/wholesalers' response, and identifying new products 103 and new designs. It was through this investment that the company finally secured markets and started to upgrade its processing facilities to suit these new requirements. The Company initially selected products that were easy to make, both by hand and machines, but generated much higher income. To cope with market change while maintaining customers' confidence in coconut wood, the Company, in partnership with an American businessman, set up a manufacturing factory in the USA making and selling cocowood under the "Made in USA" banner. MATERIALS AND METHODS 1. Product Specification The first step we took was the collection of available technical information on cocowood from our own experience both in Tonga and abroad and also through literature search. Having had all the information we needed, we selected a tradename for our cocowood products and started compiling the brochure for the new wood. 2. Wood Samples While the brochure was being prepared, 27 sets of airdried samples (3 pcs x 4" x 4" x 6" per set) were prepared for dispatch t the USA. 3. Market Segregation the potential markets that we selected to study wee initially categorized as follows: i. Wholesalers; timber, builders, suppliers, furniture, etc. ii. Retailers: include hardware merchants, furniture, etc. 111. Manufacturers: furniture makers, truss makers, joinery, etc.; and iv. Consumers: homes 4. Production Selection Products to be made and tested were selected on the grounds that they could be easily made using the existing machines and facilities and then fabrication did not need very specialized skills, such as: i. floor tiles; ii. interior panels; iii. serving trays; and iv. cutting boards. In the initial stages we wanted to introduce the wood samples first and see how the market responded to this new wood. One set of samples was personally distributed to some selected market segments in 14 different locations in the USA. Every sample was accompanied with a page-cfftechnical information about the coconut wood. Those who were very interested in the wood samples were earmarked for the second round. Only 8 104 serious customers were selected out of the initial 14. One sample each ofthe end products was distributed among the eight businesses. RESULT AND DISCUSSIONS Feedback from individual customers after seeing the first lots of wood samples varied from "unusually beautiful:", "very special", to exotic. A lot of them, however, found it difficult and I mean difficult to believe that-such a swaying tree could produce this unique timber. Salesmen must be prepared to do a little bit more explaining to convince customers that coconut palms produce this exotic timber. Wholesalers, in general, always talk in big volume, regularity of supply, and most often demand low prices. Big wholesalers in the States are no good partnes for small time suppliers in Tonga. Most retailers share the same views as most wholesalers except for prices and volume. Retailers are after smaller volume. Manufacturers of furniture demand the lowest price of all. That is, they prefer to buy timber in crude form (cheaper) and do the processing themselves. Of particular interest are the customers·at home. Women would like to replace their cutting board now and then. It was also noted that the service life for kitchen wares and accessories was short, approximately three months. Imagine, then how many boards and trays are needed by millions of homes every year. CONCLUSION AND RECOMMENDATIONS It is obvious from this study that all the people involved must know their products inside out before they start selling. This is extremely important when you are trying to market a new product. Coconut is beautiful but clients needs to know more about the characters behind the wood before they buy. It is also very important to appoint a representative and/or joint venture company, partner, and/or agent in the market place to advise you on changes in the marketplace and prices, as well as to provide other support services to the customers. 105 COMMERCIALIZATION OF COCOWOOD PALLET TECHNOLOGY by L.V. VILLAVELEZ ABSTRACT Technology on the commercial production of cocowood grocery pallet was verified and validated. Three local companies have been engaged in cocowood pallet manufacture since 1991. These are: 1) FBC Inc. in San Pablo City; 2) Philippine Pallet Resources (PPR) in Cubao, Quezon City; and 3) Pasajol Woodcraft in San Vicente, San Pablo City. This technology has significant effects on the pallet-using industry because it is an expansion of raw material base for pallet at a much lower cost to the cocowood producers, it is a development of a high-value-added products from cocolumber and to the countryside, it is a generation of employment. The favorable economic/technical feasibility analysis proves that the cocowood pallets business venture is feasible in any coconut-producing country. Keywords: pallet, coconut, cocowood, stringer, deckboard, traditional wood, cocosoft, cocohard IPaper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 2Supervising Science Research Specialist, Forest Products Research and Development Institute, College, Laguna, Philippines 106 IT. INTRODUCTION A pallet is a horizontal platfonn device used as base for asseJl}.bling, storing, handling, and transporting materials and products in a unit load. ., It consists of two component parts: stringers and deckboards. Boards are nailed to the stringers with three annular grooved nails per nail joint. To facilitate delivery of goods and reduce handling operation activities, the unitized handling system was designed. This system makes use of pallets. The goods are packed and carried as a unit, then handled and transported mechanically from the manufacturers' production lines to the end of the distribution chain in exactly the same fonn. A pallet therefore is essential in the handling, distribution, and storage of commercial and industrial products. It is necessary in any industry that handles commercial quantities of materials that lend themselves to stacking. It has been claimed that the greatest single gain in industrial handling efficiency has come through the introduction of pallets and special-purpose machinery such as forklifts. Reports of efficiency gain of 200 to 300 per cent through the system of palletization are common. Demand for Wooden Pallets Users Ave. Demand/mo./co. Softdrink companies 1000 Phannaceutical finns 500 Dolefil 2000 (shipping pallets) Del Monte 2000 ( shipping pallets) Gasoline refinery 500 B-Meg, San Miguel Corporation 500 Chemical Products 800 Ceramic Manufacturing Corporation 500 Exports for Japan 2000 107 I' :c "., PROBLEM OF THE INDUSTRY: Constraints in Supply of Pallets The country's dwindling timber resources, the government's selective logging program, and the increasing demand for wooden pallets have led manufacturers to improve the design and construction of pallets, as well as search for substitutes to traditionally used species. In the Philippines, the Apitong group of species has been the traditional material for pallet manufacturing. The Department of Environment and Natural Resources reported that log production further dipped by 21 per cent over last year's record, posting a volume of 758,000 cu.m. The continuous drop in log production is attributed to the decrease in allowable cut in consonance with the stiff conservation measures ofthe government. Lumber production dipped to 286,036 cu.m. in 1995 which is 30 per cent lower than the 1994 record (Phil. Forestry Stat., 1995). With the implementation of the selective logging program, the problem of shortage of raw materials for wood has emerged. Moreover, an increasing demand for wood pallets has resulted among others in increased cost of pallet lumber. This prompted the wood-using industry to look for substitute species to meet the demand of the pallet industry. Meanwhile, the country has large volumes of available coconut wood from senile trees which will pose a bigger problem if left unutilized. Utilizing these for pallets is one way of enhancing the economic value of coconut and meeting the problems confronting both pallet producer and end-users. A solution to the problem is the use cocowood for pallet manufacture. Ill. TECHNOLOGY DESCRIPTION Outstanding Features of the Cocowood Pallet Technology It is cheaper than using traditional lumber. Assuming that all resource requirements are the same, the comparative cost of raw materials is as follows: Type of Lumber US $*lbdft Philippine Mahogany Group .75 (P 24.00) Plantation Species .47 (ll 15.00) Imported lumber 1.40 (ll 45.00) Coconut lumber .38 (P 15.00) * Conversion: US $ 1 = II 32.00 108 TECHNICAL ASPECTS Raw Material Requirements The basic stress requirements for cocolumber intended for pallets should conform with the stress grades for structural timber. The lumHer must be sound, square-edged, and free from checks and decay. Permissible Defects and Characteristics • The materials should be free from grain-separation, i.e., splits and checks. • If the lumber material is a mixture of cocosoft and cocohard, cocosoft portion should be less than 50 per cent of the total volume of the lumber. • Only cocohard portion of mature coconut palms should be used for the components; however, a maximum of25 per cent cocosoft is admitted for immediate deckboards. Lumber Preparation • Exposed surfaces of deckboards and stringers should be planed or surfaced to an even thickness and width. Manufacturing Process A. Trimming the materials for deckboards and stringers to an exact length and width B. Planing of the materials for deckboards to an exact thickness and width C. Pre-drilling of deckboards to prevent splitting during nailing (The diameter of the drill bit should be smaller than the size of the nails.) D. Assembly 1. Arrangement of Components Maximum spacing between deckboards should be 4.44 mm. The center stringers should be parallel to and equidistant between outside stringers. 2. Raw Material Requirement The required 6" width cocowood for the deckboards is a problem that the processor must contend with; 24 board feet of raw materials are required for a pallet 999 mm x 1016 mm x 101.6 mm (39.37" x 40" x 4") big. For one month, raw material requirement is 28,800 board feet, at P 8.00 per board foot. 109 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Annual Raw Materials Total Cost Requirements No. of Unit US $* Cocowood 345,600 89,187.09 SS as Cocowood 10,800 8,361.29 * US 1$ =P 32.00 3. Plant Size/Capacity The minimum output is 50 pallets per day or 1,200 pallets per month. This could be attained if the machine operators and their helpers would shift to the assembly section, which would be the operation's bottleneck. Pallet size to be fabricated is 39.37" x 40" x 4". 4. Machinery and Equipment One unit each of the following equipment is needed in the fabrication of cocowood grocery product pallets: Table circular saw 3 HP, reconditioned Radial arm saw 2 HP, reconditioned Thickness Planer 5 HP, reconditioned Portable drill press 3/4 HP Stationary drill press 1-1/2 HP Set of handtools Manufacturing jigs 110 5. Labor Requirements The labor requirements for this enterprise depend on the scale of production. For a shop to produce a minimum of 50 pallets per day, services of the following personnel are needed. Position No. Manager 1 Procurement Officer 1 Bookkeeper (part time) 1 Machine Operator 2 Helper/carpenter 4 6. Plant Location The plant should be located where coconut wood resources are available. Advantages of the Technology 1. Comparable in durability with traditional species 2. Lower production cost 3. Lower cost of maintenance/replacement of component parts 111 Alternative Comparison by Benefit Cost Analysis Using the Equivalent Uniform Annual Cost (EUAC) Method Assumptions Traditional Cocowood Species 1. Price per bd. ft. US $ .75 US $ .47 2. Selling price per pallet 18.00 11.25 3. Maintenance and Repair 200 pallets/month with average of 2 deckboards to be repaired: 1 deckboard = 1.64 bd.ft. Cost! deckboard 1.23 .77 4. Replacement 1,000 pcs 1,000 pcs Replaced every Replaced every 2mos. 6mos. Items Commercial Wood Cocowood Pallet life 2 months 6 months Cost per pallet US $ 18.00 US $ 11.25 Initial Investment (12,000 pieces) .215 M 0.135 M Maintenance 5,412.00 3,382.50 Replacement 108,000.00 108,000.00 112 Benefits of the Technology 1. Expansion of raw material base for pallets 2. Utilization of available cocowood towards forest conservation 3. Generation of employment in the countryside 4. Development of a higher-value product from cocolumber 5. Lower cost of raw material for pallets 6. Favorable economic/feasibility indicators FINANCIAL ASPECTS Assumptions 1. Pallet Size = 1000 mm x 1016 mm x 101.6 mm 2. Financial Resources us $* 70% investment cost = Loan 34,081.53 30% investment cost = Equity 14,606.37 3. Loan payable in 5 years Interest rate = 18% 4. Production Program 1st year 60% of Production 2nd year 80% of Production 3-10 years 100% of Production 5. Selling Price = based on mark-up of 30% of production cost + unit cost + production cost 113 Economic/Technical Feasibility Analysis I. Investment Cost US $ 47,166.40 Fixed Investment a. Land US$ b. Buildings 6,250.00 c. Plant machinery and equipment 29,156.25 Total Fixed Investment 35,406.25 Pre-Operating Capital 2,343.25 Working Capital 9,416.40 11. Production Capacity 500 pallets/moo *1 US $ =12 32.00 Ill. Average Production Cost Estimate 9.00/pallet IV. Selling Price $ 11.78/pallet % mark-up 30% V. New Present Value (NPV) $ 27,669.407 VI. Return on Investment (ROI) 32% VII. Internal Rate of Return (IRR) 33% LIMITATIONS Working with cocowood easily dulls cutting tools because of the wood's silica content. The material also tends to split when nailed. Nailing is facilitated by pre-boring. 114 CONCLUSION Based on our Philippine experience, the use of cocowood for pallet manufacture is a feasible business venture which could be adopted by coconut producing countries. PRODUCERS OF COCOWOOD PALLET IN THE PHILIPPINES 1. Philippine Pallet Resources (PPR) Address: PPR, PMR, 3rd Floor MMBC Bldg. 670 EDSA Cubao, Quezon City 2. Pasajol Woodcraft Address: Brgy. San Vicente San Pablo City Philippines 3. CFB Philippines, Inc. Co. Address: 92 Maharlika Highway Brgy. San Francisco San Pablo City 4000 Philippines PRESENT DOMESTIC USERS OF COCOWOOD PALLETS 1. B-MEG, San Miguel Corporation 2. Francisco Motors Corporation 3. Fujitsu Ten Corporation 4. Energy Stewards 5. Resins, Inc. 6. Ever Electrical Manufacturing Corp. 7. Ashida Phils. Grating Co., Inc. 8. Amkor/Anam Pilipinas 9. SC Johnson and Sons, Inc. 10. PEMCO 11. BASF Coatings and Inks, Inc. 12. Vita Color 13. RoGenerix 115 REFERENCES 1. PHILIPPINE FORESTRY STATISTICS. 1995 2. Cotiguera, KC. 1990. FEASIBILITY STUDY ON THE PRODUCTION OF COCOWOOD GROCERY PALLETS. A TERMINAL REPORT. FPRDI Library, College, Laguna. 3. Villavelez, L.V. 1984. PERFORMANCE EVALUATION OF GROCERY PRODUCTS PALLETS FROM COCONUT (Cacos Nucifera Linn.) LUMBER. M.S. Thesis; FPRDI Library, College, Laguna. 4. VILLAVELEZ, L.V. and O.E. ENRIQUEZ. 1994. PRODUCTION OF COCOWOOD GROCERY PALLETS. A TERMINAL REPORT (UNPUBLISHED). FPRDI Library, College, Laguna. 116 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION A FURNITURE COMPANY'S EXPERIENCE WITH COCO LUMBER AND THE FPRDI-DESIGNED COMPOSING JIG* By Benjamin Dimaano, Jr. I. INTRODUCTION TO JERMOND Jermond International, Inc., was established in 1991 in Zamboanga City by Pau10 Dimaano. The company started out as a local contractor for school chairs. The following year, the company ventured into the export business and now markets wo.oden furniture and wooden home accessories to Europe, the D.S., and Australia. Benjamin Dimaano, Jr, now manages Jermond. It employs 135 workers and has a capacity of three 40-foot containers a month or roughly U.S.$ 46,000 a month. Jermond makes use of non-bearing fruit trees, gmelina, mahogany, and lauan. After wood is purchased from suppliers, the manufacturing process starts with slicing the wood to the desired thickness. The wood is then sprayed or soaked with chemicals to flush out the wood borers. About five days of kiln drying follows to achieve the right moisture content. Planning, lamination, ripping, and sizing of wood then follow. The wood is then sanded and patterns are cut out for particular furniture items. The wood parts are assembled then painted, after which they are ready for packing and shipping. 117 APPENDICES • Paper presented during the "International Conference on Cocowood Utilization" on 27-29 October 1997, at Holiday Inn, Manila, Philippines. A few months ago the company had a problem with wood borers but steps are now being undertaken to minimize this problem. There is also a need to improve the drying process of raw materials. Marketing has never been a problem for Jermond but sometimes the supply of raw materials runs low. Production capacity can further be improved if more sources of wood are found and capital outlay is increased. There is a need to procure additional equipment and manpower and to add to factory space. Another concern of the company is to lessen environmental pollution and this problem will be addressed in the next few months. 11 JERMOND'S EXPERIENCE WITH COCOLUMBER The use of cocolumber in furniture export has a bright future. Cocolumber is cheap, readily available, and beautiful when varnished. The problem with using cocolumber for furniture is that is has low tensile strength and coarse grain. The hardness of the wood is uneven. Cocolumber is difficult to paint and smoothen. To remedy the problem oflow tensile strength, cocolumber can be combined with other wood with high tensile strength, (e.g., lauan). Combining cocolumber with other wood could cut the raw material cost by at least 15 per cent. J ermond is concentrating on wood other than co co because the cost reduction will be offset by the prohibitive freight cost f:t:omZamboanga to Manila. The company's competitive edge is that it can purchase fruit-tree wood and other lumber at much lower cost than furniture manufacturers in Luzon. If Jermond produce's cocolumber furniture it would not be able to compete with manufacturers in Luzon. At present, cocolumber has a great demand in the export industry as frames -for boxes. It is also used as bases for mirrors, pictures frames, and shell products. If furniture designs incorporating cocolumber are developed and these are marketed aggressively, then utilization of cocolumber in the furniture industry would be maximized. III THE FPRDI-DESIGNED COMPOSING JIG About 6 months ago, FPRDI brought an A-frame composing jig and FPRDI designed composing jig to Zamboanga. Before that, composing was done using manual lamination. The steps involved in manual, A-frame, and FPRDI-designed composing jig are shown below: 118 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION MANUAL LAMINATION 1. Prepare the wood for lamination. 2. Glue the sides of the wood before pressing. 3. Press the wood. 4. Nail two or three strips of wood to hold the pieces being laminated. S. Release the item from the laminating frame and repeat the process. A-FRAME LAMINATION 1. Place the wood with glue on the frame. 2. Tighten the clamp to hold the wood. 3. Hammer or press the side to level the wood. 4. Further tighten the clamp. S. Apply 40 psi to press the wood together. 6. Let the glue dry for one hour before releasing the laminated wood. FPRDI-DESIGNED HYDRAULIC LAMINATION 1. Place the wood the glue on the lamination holder. 2. Adjust the retainer to hold the wood. ~ 3. Tighten the nut of the holder and place on the hydraulic press. 4. Apply 40 psi pressure. 5. Hammer or push the joint ofthe wood to level. 6. Further tighten the nut. 7. Apply SO psi pressure then tighten the nut holder. S. After tightening the nut, press the release switch of the hydraulic press to release the pressure applied on the holder and then remove the holder from the hydraulic press. 9. The process can be repeated with another lamination holder. 10. Let glue dry for one hour before removing the wood from the holder. At present the preferred methods of composing are by manual composing and A-frame composing. Manual composing is cheap, easy and fast. The disadvantage in manual composing is that the pressure applied on the wood cannot be measured and consistency cannot be maintained. If the pieces of wood are nailed together, the wood will have holes. If the pieces are left in the laminating jig, a number of jigs will be needed. 119 APPENDICES The A-frame laminating jig is easy to use. The pressure applied is consistent. Long or short pieces of wood can be laminated. The disadvantage of the A-frame composing jig is that it has low capacity and is expensive. The FPRDI-designed composing jig, unlike the A-frame, has a high production capacity. Unlike manual composing, the pressure can be accurately measured. The disadvantage of this jig is that it is very expensive (about PhP 50,000). Furthermore, tighting the nuts and the clamps is a tedious process. The jig can be further improved if it can be redesigned such that it would be faster and easier to clamp and tighten the pieces of wood being laminated. 120 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION ECONOMIC AND INTERNATIONAL TRADE PERSPECTIVES OF COCONUT PRODUCTION AND COCONUT WOOD UTILIZATION* Achilles C. Costales, Ph.D.** I. Introduction The coconut industry has sometimes been labeled as a "sunset" industry because of its sluggish economic perfonnance in tenns of physical productivity (nuts per tree) and contribution to gross value added in agriculture (GVA). In contrast to the 1980s, the contribution of the coconut industry has significantly fallen, and stagnated since then. This is evident in Figure 1 where the trend in GVA doesn't point to any significant recovery. In tenns of the relative contribution to the agricultural economy, coconut ranks a far fifth, contributing less than 10 per cent of gross value-added in agriculture (Figure 2). Moreover, it does not exhibit any behavior indicating it to be a potential growth sector. Even as early as the 1980s, particularly during the depressed world prices of coconut oil and copra, suggestions of turning coconut trees into coconut lumber had already been brewing. At the faDn level, the option to "capitalize" the value of a hectare of coconut trees-selling them as cocolumber, shifting to a new land use (e.g., high value crops), or even replanting them with new coconut varieties- is a valid private decision grounded on rationality. There are, however, segments of society, which frown upon the idea of transfoDning coconut trees into cocolumber because the final outputs (coconut oil, desiccated coconut) are among the country's major export products. In tlle language of economics, the production of cocolumber has opportunity costs, i.e., the foregone coconut products export earnings. Concern for the remaining coconut trees prompted the enactment of the "Coconut Preservation Act of 1995" (R.A. No. 8048). Under "nonnal" circumstances, a coconut tree shall not be cut unless it has reached 60 years of age. Whether this age is consistent with the tree's "economically productive life", hovever, remains to be empirically established. 11. Export Performance A. The Macroeconomy For an economy to attain the goal of "external balance", its imports must at least be matched by its export earnings. If a country is unable to do so, consistent trade deficits would have to be financed by foreign borrowing. And where there are no restrictions in the foreign exchange market, chronic trade deficits will exert pressures on the domestic currency to depreciate. The trade perfoDllance of the Philippines from 1990-1996 is shown in Figure 3. Obviously, aggregate export perfornlance, though exhibiting positive growth, has consistently fallen short of the "balanced trade" standard. It can be argued that an unabated transformation of coconut trees into coconut lumber would further exacerbate the trade deficit1Jroblem. The question is: "By how much?" B. The Coconut Industry The role of the coconut industry in total export perfonnance can be evaluated from the viewpoint of growth in the export value of coconut products over time, and its share to the total exports. Table 1 presents the perfonnance of traditional and non-traditional exports between two periods, 1986 and 1996. The export of coconut products has maintained its position as "top traditional export", growing by more than 55 per cent in a *Paper presented at the Intemational Conference on Cocowood Utilization 27-29 October 1997, Holiday Inn, Manila, Philippines **Chair and Associate Professor, Department of Economics, College of Economics and Management, University of the Philippines, Los Baiios. 121 APPENDICES decade's time. Its rate of growth, however, was slower than that of exports of fruits and vegetables (255%), and even that of mineral products (170%) over the same period. More significantly, however, the non-traditional export products have begun to dominate, both in absolute terms and in rates of growth while non-traditional exports products have increased fivefold, traditional exports had not even doubled in value. In terms of shares in total exports, the contribution of coconut products fell from about 10 per cent in 1986 to only about 4 per cent of total export value by 1996. This is shown in Table 2. Note that the share of non-traditional exports has grown from 74 per cent in 1986 to about 89 per cent by 1996. C. Coconut Export Products: Traditional and Non-Traditional, 1994-96 Traded (exported and imported) commodities are identifiable by their standard commodity code number. The number refers to their relative proximity to the rawest form of the product, to the more complex processed forms (Table 3). Coconut export products are classified as either traditional or non-traditional. Traditional products refer to those that exhibited historical dominance such as Copra and· Coconut oil. non-traditional products include coco-chemicals and other products, most of which are close to their primary forms. There are, however, items where the commodity number does not refer to products explicitly of coconut origin. Over the last three years, 1994-1996, the traditional products continued their dominance over the non-traditional forms (Table 4). Of these, crude coconut oil continues to be the main source of foreign exchange in the coconut industry. Of the non-traditional products, export revenue from coco-chemicals had been falling. In contrast, export revenue from other products has surpassed that of coco-chemicals by 1996. Under coco-chemicals, fatty alcohol remains to be the dominant export. Under other products, nata de coco occupied the top position in 1994, but drastically declined afterwards. In 1996, the most significant revenue source was the export of fresh young coconut. Table 5 provides a summary ofthe sources of export revenue of coconut products. Except for the falling revenues from coco-chemicals, no other definite trend could be established. Table 6 provides a similar summary of the share of the three major sources, where traditional products continue to be the major export earners, while coco-chemicals show a declining importance as export revenue source. Within the traditional sector, only the increasing relative share of refmed coconut oil exhibits a definite significant trend (Table 7). Crude coconut oil, again exhibits continued dominance. Under coco-chemicals, the relative importance of fatty alcohol again stands out. For other non-traditionals, the contrast is shown between nata de coco and fresh young coconut in terms of changing relative importance. There are other minor coconut products which may have been exported at one time or another. Unless, however, a commodity number is distinctly assigned to them, they fall under the heading of a more generic name, not all being of coconut origin. Among these would be coconut lumber, coconut wooden pallette, and coconut-based handicrafts - all which may come from coconut wood. These are listed in Table 8. ·122 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Ill. Cocowood: Opportunities and Opportunity Costs In the last three years, coconut export products contributed an average of around US$836 million per year. This is shown in Table 9. The value of coconut-based production was about P28.9 billion in 1996. Gross value-added in 1995 in coconut and copra production was put at P21.8 billion. The coconut industry still contributes a significant share to the economy. ,Does the Coconut Preservation Law of 1995 then stand on firm ground in placing restrictions on coconut tree cutting? Computed on a per-tree basis, with about 285 million bearing trees, export revenue is about US$2.93 per tree per year. Value of production would be about PlO 1 per tree. Gross value added would amount to P76 per tree. Thus, on the one hand, the aggregate contributions to the economy are large. On the other hand, the individual contribution per tree is computed to be rather small. Is there a strong case then for cutting coconut trees, transforming them into cocolumber or processing them into higher-value products, and exporting them, too? A. To Cut or Not to Cut The question of whether to cut or not to cut is not best approached legalistically. If the objective of the society is to maximize the benefits from each coconut tree over its lifetime, then measures of its total net worth can be reckoned with on the basis of its physical productivity (i.e., as long as the tree still bears nuts). There are real costs incurred in maintaining trees to bring out their productive potentials (e.g., clearing, fertilizing, harvesting, etc.). On the benefit side, given the price of output, the sum of (cumulative) expected revenue would increase overtime, but at a decreasing rate, dictated by the diminishing marginal productivity of a coconut tree as it ages. Granting constant maintenance costs per tree, per year, there comes a time when the expected additional revenue for the following year would be less than the maintenance cost. That may not necessarily be when the tree has reached 60 years of age. Maximizing the net benefits from a coconut tree also does not mean that the tree be cut only when the sum of all eamings through time has become equal to the sum of accumulated maintenance cost. Otherwise, net benefits would be zero, except for the cocolumber value of the tree at the end of the period. There is, then, such a thing as an optimal cutting age of a coconut tree. That is the age when the expected additional eamings of that year have fallen to match the maintenance cost for that year. Additional revenue would also be eamed from the sale of tree as cocolumber. Nothing prevents the farmers from investing in a new tree, or a new cropping system. Cocolumber can further be processed into higher fomls. A simple model of determining the optimal cutting age of a productive tree is given in Figure 4. The cumulative eamings curve assumes diminishing marginal productivity of a tree over time. The straight-line cumulative cost assumes a fixed planting cost and constant maintenance cost per year. In the choice of the optimal cutting age, maintaining a tree until point A (e.g., 60 years) would entail a loss to the farmer. Point B, at the age equal to t*, would correspond to a zero-profit option. Maximum net benefits would be attained at point E, corresponding to much earlier period of cutting age t** 123 APPENDICES The same idea could be presented through a standard "marginal analysis" method. All values are reckoned with on the basis of "additional" revenue and "additional" cost per tree, per year. This is depicted in Figure 5. Cumulative net benefits, the shaded area, is largest at point B, where additional revenue would equal to additional maintenance cost, at optimal age. B. Determinants of the Optimal Cutting Age 1. Export Prices of Final Output, Reflected Farmgate Prices Coconut In the model, higher expected price for coconut would raise the expected cumulative earnings. This would have the effect of lengthening the optimal cutting age to take advantage of higher price of output. A fall in prices would act as disincentive to maintain the trees longer, thus exerting an opposite effect. The trend in export prices (unit values) of major coconut export products is seen to be rising over time (Figure 6). 2. Foreign ExchangeRate A depreciation of the peso against the US dollar, reflected in the peso revenues of exporters and transmitted to higher peso farmgate prices, would encourage maintaining the trees a little longer. A stronger peso, all things being equal, would have the opposite effect. TillS is depicted in Figure 7. IV. Conclusion From the viewpoint of economics, taking into consideration the opportunities of generating export earnings, there should be no irreconcilable conflict between cutting or not cutting a fruit-bearing tree. The coconut tree has value, both as export earner and as cocowood, and all its potential uses. It is simply a matter of timing. The timing has to take advantage of both the height of productivity of the tree and its expected value as cocowood at "culling time." There is such a thing as optimal cutting age. It should not be earlier, or the potential of increasing net profits from the fruits the next period would be forfeited. Neither should it be later, otherwise, incremental costs would be higher than incremental benefits. Furthermore, there are opportunity costs to delaying the "capitalization" of the investment in the tree as potential cocowood. It should be borne in mind that beyond the optimal cutting age, the tree would still be physically productive (i.e., still bearing some nuts per harvest cycle). From the economic perspective however, it would be inefficient and uneconomical to maintain it, even if gross export earnings could still be generated. Thus, the presence of positive export revenues and extremely low revenues per tree, per year, can coexist where there are legal restricitions to when trees can be replaced. It is quite senseless from the economic standpoint to generate coconut export revenues at all cost. There are particular implications that would be forthcoming if the "optimal cutting age" rule were followed. The more silent ones would be: 1. Coconut trees may have to be cut much earlier than the Law (R.A. No. 8048) prescribes; 2. At the optimal cutting age, the physical productivity of the tree may still be higher than the current averages (e.g., 40 nuts per tree, per year), and the realized gross export earnings may still be higher than the current averages (e.g., US$2.93 per tree, per year); and 3. The value of the resulting cocowood as the tree is cut at the optimal age may be significantly higher than what would be realized when one waits for the tree to be attacked by pest and diseases, or to be retired due to senility. 124 COCOWOOD W ARES* by Mr. Domingo H. Ladao Proprietor, Davao Etnokraft Design I. INTRODUCTION HISTORY In early 1954, our late father Mr. AI:fredo Dulanas Ladao started a wood turning enterprise as a means of supporting his 11 children in our hometown at Padada, Davao del Sur in 1954. At that time, he used a fabricated wood lathe run by a one-horse-power gas engine. We were turning then wooden balusters as big as four inches in diameter, using different hardwood material~abundant at that time in any lumber yard. Later, we renovated some of the wooden lathes and were able to produce flower vases, jewelry boxes, other wooden vases, and other designs. With the favorable outcome, we tried other woods from big pagatpat and old guava trees gathered with an ax, a two-man saw, and a hand saw. From these, beautiful products were produced and marketed in Davao City. In 1961, the family decided to move to Davao City and continue the business. Gathering pagatpat trees along the shore was tedious using only 2-man saw, hand saw, and an ax. Fortunately, when the city government started its widening project, huge acacia trees were cut down and offered to us when dispose became a problem And so, we were able to make big jars. The time came when the family decided to name our establishment the Ladao-Herrera Woodcraft and acquire a business. When the city government noticed and acknowledged our products, we were invited to participate and promote our products in different exhibits and occasions. * Paper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 125 APPENDICES The business started only with the Ladao children and three grade six pupils who voluntarily worked as helpers for financial support for their education. With the government's banning of the cutting of mangrove and acacia trees, our raw materials became scarce. The most dramatic thing happened when the business decided to close temporarily, until such time when new subdivisions opened and land owners and developers cut down coconut trees. It was at this time that we tried to find other alternatives. We then made products from cocowood painted with ethnic designs. Marketing was done by attending several trade fairs sponsored by the National Cottage Industries Development Authority (NACIDA). We registered as a cottage industry in 1983 with Philtrade along Dewey Boulevard in Manila. Several buyers became interested in our products. This inspired us and encouraged us to keep improving. Davao Etnokraft was established in 1985 as a separate establishment by the Ladao's eldest son. NAME OF THE COMPANY The company's name DAVAO ETNOKRAFT DESIGNS was chosen because of the company's ethnic designs. YEAR ESTABLISHED The company was established last 1985 when the eldest son of Mr. Alfredo Dulanas Ladao put up his own company. LOCATION The company's office is located at the home of Mr. Domingo H. Ladao at #53 Jupiter St., GSIS Heights Subdivision, Matina, Davao City. Its shop is located at Matina Aplaya, Matina, Davao City. The availability of raw materials and transportation presents no problem since the working place is just a short drive away from the city. 126 D. PROFILE OF THE COMPANY A. Type of Company The company is a single proprietorship. It is a small business, thus, the proponent does the planning, organization, and management. Considering its size, only a small group of people manage and supervise its activities. B. Activities/Services of the Firm The owner serves as general manager of the company and oversees its program At present, the company is engaged in various activities such as attending business affairs, recruiting skilled workers, coping with the demand for the product, delivering products and transacting business. Moreover, the products are being produced as they are ordered. However, the volume of the products depends on production capacity. The customers accept all we produce. C. Plant Capacity The plant, located at Matina Aplaya, Matina, Davao City, is accessible and spacious. It has the capacity to stock co co wood averaging 500 pieces, 400 pieces, and 100 pieces of small, medium, and large, respectively. It can also accommodate the machines needed for the manufacturing of the products. D. Raw Materials • Co co trunks • Bamboos E. Overview of Manufacturing Processes The trunks are cut into desired sizes by the chain saw then turned into items while they are still fresh. Then the items are dried for least two to three days in a controlled temperature and air dried for a day or two under the shade. Machine sanding for both inner and outet:portion of the items follows. 127 APPENDICES Preservatives and chemicals are put on the items, smoothed by hand, and then stained. They are then hand painted and stained. F. Products The company manufactures products from co co and bamboo for gifts, house and office decors, and house wares. It is recommended that prices be based on total variable cost, since this is the factor most likely to change. Prices, too, will vary in accordance with the sizes of finished products. F. Market of Products The products are marketed to stores serving local consumers and tourists. They are being exported to foreign countries. To ensure a steady market, we participate in fairs and exhibits to promote the product and to get in touch with importers and/or their agents. In addition, the company is making quality products with nice designs painted on them pace with market and fashion trends. Trainings and product development seminars help us do this. The company, too, has a showroom to display attractively designed products. ID. PROBLEMS AND CONSTRAINTS The company faces problems such as lack of capital to aid in the buying of new equipment and machinery. Production and orders will be limited if without substantial financing. IV. RATIONAL By generating employment and income, the business directly benefits individuals and families. Indirectly, the entire economy may benefit. More income in the hands of people would mean greater demand for other goods. This additional demand may, in turn, stimulate the production of more of the other goods, thereby generating further employment and income. The company will turn out to be a worthwhile venture, given the recommendations of forwarding our efforts and all the best the company can do to produce products of better quality. 128 SECONDARY PROCESSING OF COCONUT PALMWOOD* by Dieter Fink Application Training And Management GmbH Reutlingen/Germany The following paper on ''Secondary Processing of Coconut Palm Wood" is based on experience gained in the course of a research program "Utilization of Coconut Timber from North Sulawesi, Indonesia" executed on behalf of the Federal Research Centre for Forestry and Forest Products in Hamburg/Germany. In addition, the findings presented in this report reflect practical experiences made in plants in South East Asia and in the Pacific region, where coconut wood is processed. First of all, I must state that, as far as chipping is concerned, cocowood has been the most difficult wood I ever had to do with. Even tropical species with a density in excess of 1 are less demanding them medium and high density cocowood as far as tools, machines and human skills are concerned. Before getting into the matter, I must therefore state that principally the further processing of cocowood is more cost-consuming than traditional species, as subsequent calculations in various plants have shown. This is due to: • high tool wear, • an extremely low machining performance per unit of time and, consequently, • low processing speeds and a low output, • high investments in highly dimensioned machinery, tools, and extraction • equipment, • relatively small log diameters/dimensions, • wooden parts of one raw density class featuring small cross sections, and a lot of grading and sorting work. • Paper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 129 APPENDICES However, much lower harvesting and transport costs can make up for the high processing costs (the plantations are on relatively even ground and easily accessible, no forest roads are required since there are large distances between the trees). In the following I will cover the most important findings regarding • machining of cocowood • gluing • surface finishing Machining properties In the course of the above-mentioned research programme, the following machining methods were explored: • Circular sawing • Band sawing • Planing • Profiling/moulding • Form shaping/moulding • Boring • Mortising/tenoning • Dovetailing • Swing chisel mortising • Sanding (wide faces, edges, profiles) • Lathe-turning The results of the study were verified and complemented in various plants where cocowood is processed. All cutting edge materials used for its machining were studied, with the exception of mono- and polycrystalline diamonds and ceramics for cutting edges or knives. Besides aluminum oxide (Ak03) as conventional sanding material, we also tested zirconia alumina, which is normally used to grind metals. Both the surface and the edge quality were vjsually evaluated directly after the machining process to see whether there are any splinters (tom out vascular bundles) and raised grains. 130 The reference species were popular (compared with Cocos M.D.) and dark red meranti (compared with Cocos H.D.) In addition, we measured the cutting edge wear and the dulling of the cutting edge where this was technically possible. The suitability for machining and the surface quality depends on various factors: • the material • the process • the tool and • the machine To come straight to the point: our studies revealed that the absolute value of the feed per tooth :fZ, plays an outstanding role, compared to the other parameters. It is much more important than, for instance, cutting with feed or cutting against feed method, which usually plays a major role when processing conventional species, among others, because of the pre-splitting effect, which is more or less strong when processing conventional species. In the following, the relevant results of our findings are summarized: • Carbide-tipped cutting tools are the prerequisite for economical and good quality processing on an industrial scale. Stellite-tipped circular saws, for instance, can provide good results when cutting logs. And stellite can also be used for planing operations to achieve satisfactory results. • The cutting material, the density of the cocowood, and the feed per tooth:fZ, as the most important process parameter, must be well-matched. • As far as cocowood is concerned, the feed per tooth :fZ has a greater influence on the processing quality than the cutting with feed or cutting against feed factor. • Profiling vertically to the fibres should be avoided, if possible. • For large cutting depth or chip removal volumes, multiple processing steps or passes are necessary. • End-face planing (hogging) ensures, compared to peripheral flat planing or conventional planing, better surface qualities. • Boring in all fibre directions brings satisfactory results, even when using HSS bits. Conclusion: dowelled joints are ideal for cocowood. • Narrow band sawing using carom-vanadium sawblades is very problematic when cutting cmved work pieces; the average life-distance is 3 m per sawblade. Therefore, hardened band-saw blades are strongly recommended. • Mortising, tenoning, and dovetailing are possible. However, there are extremely strong cutting forces, as well as splinters at the tool exit side. Good counter-stops are 131 APPENDICES therefore necessary. Better: to avoid these processes and to use dowelled joints, provided that the stability of the joint is good enough. • When using aluminum oxides (Ak03) for the abrasive particles, sanding is highly problematic because of the very short lifespan of the sanding belts. Recommendation: 1. Sanding process: across the grain 2. Sanding process: with the grain Use sanding belts with zirconia alumina. Lathe-turning does not pose any problems when processing cylindric work pieces, even when HS cutters are used. Avoid highly profiled lathe-turned components with a profile base narrowing to a point. The cutting tool tip (lance) should always have a certain radius and should not taper to a point. Concluding, the following can be stated regarding the above-mentioned processing methods: • high blade wear, even when using carbide-tipped tools, and, consequently high tool costs • due to relatively small feed per tooth rates, the. output is smaller than with conventional species • high cutting forces with co co 's lID high amount of dust and fine particles - polluting the direct environment - tool dulling 4 good dust extraction equipment is necessary • machines, drives, bearings and guides must be adequately dimensioned 4 industrial processing of cocowood requires ''best'' machines and tools • wet cocowood is easier to machine than dry cocowood. Recommendation 1. pre-processing in "wet" condition 2. kiln-drying to the required final moisture content 3. final processing 132 Attention: Dimensional changes and possibly surface cracks have to be taken into consideration! Gluing Gluing is not only necessary in case of constructive joints such as dowelled joints, but also with a view to the relatively small cross sections of a density group. In addition, gluing is required to achieve larger dimensions, for instance when producing solid wood panels and scantlings. Basically, all types of glue designed for gluing wood can be used to glue coconut palm wood. This includes PVA adhesive, urea, melamine and phenol-form-aldehyde adhesives, as well as epoxide and polyurethane adhesives. The choice of the adhesives depends mainly on the conditions of use (interior/exterior use, climate resistance) and on the machining conditions Goint gluing, assembly gluing, fitting tolerance of the components, wood moisture content). In principle it can be stated that coconut wood has a very good glue-ability. Pre-conditions for gluing Cocos nucifera • The cocowood must be dried to the final wood moisture content corresponding to the subsequent application climate. • The surfaces that are to be glue-bonded must be smooth and dust-free, and there must be no vascular bundles projecting from the surface, as they impede the required joint fit. • Wood joints must be machined to an accurate fit and must have sufficiently large adhesion surfaces appropriate to the joint strength requirements (dowels versus double mortise and tenon). • A sufficient amount of glue must be applied. The basic parenchrymatic tissue of coconut palm wood has a high absorbency that takes up the adhesive rapidly and thus leads to a starved glue line~This effect occurs especially with cross-grain wood surfaces and with Cocos nucifera LD. Remedies include high-viscosity adhesives (based on PVA) or a double application of adhesive to these critical surfaces. Note: Dowel holes may have a high proportion of cross-grain surfaces. 133 APPENDICES Special instructions regarding the technique for glue-bonding Cocos nucifera The use of glue-bonded profiles for full-width glue bonding may have advantages in certain applications (strengths, reduction of thickness misalignment). Care should be taken to ensure that glue-bonded profiles do not taper to a point, since otherwise there may be machining problems and less accurate fits as a result of projecting vascular bundles. For this reason, finger joints are not recommended. It is absolutely possible for the various layers to have different densities when manufacturing laminate scantlings and boards made of multiple layers. Thus, in three-layer panels the facing layer can be made of Cocos nucifera HO and the core layer of Cocos nucifera MD. This must be seen as a great advantage for the economic use of coconut wood, since the yield factor can be improved considerably as a result of the ability to use medium and low density wood. Surface finishing A well-sanded wood surface is a pre-condition for high surface quality. The fine sanding of Cocos nucifera should be carried out with 100/120 grit, parallel to the grain, and at a low pressure. Staining Cocos nucifera absorbs stain very well. The variations in the colour of the wood of the kind that often occur with Cocos nucifera can be evened out very well by staining. Because of its properties, the parenchyma absorbs the stain more strongly during staining than the vascular bundles, which lead to a negative staining pattern in the case of very dark stain shades (i.e., the vascular bundles appear paler than the parenchyma.) Prime and top coating The prime and top coating of Co cos nucifera. MD can cause problems if the coating material is not properly formulated because the parenchymatic tissue is softer than the fully curedlhardened coat layer. In the event of mechanical stress, the brittle coat cracks or ''whitens'' because of the soft substrate. This effect can be avoided by using elastically formulated PU (polyurethane) paints. Fibres raising after application of the prime coat, especially with water-based materials, must be removed by intermediate sanding. 134 Coconut palm wood can be treated with all of the finishing systems that are suitable for finishing/painting wood, provided that the material is formulated "elastically". Finalremarks The industrial use of cocowood requires professional approach and processing. This already begins with the design of the end product. Not all of the design and construction principles and methods of realisation, which are known from conventional species, are applicable to cocowood. As outlined before, the processing costs are relatively high due to high tool wear, a low output per time unit, and the relatively high requirements regarding the machine and tool design. The proportion of manual work during secondary processing should be kept low, since the tools that can be used here are not very efficient. Nevertheless, realisation of processing quality that meets international standards is a challenge, in particular for up market products such as furniture and interior decoration items. But despite this, I would like to encourage potential wood processing companies to use this valuable and aesthetic raw material in an economically sensible way. Meanwhile, sufficient positive experience and know-how are available to help avoid mistakes and to enable manufacturers to process and market this material in a profitable way. In the future, there will be a shortage of wood in this part of the world. In the long run, wood from plantations such as rubberwood and gemelina, which are heavily used today, is not the perfect.solution. The market depends on change. It is high time for cocowood to come in. 135 COMPOSING JIG FOR THE PRODUCTION OF CO COP ANELS FOR FURNITURE] by E.B. Bauza2 ABSTRACT Composing jigs designed at the Forest Products Research and Development Institute (FPRDI) were fabricated and service-tested at Jermond Sash and Furniture Co., in Zamboanga City, Philippines. One design is an A frame-like structure made from apitong lumber fastened to each other with bolts. Pressure is supplied by means of an inflated water hose canvass by pressing on the glued assembly edgewise. The other design is a hydraulically- operated press where a hydraulic jack supplies the pressure. The A-frame composing jig could produce cocopanels with a maximum size of l.2m x 1.5m. the hydraulically operated composing jig could produce cocopanels with a maximum size of I.Om by I.Om. Continuous operation is possible. Panels were made by edge-gluing lumber strips using polyvinyl acetate glue. Pressing was done with the use of the composing jig. Panels produced were made into trays, medicine cabinets, slim chests, and other products exported to other countries. Keywords: composing jig, coco panel composes, cocolumber, and composing jig I Paper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila. 2 Senior Science Research Specialist, Forest Products Research and Development Institute, College, Laguna. 136 H. INTRODUCTION The biggest problem the wood-based industry is facing today is scarcity of raw materials. Traditional sources of raw materials are diminishing both in quality and availability. The industry is faced with the challenge of using lower quality wood, finding substitute species, and increasing recovery. Senile coconut trees are abundant in the country. Statistics shows that there are 132 million trees that need cutting. This big volume of available lumber can be used as substitute raw material for the furniture industry. One drawback in the use of cocolumber, however, is its narrow width. This is because during sawing the trunk has to be turned several times to obtain a lumber of uniform density since density variation is very large from the central zone to the peripheral zone. To fully maximize coconut lumber as a furniture component, this may be formed into wide panels by edge gluing the lumber narrows. Edge gluing can be done with the aid of a composing jig, an equipment which can be operated manually or automatically. The composing jig is designed for small-scale furniture makers. With this gadget lumber narrows can still be used in furniture making instead of just being used as firewood. Ill. TECHNOLOGY DESCRIPTION Technical Aspect Features ofthe Technology Two designs of composing jig were made. One is an A-frame like structure made from apitong lumber fastened to each other with bolts. Pressing is done by means of an inflated waterhose canvass which pushes on the glued lumber strips edgewise. A panel with a maximum size of 1.2 m x 1.5 m can be made with this gadget. Another design is a hydraulically-operated equipment which has a working table made from low carbon steel. A hydraulic pump from pushing the hydraulic jack against the glued lumber strips supplies pressure. Retaining clamps are provided to hold the glued panel in place after pressure has been applied. The whole setup can then be removed from the table, then continuous operation is possible. This gadget can produce panels with a maximum size of 1.0 m x 1.0 m. 137 Process Flow Production of composed panels involves eight operations. 1. Planing - machining lumber strips on both sides to obtain the desired thickness 2. Ripping - machining lumber strips to the desired width 3. Cross-cut trimming - cutting lumber strips to the desired length 4. Sorting - sorting lumber strips to discard inaccurately machined and defective strips 5. Gluing - applying glue on the lumber strips through a manual roller spreader 6. Assembly - arranging the glued lumber strips in the working table with the retaining clamps 7. Pressing - applying pressure by means of a hydraulic press (Retaining clamps are tightened once the right pressure has been attained) 8. Curing -removing the whole panel which has been clamped from the table and setting it aside until the glue has been properly cured Resource Requirement 1. Composing jig (assuming that the adopter already has the basic woodworking equipment) 2. Additional manpower for the sorting, machining, gluing, and pressing operations Economic Aspect Market Study Local Market - The use of composed panels for furniture making is not very common. It had been used before mainly as the inner core for blockboard making. Recently, with the depletion oflarge-diameter logs, small-diameter logs have been tapped for furniture making. To produce wider boards, the lumbers from small diameter logs are composed using a wood composer. Composed panels are used mostly for small furniture items such as small cabinets, chests, and trays. Interviews with furniture producers revealed that most of them did not know that coconut could be composed and used for furniture making. They did not use cocolumber because traditional woods, such as lauan, tanguile, narra, mahogany, etc. were still abundant in their place. Only one firm tried using coco-composed panels but found it was difficult to use fot furniture making. 138 Export Market - Composed panels produced locally are geared towards export. According to a local manufacturer there is a demand for composed panels in the foreign market, specifically Japan. Foreign companies prefer panels that are light in weight and in color. A foreign company needs 80 cu.mlmonth of finished composed panels but the cooperator can only supply half of the demand, i.e, 40 cu.m. Investment Profile same as Export Market Production Capacity 400 slim chest/moo Initial Investment Cost P231,152 Fixed Investment P 85,000 Pre-Operating Capital P 20,000 Working Capital P 126,152 Production Cost/Slim Chest - 164.37 Selling Price 213.68 Financial Evaluation New Present Value P 167,742 Internal Rate of Return 34% Return on Investment 39.4% Payback Period within 5 years Advantages/Benefits This technology: 1) broadens the raw material base for the furniture industry; 2) expands coconut wood utilization; 3) makes possible higher recovery from cocolumber; and 4) employs additional. LimitationslDrawbacks Coconut wood is difficult to machine. It dulls blades of woodworking machines because of its silica content. Its dark color is another drawback since the market prefers light colored panels. IV. Valuable Lessons/lnsights Gained During Project Implementation/ Technical Commercialization Activities The equipment was brought to a cooperator in Zamboanga City, Jermond Sash and Furniture Co. Its product lines include trays, plant hangers, chest, cabinets, and other novelty items exported to other countries. The raw material for these is lumber from fruit trees. Lumber is edge-glued with the use of a manual composer. The equipment proved to be very useful to the company. Production of composed panels was increased with the use of the composing jig. 139 However, the use of coconut lumber raw material is still unacceptable to the cooperator. He fears that cocowood panels do not have a market, especially abroad. Aggressive promotion of coconut lumber as substitute species is imperative. Manufacturers must be convinced that it is an acceptable material and that it is appreciated worldwide. Promotion can de done through trade fairs and exhibits of various products from cocolumber. V. PROSPECT/FUTURE DIRECTIONS Coconut lumber as a raw material for the furniture and novelty products industry has a bright future because of its abundance and affordability compared with lumber from the traditional species. However, promotion and marketing strategies must be carefully planned and implemented to encourage manufacturers to use it. The composing jig, on the other hand, seems easier to market because it can be very useful to small scale manufacturers, affordable, and easy to operate. VI. CONCLUSION Technology on the production of cocopanels through the use of a composing jig is designed for small-scale manufacturers of furniture and novelty items. It is a low cost technology yet very useful, especially on the production of high value added products. However, the use of cocolumber needs some promotion and marketing strategies for it to be better appreciated as a substitute raw material for the furniture and novelty products manufacturers. 140 LITERATURE CITED Killman, w. 1988. How to process coconut palm wood. A Handbook. Deutsches Zentrum fur Entwicklungstechnologien - GATE. Federal Republic of Germany. Laxmana, M.G. and D. Hemandez. 1989. Development of composing jig for lumber core production for furniture components. Terminal Report. FPRDI Library, College, Laguna. Mosteiro, A.P. 1978. Utilization of coconut palm timber: its economic significance in some countries in the tropics. Forpride Digest 7(1): 44-55. 141 COCOWOOD FURNITURE by Florentino G. Torres I. INTRODUCTION Brief history of the company Name of the Company FURNITUREVILLE, INC. Year established 1980 Contact address Mr. Florentino G. Torres ll. PROFILE OF THE COMPANY A, B, C, (See attached paper) D'. Raw Materials: Mahogany E. Overview of manufacturing process F. Products 1. Primary Product chairs, tables, consoles, frames, armoires, living room set 2. Specification K.D. Solid Mahogany wood/plywood/veneered MDF with hand carved highlights and lacquer finish with some gold leafing 3. Production 1-45 footer container a month 4. Price FOB Manila G. Market of products 1. Local 20% end users 2. Foreign 80% USA, UK, Hongkong Hotels Furnished Diamond Hotel Hotel Nikko Manila Garden (now Dusit Hotel) Hotel Intercontinental Manila 142 List of Foreign Buyers Pettigrew Associates, Inc. (Dallas, Texas USA) Florida Manufacturing (Miami, Florida) Golden Oldies, Ltd. (New York) Stein World International (Memphis, Tennessee, USA) Pierce Martin Corporate Office (Atlanta, Georgia) Royal Green Enterprise Ltd. (Ontario, Canada) Clock House Furniture (United Kingdom) Hera Corporation Ltd. (Seoul, Korea) Signature Imports (Australia) International Interiors (Phoenix AZ, U.S.A.) Korea Trading International, Inc. (Seoul, Korea) The American Suppliers (Guarn) Fuente Furnishing (Malaysia) Smile Industries, Ltd. (Hongkong) World Glory Trading, Ltd. (Hongkong) Edwards International (Shelbyville, Tennessee) Mrs. Lilian Plummer (Mt. Butler Rd., Hongkong) Mrs. Carol Souders (Hongkong) Mrs. Beth Krueger (Hongkong) Sherlock Brothers, Ltd. (Dublin, Ireland) Phil. Am. Food Mart (New Jersey) Pricing FOB Manila Irrevocable Letter of Credit on Sight to the account of FLORENTINO G. TORRES FAR EAST BANK & TRUST COMPANY FEBTC Bldg. Muralla, Intramuros, Manila Forwarded to FEBTC Dolores Branch San Fernando, Pampanga, Philippines FCSA Account No. 1199-0038-8 Minimum Order US$ 10,000.00 Below US$ 10,000.00 an additional ofUS$250.00 for documentation, DHL, and other shipping requirements (Crating if necessary is additional on cost.) 143 COMPANY PROFILE Name of Company FURNITUREVILLE, INC. Pampanga Showroom 29 San Juan Bautista, Betis, Guagua, Pampanga 2003 Factory & Office Address Bldg. #3 Pio Production Center, Porac, Pampanga Manila Showroom #95 Scout Rallos, Quezon City Contact Person Florentino G. Torres, President & Chief Executive Officer Imelda S. Torres, Treasurer & Chief Operating Officer Telephone No. Pampanga Showroom (63-45)910-118 Res. 63- 15) 910253 Pampanga Plant/Office: CM(0912)301- 9881 :360-9544 Q.C. Showroom: 426-1437 Res. Manila (632) 716-3947 Fax No. (63-45)910-075 Year Established 1980 Year of Export 1988 Classification Manufacturer and Exporter Legal Status Corporation No. of Employees 100 Product Range Finely Handcarved Chairs, Tables, Consoles, Frames Pedestals and Sofas Total Assets P 25 million Export market U.S.A. Ireland, Hongkong, Australia, Singapore, Korea Registered with Export Promotion Organization CITEM Membership with Trade Associations Member, Chamber of Furniture Industries of the Philippines (Pampanga) Exhibit Participation C.l. T .E.M. 1988-89-90-91-92-93-94-95-96, & 97 ECC-Asean, High Point North Carolina, USA 1989-94 Hamburg Furniture Fair 1992 Singapore International Fair 1992 Berlin Fair for Progress Show 1992 Birmingham, U.K. January 1993 144 Grants Taipei Study Mission 1986; EEC-Asean Program U.N.D.P. 1989; North Europe Selling Mission 1990; Japan's Jetro Selling Mission 1990; U.N.D.P. Prodex Program 1992; Swedecor Program 1992; CDG Export Marketing Program 1992; 1996 ECCP European Wood Mission 1997 High Point Furniture Show in North Carolina Ill. PROBLEMS AND CONSTRAINTS 1. Good quality wood supply 2. Lack of middle managers and floor supervisors 3. Shortage of skilled technical personnel especially in the milling and finishing department 4. Marketing - finding a buyer who would require a minimum number of designs in volume order and who has constant orders so production could be scheduled IV. RATIONAL/CONCLUSIONS 1. Look for alternative wood materials suited for reproduction furniture, if possible locally sourced. 2. Employ qualified employees even though their pay is higher. 3. Conduct intensive marketing drives offering world class products at competitive prices. 4. Streamline product line to attain higher productivity through repetitiveness 145 COCO-CHARCOAL BRIQUETTING by Dante B. Pulmano ABSTRACT Charcoal briquetting is the process of converting ground charcoal or charcoal fines into a compact form of fuel with the addition of binder and application of pressure to produce the desired uniformed-sized charcoal briquettes. The two-ton, eight-hour charcoal briquetting system developed by FPRDI is composed of a mechanized rotary type charcoal briquettor, a charcoal binder mixer, and a briquette dryer. A hammermill or crusher is optional equipment. All materials used in the fabrication ofthe equipment are locally available. The technology converts available charcoal fines generated by coconut shell granulating plants into a saleable product that provides an alternative source of energy. Other biomass wastes can also be used. Keywords: coco charcoal briquette, briquetting, charcoal fines utilization mechanized briquettor 1 Paper presented in the" International Conference on Cocowood Utilization ",27-29 October 1997, Holiday Inn, Manila. 2 Science Research Specialist 11, Forest Products Research and Development Institute, College,Laguna, Philippines . 146 I. INTRODUCTION Coconut husks, shells, and trunks could be readily converted into heat energy through combustion. All are physically light, and thus easy to ignite and burn. Through carbonization, the heat energy content of these materials can be increased. In charcoal form, they are brittle and porous, therefore, susceptible to damage. This poses a problem, especially in their transport as they do not weigh much but are considerably bulky. Thus further processing of the charcoal into a more densified and compact form fuel would improve its efficiency and quality. This process of converting charcoal into a more densified and compact fuel form is called charcoal briquetting. 11. RESOURCE REQUIREMENT A. RAWMATERIALS 1. Charcoal As of December 23, 1995, the Philippine Coconut Authority listed about nine registered activated carbon manufacturers in the country. They have a total capacity of 53,087 MT with by-products of semi-carbon briquettes and charred granules with a capacity of3,120 MT and 574 MT, respectively. There are also 14 coconut shell manufacturers/exporters with undetermined capacities. However, it has been estimated that the volume of charcoal fines generated by these plants is about 10 per cent of the total annual capacity of 5,308 MT. This is 0.03 per cent ofthe total volume of coconut shell available for disposal. There is an estimated 7.74 million MT of coconut shell and coconut husk. A conservative estimate of 10 per cent ofthis or about 77,400 MT is available as raw material annually for charcoaling. At 25 per-cent-average charcoal recovery, 193,500 MT is available for briquetting every year. 2. Binders Binders are classified into: Smokeless Binders - The meal binders, such as cassava starch, corn starch, and other "starches, are smokeless but not moisture-resistant. They are normally in the range of 4-8 per cent on the oven dry basis. In S01Jlecases, small amounts of a moisture resistant binder are added. Smoky Binders - The known smoky but moisture resistant binders are tar, pitch, asphalt, and sugar cane molasses. Wood tar pitch and coal tar pitches are recommended in percentages of less than 30 per cent: These two binders produce briquettes "that are smoky when ignited and not recommended for home fuel or cooking. 147 B. EQUIPMENT The FPRDI briquetting machine converts 40 mesh-sized agro-forestry wastes to charcoal briquettes. This is a rotary type model with a pair of triple row cavity molds producing pillow-shaped charcoal briquettes. The approximate capacity of the equipment is 250 kg of briquettes ( dried weight) per hour. The unit is driven by a 3-Hp (2.2 kw) electric motor, 220 VAC, 50/60 cycles coupled to a speed reducer gear box complete with magnetic starter and overload relay to drive the moIds at about 6 rpm. The briquettes produced from coco-shell charcoal fuel have an approximate density of 0.80 g/cc. The charcoal-binder mixer is a "Pan Muller" batch type system with approximate mixing capacity of250 kg/hr charcoal-binder mixture. It is driven by a 3.7 kw electric motor with gear box speed reducer and magnetic starter with overload relay. The furnace-type dryer which uses agro-forestry wastes as fuel, is a fixed bed, tray type batch system with a maximum drying capacity of two tons per eight-hour cycle. Ill. MANPOWER A two-ton, eight- hour charcoal briquettor would need six laborers to: a. Cook cassava starch into the desired consistency; b. Operate the mixer and briquetting machine, c. Arrange briquettes in trays and load them in the furnace-type dryer; d. Monitor the temperature and the fuel of the dryer; and e. Unload and pack the finished products. A supervisor is needed to oversee the production and selling of charcoal briquettes. Ill. (a) PRODUCTION PROCESS First, is the preparation of the raw materials. Lump charcoal is passed through the hammermill, then screened through a mesh 40 wire to remove soil and other contaminants. However, charcoal fines from the granulating plants could also be used. Cassava starch is mixed with water at a certain consistency and boiled until gelatinized. Charcoal fines and the binder (cassava starch) are mixed for about 2-3 minutes prior to briquetting. The briquettor produces a pillow-shaped briquette at 250 kg/hr or more. The newly produced briquettes are wet so they must be arranged in trays and placed inside the tunnel dryer. Drying takes about 8-10 hours after which the briquettes are ready for packaging. 148 IV. FEATURESOFTHETECHNOLOGY The technology: · Uses simple and locally-fabricated equipment; · Is comparable to a more expensive imported briquettor of the same capacity ( 250-600 kglhr ); · Can process other agro-forestry waste charcoal fines (e.g., sawdust, coffee, bean, corn cobs ); · Reduces use of wood charcoal for domestic and industrial fuel; and · Produces quality coco-shell briquettes. V. MARKETS FOR BRIQUETTES Export Commodity Demand for Charcoal Briquettes: Country Demand Level, mt/yr germany 52,800 holland 8,500 belgium 10,900 korea 24,000 Japan 12,000 Total 108,200 Demand And Supply Compatibility Basic Considerations: materials to be used coconut shell and coconut husk available volume: coconut shell 1.965 mtlyr coconut husk 5.73 mtlyr BASIC ASSUMPTIONS: 1. To service 10 per cent of market demand of the countries mentioned above 2. One per cent utilization ofthe coconut shells' volume and 0.5 per cent of coconut husk 149 The following demand and supply compatibility is thus presented: Demand for briquette Supply of raw materials 108,200 MTNR coconut shell = 1.965,000 MT coconut husk = 5,730,000 MT Targeted market share Targeted raw material utilization (10%) coco shell = 19,650 MT ( 1%) = 10,820 MTNR coco husk = 28,650 MT (0.5%) Total = 48,300 MT At 25% charcoal yield, the available charcoal is: = 48,300 x 0.25 = 12,075 MTNR Source: (PCA as of Dec. 23,1995 ) LOCAL CONSUMPTION Basic Information on the Use of Charcoal for Poultry Brooding Total popUlation * (Number of chicks for brooding) 11,800,000 head Estimated share of poultry farms using charcoal as fuel 50% Total population using charcoal as heating medium 5.9 million Average charcoal consumption per head 0.1 kg Total charcoal consumption per brooding season 590MT Total annual charcoal consumption 2,360MT (At four brooding seasons per year) Total wood requirement 13,500 MT Estimated share of coconut shell husk if used as 0.175% substitute for wood on the total production of 7.7 million MT * BAS August 1989 150 VI. FPRDI's PRIORITIES/COMMITMENT TO THE TECHNOLOGY 1. Extend complete technical assistance concerning the fabrication/installation of the briquetting plant. 2. Conduct seminars/training on the operation and maintenance of the plant. 3. Exert efforts to promote the use of the technology. INVESTMENT PROFILE Production Capacity 2-ton/8-hour operation or 480 MT/yr Fixed Investment Bldg. ( 12x18 m at P 3,000/m2) P 648,000 Equipment : Briquettor 160,000 Charcoal mixer 140,000 Dryer 180,000 Total Fixed Investment P1,128,000 Product Cost/kg P 7.82 Selling Price/kg P 10.95 Finaneial Evaluation Net Present Value ( NPV) 1,433.991 Internal Rate of Return (IRR) 34% Return on Investment (ROI) 29.6% $=P 30 The total production capacity of the mechanized charcoal briquettor is 2 tons/8 -hr operation or an equivalent of 480 MT /yr. It will need a fixed investment ofP 1,128,000 broken down into the following: a 216- sq m-building which would cost P648,000; a briquettor (P160,000); a charcoal mixer (P140,000 ); and a dryer (P180,000). Based on the financial evaluation, the Net Present Value (NPV) is 1,433,991; Internal Rate of Return (IRR) is 34%; Return on Investment (ROI) is 29.6%, and the Payback Period is around four years. 1 51 EXPECTED BENEFITS The conversion of agro-forestry wastes into charcoal briquettes using the FPRDI mechanized briquettor would mean : 1. Additional livelihood opportunities; 2. Optimum utilization of charcoal fines generated during the processing of granulated coconut shell which represents 15 percent of total weight for export; 3. Expansion of raw material base through the utilization of agro-forestry wastes; 4. Prevention of further denudation of forests by lessening dependence on wood charcoal; 5. Fossil fuel conservation; 6. Adoption oflocally developed technology and substitution of expensive imported charcoal briquetting equipment; and 7. Generation of foreign revenues through the exportation of produced briquettes to Europe, Japan, Korea, Germany, and the USA, where these are in high demand. LITERATURE CITED 1. Philippine Coconut Authority. 1995. EXECUTIVE SUMMARY ON COCONUT COIR AND SHELL. 2. Estudillo, Calvin P. COCONUT SHELL CHARCOAL AND BRIQUETTES: Their Quality, Production Cost, and Uses. 3. BUREAU OF AGRICULTURAL STATISTICS. August 1989. 4. Pulmano, Dante B. COMMERCIAL APPLICATION OF FPRDI MECHANIZED BRIQUETTES USING COOCNUT SHELL, HUSK AND TRUNKS. 5. Philippine Coconut Authority. 1992. NATIONAL COCONUT PROFILE. 152 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION CHAINSAW-TABLESAW COCOLUMBER PROCESSING SYSTEM by R.A. NATIVIDAD and P.L. ALCACHUPAS 1. Abstract Studies conducted by the Forest Products Research and Development Institute (FPRDI) indicate various techniques of processing coconut logs into lumber depending on the scale of operation, quantity, or distribution of available raw materials, availability of skilled manpower, market site, and investment cost. In the Philippines, the traditional or most common method of cocolog conversion into lumber in the rural areas is by chainsawing method. This process is being discouraged due to low lumber recovery and low lumber quality. In 1987, FPRDI developed the chainsaw-table-saw cocolumber processing system. This process involves fellinglbucking of coconut trunks by chainsaw; log breakdown or conversion of the log into flitches by chainsaw at the cutting site to facilitate handling and transportation of raw materials; and resawing the flitches to required lumber sizes using a portable tablesaw (equipped with carbide-tipped blade) along roadsides or stationary tablesaw in lumber yards/shops. This processing system results in higher lumber yield and quality compared to the pure chainsawing operation. This technology (or the principles involved) is now commercially adopted by several cocolumber processors in the country. This paper presents the technical and economic features of the technology. Keywords: Cocolog, cocolumber, chainsaw, table saw, flitches, carbide-tipped blade, manual/animal skidding, lumber recovery, and quality IPaper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 2Supervising Science Research Specialist and Senior Science Research Specialist, respectively. Mechanical Processing and Product Development Division (MPPDD), Forest Products Research and Development Institute, College, Laguna, Philippines 153 APPENDICES ll. INTRODUCTION The Philippine Coconut Authority (PCA) embarked on a national coconut replanting program in 1974. This program, promulgated through Presidential Decree 582, entails cutting millions of senile or unproductive coconut palms (60 years old or older) to give way to replanting of early fruit-bearing and high-yielding varieties. One of the major problems associated with this undertaking was the disposal of felled trunks or logs from old coconut palms. If these were stored or left to rot along plantation boundaries, these served as breeding grounds for insects (e.g., beetles), which damage subsequent crops. On the other hand, the Philippine wood industry has been experiencing huge shortage of timber supply for the past two decades due to various destructive anthropogenic activities, like illegal logging, conversion of forestlands to other land uses, "swidden" or kaingin farming, etc. Among the important strategies implemented by the government to alleviate or solve this problem were the industrial tree plantation (ITP) development and the log/lumber export ban. However, the timber supplies from the natural growth forests and ITP are still inadequate to meet the increasing timber demand in the wood industry, as well as housing construction materials for the growing Filipino population. At present, the estimated annual timber demand in the country is 4 million cu m (log form). Local log production is 0.758 million cu m (DENR, 1995) while annual imports average 1.5 million cu m. Thus, the deficit of timber supply in the country is around 1.74 million cum. Realizing the immense potentials of coconut trunks in bridging the gap between timber supply and demand in the country, both FPRDI and the PCA had been conducting R & D programs along this field since the early 1970s to generate technologies on coconut processing and utilization. This paper presents a commercialized technology developed by FPRDI for efficient conversion of coconut logs into lumber. Ill. TECHNOLOGY DESCRIPTION Studies show different equipment for processing coconut logs into lumber. These include the two-man rip saw, stationary or mobile sawmills (circular or bandmill), and chainsaw (Eala and Alcachupas, 1988; Eala and Natividad, 1987; Natividad, 1992; Alcachupas and Natividad, 1991; Killman, 1988; and Pontenilla, 1990). The choice of proper equipment for a particular site depends on the scale of operation, quantity/distribution and accessibility of raw materials, availability of skilled manpower, market size, and investment cost. 154 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION One of the most efficient methods for converting of coconut logs into lumber is the chainsaw-table saw cocolumber processing system (Robillos and Eala, 1989; and Siriban and Eala, 1991). This was developed by FPRDI in 1987 and piloted in Southern Leyte and San Pablo City in 1988. The technology was commercially adopted in 1989 by the Quezon Lumber Co. in Lucena City; the Daraga Agri-business Venture, Inc., Daraga, Albay; the Rances Construction Enterprises, Bagaucay, Tinambac, Camarines Sur; and the MCB Construction and General Services in Sta. Rosa, Laguna. To date, it is being used by Alwyn Enterprises in Pitogo, Quezon and by severalhardware business entrepreneurs in Laguna, Quezon, and some other provinces in the Philippines. A. TECHNICAL ASPECTS Outstanding features. The chainsaw-table saw cocolumber processing system has the following outstanding features: 1) it requires relatively unskilled labor and lower investment cost than the traditional sawmilling system; 2) it produces higher lumber recovery and quality compared to pure chainsawing system because the table saw (equipped with carbide-tipped blade) provides an efficient equipment for resawing coconut flitches to required lumber dimensions; 3) the operation involves portable to semi-portable processing system; and 4) the operation conforms well with the rural setting, i.e., generally poor accessibility of coconut plantations by motorized vehicles and dispersed sources or uncertain long-term log supply from a particular area (Madrazo and Juson, 1983). The chainsawing method is commonly used in the Philippines for cocolumber processing. However, this is being discouraged due to low lumber recovery (25-30 per cent oflog gross volume) caused by wide saw kerf(10-12 mm) and low lumber quality (rough surface with high variation of thickness and width). The chainsaw-table saw tandem gives about 38-46 per cent recovery of better quality lumber depending on the sizes of lumber output. Process flow and resource requirement. The chainsaw-table saw cocolumber manufacturing system involves simple process and equipment. Figure 1 shows the schematic diagram of the operations involved. At the cutting site, the coconut trunks are felled and bucked to desired lengths by chainsaw. Subsequently, the logs are broken down into flitches using the same equipment. Resulting flitches are transported for resawing or ripping required lumber dimensions along roadsides or to lumber yards and shops using portable or stationary table saw. 155 APPENDICES The breakdown of the log into flitches facilitates handling and transport of the raw materials from the cutting area to roadsides where these can be directly resawn by a portable table saw or shipped by other means of transportation for final processing at lumber yards. From the cutting area to the roadsides, the flithces can be easily transported along trails in batches by animal skidding (e.g., carabao or horse) or piece by piece by manual method. The major equipment used in this technology are listed and briefly described below: 1. Chainsaw Horsepower ------ 10Hp Number of teeth ------ 52 teeth Chainsaw blade (for flitching) ------ ripping style Accessories ------filling tools 2. Portable table saw ~nginetype ------ Diesel Basic horsepower ------ 20 Hp Transmission power ------ V-belts Sawblade diameter ------ 508 mm Sawblade thickness ------ 3mm Kerf width ------3.5 mm Teeth type ---'------carbide-tipped Number of teeth ------ 40 Peripheral speed ------940 rpm The total investment requirement is P 1,175,720 and this is broken down as follows: 1. Fixed investment Land (1,000 sq.m. at P 400.00/sq m) 400,000.00 Building/shed (200 sq m floor area) 100,000.00 ~quipment(one portable table saw and 2 Chainsaws) 200,000.00 Office equipment/supplies 10,000.00 710,000.00 2. Working capital 394,720.00 3. Pre-operating capital 71,000.00 Total (P) 1,175,720.00 156 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Table I shows a detailed presentation of the inputs and expenses in the operation. The monthly lumber production capacity in the operation is about 60,000 bd ft or 2,500 bd ft per day (although the project cooperator reported that the portable tablesaw has a maximum resawing capacity of 4,000-6,000 bd ft per day). The lumber production cost is I! 4.00 per board foot. Table 1. Cocolumber manufacturing cost based on 60,000 bd ft. production per month Total Cost Distribution Items (Plmonth} (%) 1. Raw materials 20 trunks/day xl! 300.00/trunk x 24 days 144,000 59 2. Direct labor Felling and flitching (contractual) 20 trunks/day xl! 75.00/trunk x 24 days 36,000 15 Table sawing (l! 450.00/day x 24 days) 10,800 4 I-operator x l! 150.00/day = 150 I-receiver xl! 100.00/day = 100 2-helpers xl! 100.00/day = 200 400 3. Fuel and lubricants l! 351.00/day x 24 days) 8,424 3 8 li gasoline/day x l! 12.25 li = 122 3 li oil/day x l! 45.00/li = 135 12 li diesel/day xl! 7.80/li = 94 351 4. Hauling of flitches/lumber 3000 bd ft/day xl! OAOlbd ft x 24 days 28,800 12 5. Repair/Maintenance 4-chainsaw blades/moo @l! 1,100.00 = 4,400 4-round files @ l! 95.00 = 380 Retipping of circular saw = 1,200 Circular saw sharpening = 200 6,180 6. Depreciation (I! 373.00/day x 24 days) 8,952 4 2-chainsaws (l! 90,000/300 days) = 300 Table saw (l! 110,00011,500 days) = 73 373 TOTAL 243,156 100 157 APPENDICES B. ECONOMIC ASPECT The Alwyn Enterprises in Pitogo, Quezon, the latest adoptor of the technology, has various outlets of cocolumber. The company supplies an average of 51 ,000 bd ft a month to different construction sites and hardwares in Metro Manila, as well as in the provinces ofBulacan, Nueva Ecija, and Pangasinan. It also supplies some raw materials for making cocopallets to the Pallet Resources Corporation. The selling price per board foot is as follows: short lumber (4 ft) = P. 4.00; 6-8 ft long = P. 6.00; and 8 ft and longer = P. 8.00. Based on the technical description of the technology presented earlier and assuming that the company borrowed 70 per cent of the total investment from a bank (payable in 5 yrs at 20 per cent interest) and it can dispose 60,000 bd ft cocolumber per month at an average selling price ofP. 6.00 per board foot, a 10- year financial analysis of the operation reveals the following profitability indicators: Net Income after tax (ave. per year P. 991,302 Net Present Value (NPV) + 3,758,377 Internal Rate of Return (IRR) 23% Return on Investment (ROI) = 91.5 Benefit Cost Ratio (BCR) = 1.3 Cash Payback Period (CPP) = 0.84 yr or about 10 moo C. BENEFITS FROM THE TECHNOLOGY D. LIMITATIONS/DRAWBACKS Unlike conventional tree plantations, coconut plantations do not provide sustainable log supply in a particular area. For this reason, the technology is designed only for small-scale operation (with some flexibility to move or transfer to any area where raw materials are available in reasonable quantity). Another drawback of the technology's application in the rural areas is the use of carbide-tipped blade for the table saw. This is required to counteract the rapid dulling of cutting tools in sawing coconut wood. However, the facilities for the sharpening and retipping of the blade are available only in the urban centers. Spare blades are needed for the continuity of the resawing operation. 158 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION IV. VALUABLE LESSONSIINSIGHTS GAINED FROM THE PROJECT The technology commercialization/promotion activities yielded a new paradigm in the processing of cocolumber in the rural areas. Although the technology was not exactly followed in some areas, the principles involved were adopted in modified form by some cocolumber processors. In the Southern Tagalog and Bicol Regions, chainsawing is still prevalent but the operation in the field is now mainly confined to the production of coconut flitches ("dos por lapad" or live-sawing coconut logs to 50 mm thick flitches). The flitches, which are slightly edged, are sold along roadsides for resawing to required lumber sizes at hardwares/lumber yards in urban areas by using electric-powered stationary table saws. V. PROSPECTS/FUTURE DIRECTIONS The pro8pects of the cocolumber industry in the Philippines are bright. The major reasons for this are the following: 1. Coconut plantations are not covered by the logging ban; 2. The potential volume of available raw materials is enormous (132 million trees or 106 million cu m) (Palomar, 1996); 3. Coconut lumber is highly in-d.emand because it is cheaper than traditional lumber (l! 4-12/bd ft vs. l! 18~32/bd ft); and 4. Coconut wood is suitable for various uses (low-cost construction, furniture, handicrafts, pallets, etc.) At present, a significant volume of cocolumber is used in the construction industry, i.e. scaffoldings, form lumber, etc. However, there are some new emerging cocowood-based industries other than handicrafts. A company based in Tacloban City, Cocowood ofthe Philippines, is engaged in the production of coconut T & G flooring and S & V -cut panelling while another company in Cebu City is reportedly producing coconut furniture for export (Kilian, 1997). Tonga, a small country in the South Pacific, is exporting coconut wood parquet to New Zealand (Tamayo, 1997). In view of the present timber crisis in the country, cocolumber production or coconut wood utilization will continue to be a major source of subsistence and livelihood in the rural areas. It is also possible that with the advancement of science and technology, cocowood utilization will gain more niches in the wood-based industries. 159 APPENDICES VI. CONCLUSION Cocolumber production is a profitable business and one of the simplest and most efficient technologies for processing coconut logs into lumber is the use of chainsaw (for flitching) and the table saw (for resawing flitches to desired lumber sizes). This system entails higher lumber yield and quality than the pure chainsawing method which is commonly used in the rural areas. Considering the emergence of some new cocowood products, which require quality cocolumber, it is expected that the chainsaw-table saw processing system will gain more acceptance among the small-scale cocolumber processors in the country. 160 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Fig. 1. Process flow in the chainsaw-table saw cocolumber manufacturing system Cutting Site Log preparation (chainsaw) I Felling, I I Bucking I Log breakdown (chainsaw) I Flitching I " Hauling Flitches to Roadsides for Temporary Storage (Manual or skidding by horse/carabao), " Transportation/Storage Resawing at Lumber Yards Portable or Hardwares Table saw ,Ir ~r Lumber sorting! Resawing in stationary Piling table saw ~ Marketing f.- 161 APPENDICES LITERATURE CITED ALCACHUPAS, P.L. and R.A. NATIVIDAD. 1991. Improvement of the two-man rip saw. IDRC-FPRDI-PCARRD Project, Terminal Report, FPRDI, College, Laguna. EALA, R.C. and R.A. NATIVIDAD. 1987. Delivery of co col umber manufacturing Technology in Region IV (First Progress Report). FPRDI, College, Laguna. EALA, R.C. and P.L. ALCACHUPAS. 1988. Harvesting and processing of raw lumber products. Coconut Wood Utilization Research and Development: The Philippine Experience, FPRDI-IDRC. p. 25-35. KILIAN, T. 1997. Personal communication. KILLMAN, w. 1988. How To Process Coconut Palm Wood: A handbook. Branchweig: Friedr and Sonh Verlagsgesellshaft mbA. MADRAZO, R.M. and R.A. JUSON. 1983. The production of coconut lumber. Sawing and sawing facilities. Paper presented at the general training course on coconut, Zamboanga City, Philippines. NATIVIDAD, R.A. 1992. Coconut lumber manufacture and classification. Paper presented at the Seminar on Coconut Wood as a Construction Material, 11 February, 1992, FPRDI, College, Laguna. PALOMAR, R.N. 1996. Coconut wood utilization in the Philippines. Paper presented at the Regional Experts' Meeting on Coconut Wood Utilization, 01-07 February 1996, FPRDI, College, Laguna. PONTENILLA, R. 1990. Cocolumber: A viable alternative. Asia Pacific Forest Industries (December issue): 26-29. ROBILLOS, Y.U. and R.C. EALA. 1989. Delivery of the coconut wood lumbering technology. The DAVI Case (Manuscript), FPRDI, College, Laguna. SIRIBAN, F.R. and R.C. EALA. 1991. Transfer of some technologies on coconut wood utilization. IDRC-FPRDI-PCARRD Project. Terminal Report. FPRDI, Colle_ge, Laguna. TAMAYO, G.Y. 1997. Personal communication. 162 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION COCONUT WOOD: THE QUEST FOR BETTER VALUE-ADDED UTILIZATION By Sudarshan Jayawickrema 1 & Sugath Dissanayake 2 ABSTRACT Sri Lanka is one of the leading countries in the cultivation, utilization and export of coconuts and coconut based products including a variety of articles made of coconut wood. Although, in the past, senile population of trees in coconut plantations were simply felled without tapping its potential for use as timber, some are now selling this wood for applications similar to those of other tropical hardwoods. Traditionally, coconut planters looked upon any income resulting from the sale of coconut wood logs during replanting period as a bonus and coconut wood was thought generally to have little economic value. It was seen as a waste product, rather than a resource. Nowadays, coconut wood is sold in a variety of processed or semi processed forms and the process of value addition plays a significant role in the rural economy of Sri Lanka. I Director _ Market Development and Research, Coconut Development Authority, Sri Lanka. 2 Assistant Director - Mark;et Development and Research Coconut Development Authority, Sri Lanka 163 APPENDICES In Sri Lanka, coconut trees are planted mainly to exploit their coconut yield. In the past ten years however, it has become increasingly apparent that even though a coconut tree may have reached the end of its useful life for bearing purposes, the wood itself may offer an added economic value. It is this wood that provides the basic resources for the newly emerging coconut wood industry. The potential for the utilization of coconut wood is very large. The properties and versatility ofthis wood for a wide spectrum of end-uses are encouraging when considering the diversification in both the range of products being manufactured and the markets being approached. Therefore, countries that are current or potential producers of coconut should look in to the opportunities that this wood offers as a raw material for developing value added products. Most significantly, coconut wood can also meet the growing concern in domestic and international circles for environment-friendly use of natural resources. This paper discusses the importance of coconut wood being used for value added applications and the demand prospects for coconut wood based merchandise in the foreseeable future. INTRODUCTION The coconut is s wonderful tree. In beauty and utility, no other tree can surpass it. No matter where it originated it has served man for thousand of years. In Sri Lanka, Coconut is cultivated in about 416,000 ha (about 1 million acres) and is predominantly a small holder crop with about 75% of the area in holdings below 20 acres. Distribution of coconut small holdings and estates by size classes is shown in annex (l). Coconut is the most extensively grown nut in the world and the most important of palms. It is found in nearly 90 countries whose annual production ranges from 2.5 million nuts to 12 billion nuts. The total world area planted with coconut in 1996 is estimated around 10 million hectares. Its uses are many and varied. From its top to the bottom there is no part which is not put in to some use or other. It provides food, drinks, sh~lter,fuel, furniture, medicine, domestic utensils, handicrafts, decorate materials, fibres, alcohol, sugar and many more. New export opportunities may exist for countries that grow coconut in that, addition to the coconut kernel and coconut fibre based products, which until recently were considered to be of much commercial value, the coconut wood itself can be used for a range of export products. Imports of coconut wood based products mainly in to developed countries from leading coconut growing countries have witnessed a steady growth in the past few years, a trend that is likely to continue. The growth of trade in coconut wood based articles among coconut growing countries has been equally impressive. Suppliers in coconut producing countries should be able to increase 164 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION their supply base of coconut wood based products in line with rising international demand. Coconut wood can serve as a substitute for certain tropical hardwoods that now risk depletion. Due to the fact that coconut trees are comparatively inexpensive to cultivate, they represent an economically sustainable resource and can be a viable alternative to increasingly rare tropical timbers. Therefore, coconut growing countries should look into the opportunities that this wood offers as a material for developing value added export products. Utilization of Coconut Wood Coconut wood when freshly cut gives a whitish yellow colour and it seasons to a pale cream with a brownish tinge. It is widely known that the strength ofthe coconut wood increases with age. Although, coconut wood is often seen primarily as a substitute timber, more recognition has begun to be given to the fact that it is a timber with pleasing characteristics of its own. Maturation comparisons of coconut wood with other more traditionally used timbers for which coconut wood could be seen as a substitute indicate that a quality tropical timber such as teak takes around 60-65 years to mature, whereas eucalyptus, at the opposite end of the market scale requires about fifteen years. Coconut wood has an even, moderately coarse texture and is easy to saw, stain, machine etc. This combination of even texture and color, with easy working properties can in the right circumstances, make coconut wood an attractive raw material for a wide range of wooden products. If the coconut wood is not properly treated its added value gets reduced. It is probably in the research and development of successful protection, seasoning and processing of coconut wood that the long-term sustainable future of the coconut wood industry is rooted. The potential for the utilization of coconut wood is very large. International markets take quality coconut wood exclusively. Either coconut wood is sold as finished manufactured products and components such as furniture or the wood may be integrated into some other products. Many finished articles, such as furniture, toys and kitchen equipment including trays, bowls, chopping boards and similar items make us of coconut wood. Therefore, it is evident that coconut wood can be used more widely in manufacturing variety of products. Domestic markets in the coconut producing countries absorb some high quality coconut wood products, but they currently provide the major outlet for items using coconut wood that is not up to export standards. Some such products found in the domestic markets ofthe supplying countries may be of a comparable nature to those produced for the international market. Others are of a different type. For instance, treated coconut wood can be used for low cost housing and local style furniture, while untreated material can go into packaging. Popular products made of coconut wood are given in annex (2), few of which are discussed below; 165 APPENDICES / ------~------Furniture Sound working qualities for machining, pleasant appearance and acceptable durability of coconut wood, make it ideal as a raw material for furniture. It can also be a substitute for lower priced timbers used for concealed components in items such as upholstered furniture. In most of the major export markets for coconut wood based furniture, the manufacturing base with which suppliers compete falls mainly into the following areas; • Upholstered or padded furniture; The frames are likely to be made of coconut wood but the seats and backs are usually covered with textiles, leather etc; • Dining Furniture; Chairs, tables and cabinets are made of wood but seats are often upholstered. • Bedroom furniture; This includes items such as beds, hard boards, dressing tables and side tables. Composite Woods These are essentially wood products made of timbers that have been built up, bonded, or otherwise processed and treated by various physical and chemical methods to obtain larger dimensions, better utilization and different shapes from timber. They attempt to provide all of the advantages of timber and decrease the natural disadvantages. Coconut wood is a valuable resource of such processing. Lavered construction material and particle boards. Coconut wood has been found to be useful as a core material in construction articles. Coconut wood has also served as a raw material for the manufacture of particle boards. The industry uses off cuts, trimmings, slabs and small logs of coconut wood and therefore provides an outlet for otherwise less marketable parts of the coconut tree. Laminated and finger-jointed products Small sizes and short lengths of coconut wood can be glued together to make larger and longer pieces that are used for example, for steps, railings, window components, floor boards, and beams. The potential of coconut wood in meeting the growing market demand for such products is large. 166 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Moulded products Many types of articles in this category can be produced from coconut wood. For instance, high demand exists in general for panelling, beading and edging, and much of this could be met by coconut wood products. Potential for coconut wood products The marketing structure for coconut wood products in general within the markets tends to be well established. The major kinds of outlets in marketing coconut wood products are; • Traditional furniture retail shops that market solid, already made up high priced coconut wood based products such furniture. Supplies usually come direct from the factories of equally traditional processor/manufacturers. • Larger retail outlets offer value added articles made of coconut wood. Often such items are packed ready for sale to the mass market. According to the nature ofthe coconut wood industry in Sri Lanka, it would appear that the best potential market for manufacturers of coconut wood products is in the area of furniture materials. The market is large, but the purchasing base is diverse. Coconut wood is also suitable for use in kitchen furniture as drawer fronts. The kitchen furniture market is large and the natural colour of coconut wood finds favour with customers because such finishes are considered to be fashionable. Overall, the best prospects appear to lie in the marketing of furniture articles made of coconut wood. This market requires consistent quality, acceptable prices, manufactured to customer specifications, guaranteed delivery schedules, continuity of supplies, and more importantly, readiness to accept customer design. The advantages of coconut wood for the manufacture of furniture are believed to compensate for the recognized problems of variations in the wood's colour and density. But the need remains for high quality preservation and drying treatments if discoloration is to be avoided when exposed to different climatic conditions. Prospective entrants to the markets of coconut wood based products should be aware that marketing costs are high and competition is strong. Profits are not going to be particularly large unless high values of sales can be achieved. Promotion of coconut wood based products The opportunities for marketing different coconut wood products vary. Ifproduction is to be carried out successfully, both coconut wood products and coconut wood as a timber must be promoted. Certain countries have been successful in the marketing and promotion of coconut wood and coconut wood products and provide an example that other countries may wish to look at. In this area, the respective Governments of coconut growing countries have to institute support programmes for the progress of their coconut wood industries. In doing so, they can reap 167 APPENDICES rich benefits at the national level; it provides considerable added value to a widely available resource, generates employment opportunities, and makes available opportunities for export that in turn can open the door for the export of items produced by other industries. The major international markets for a range of coconut wood articles, especially furniture, are the United States, European Community Countries, Japan and Korea. Although, trade in'the area of furniture is largely among the developed countries, and exports of furniture from the main coconut growing countries in Asia are small, still there are possibilities of breaking into those affluent markets due to demand factors. Countries that can offer adequate supplies of raw materials and have economic labour costs, among other factors, are in a strong position to take advantage of the opportunities not only to penetrate expanding export markets but also to attract inward investment. Development Strategies Coconut is grown in various locations in Asia, Africa, Far East and Latin America. The largest areas under cultivation for commercial purpose are in Asia, followed by Africa. Countries in Asia that have large coconut plantations include Indonesia, The Philippines, Sri Lanka, India, Malaysia, Thailand. In addition, the coconut tree grows wild in a number of other countries in various parts of the globe. Integration of the coconut growing and coconut wood processing industries are going to be the order of future which depends on several factors. One is for the plantation sector to continue to grow coconut as a crop on the current scale. Another factor is for the plantation sector to accept coconut wood processing as an integral part of its operations. It is not going to be a difficulty that coconut wood processing could be operated as a separate activity or integrated with traditional timber industry. The former would be likely to increase the costs of coconut wood substantially, buta move in the latter direction could be facilitated by the fact that the traditional timber industry will be in a position to link its activities more closely to general environmental concerns. Future Prospects The demand for coconut wood is likely to outstrip supply in the foreseeable future and the production of coconut wood articles therefore, appears to offer profitable prospects for coconut producing countries. Reasons for encouraging the development of the coconut wood processing industry as a whole including the fact that the capital cost and technology required for coconut wood processing are low compared to many other manufacturing processes, while designs and specifications can be produced relatively easily. Moreover, many of the potential processing countries have large populations, so that the respective domestic markets can be anticipated to grow overtime, thereby providing an outlet for production in addition to exports. 166 INTERNATIONAL CONFERENCE ON COCOWOOD UTILIZATION Furniture manufacturers in export target countries seem increasingly prepared to invest in setting up furniture production plants in low cost countries to meet the growing demand for coconut wood based articles in their established markets. Therefore, not only will foreign ipvestment in coconut producing countries grow, but a degree of technology transfer and skill upgrading could also be expected. Conclusion Properly managed coconut wood processing activities can substantially increase income form coconut holdings. Such activities also provide increased employment prospects. The processors should therefore, give attention to proper management and attempt coconut wood processing on a systematic and scientific manner to maximize productivity and increase income. The expansion of coconut wood based industries in the producing countries, in general is expected to move forward at a rapid pace. This would further open up possibilities for increasing marketing of new types of coconut wood based products and of expanding the volume of those already sold in domestic and international markets. References Alston, A. S. "Coconut Palm Timber. Fiji Timbers and their uses", Dept. of Forestry Suva, 1993. Punchihewa, P. G. "Coconut Industry Today and its Future", Ceylon Daily News, Sri Lanka. Oct. 30th 1990. Tillekeratne H. A. "Processing of Coconut products in Sri Lanka," APCC, 1995. 169 COCOWOOD CARVINGS IN TANZANIA: CHALLENGES AND OPTIONS by Mpagalile, J. J. and Temu, N. ABSTRACT Tanzanian traditional carvings known as the Makonde cavings are famous worldwide and are one of the country's main tourist attractions. Over the years, traditional carvers in Tanzania have been using traditional back wood (Dalbergia melanoxylon) and other traditional timber for their work. These trees have provided a reliable source of raw materials for the carvers for so long. However, this is now changing. Excessive cutting of these trees has led to a shortage ofthe raw materials. Carvers are now looking for other sources of raw materials. It is for this respect that the coconut industry stands a better chance to save this industry if efforts to promote use of cocowood are further enhanced. This paper reviews the general status of the utilization of coconut wood in Tanzania with emphasis on carvings. The paper analyzes problems related to the carving industry and gives suggestions on how to improve the situation. Emphasis is placed on the utilization of coconut woodcarvings bearing in mind the suitability and even availability of coconut trunks. The estimated coconut palm population of over 22,000,000 ensures a reliable source of raw materials, which in turns offers an added advantage. General technologies used in making different types of carvings from the coconut trees are also discussed. Technical areas in need of immediate attention are also highlighted. Government policy on this industry is discussed as well. While the direct financial benefits obtained from the use of coconut wood are discussed, the paper gives emphasis on other benefits as well. Such benefits include getting rid of trunks that could otherwise harbor such pests as rhinoceros beetles. Also the use of coconut trunk as an alternative source of raw materials will allow other endangered tree species to rejuvenate thus saving the environment. The paper discusses and gives suggestions on the future of the coconut wood carving industry in Tanzania. lPaper presented at the International Conference on Cocowood Utilization, 27-29 October 1997, Holiday Inn, Manila, Philippines 170 1.0 INTRODUCTION Coconut trees have been playing an important role in the economic life of the people along the coastal belt. However, despite its many uses, there is no historical evidence to show that coconut wood was produced for local or foreign markets in the past. Only limited amounts of coconut trunks were reported to have been used locally mainly for construction purposes only. Since there has been no crisis with timber, people along the coast used coconut trunks for charcoal or limestone burning. It is only in recent years that use of coconut timber has been promoted seriously. There are many benefits of using coconut timber. From the agricultural point of view, utilization of over-aged palms is encouraged to reduce the breeding sites ofthe Rhinoceros beetle (Oryctes monoceros). Cutting of over-aged palms will not only allow for replanting with improved planting materials, this will also add value to palms affected by lethal disease which are increasing farmers' frustration because of their inability to produce coconuts. Also, by using coconut wood, other species would be preserved thus avoiding deforestation, which is one of the major causes of soil erosion in Tanzania. Already most of the trees in natural forests are felled for fuel wood, building materials, shifting cultivation, poor farming systems, and annual bush and forest fires at an alarming rate. Once the forest cover is gone there;remains a fragile soil that becomes vulnerable to rapid destruction by wind and water erosion. Generally, it can be said that use of cocowood is beneficial to farmers, as it is also an environmentally friendly course of action. Because of over lumbering, the future of native hard woods, such as the African TeakIBloodwood (Pterocarpus angolensis) is also hard to predict. The availability ofthe woods used for carving, such as the famous African black wood (Dalbergia melanoxylon), is also on a steady decline following its continued and unplanned use that includes export of logs. Although the government has prioritized forest conservation, the forests are still vanishing at a frightening rate, taking with them a rich variety of fauna and flora. The dramatic threat to these sensitive ecotopes from industrialization, urbanization, overpopulation, and poverty must therefore be averted. 1.1 THE COCONUT INDUSTRY IN TANZANIA The contribution of the agricultural sector to the GDP of Tanzania in 1995 was estimated at 56 per cent (EIU, 1995). The agricultural sector has been and continues to be an important contributor to the country's economy in terms of foreign exchange earnings, import substitutions, and provision of food. In Tanzania, the coconut palm (Coco nucifera) is among the important treecrops that is very popular along the coastal belt. Coconut production plays an important role in the agricultural industry in terms providing a broad range of dietary, cash income, and 171 various employment opportunities. In the mid-eighties, Beuter (1984) noted that the area under coconut cultivation in Tanzania was about 240,000 hectares. Currently, with the increase in the farmers' interest in planting more seedlings, it is very likely that this area has increased quite considerably. The corresponding annual coconut production at present is estimated at over 530 million nuts realized from a coconut palm population of over 22 million. Barkey and Rwegasira (1988) reported that smallholder farmers produced nearly 95 per cent of the total annual production. The average size of the small holder farms range from 1 to 3 hectares. The regional coconut production expressed as a percentage of the total annual, production is: Mtwara, 1.3 per cent; Dar Es Salaam, 7.5 per cent; Lindi, 8.5 per cent; Tanga, 17 per cent; Zanzibar, 26 per cent; and Coast region, 39 per cent (see attached map). 1.2 COCONUT FOOD AND NON-FOOD UTILIZATION Postharvest activities involving processing of crops are important before crops can be consumed or prepared into valuable products. Women in most communities are involved in crop processing aimed at producing food for their families and selling the surplus to earn cash for other household requirements. This is not an exception in coconut processing in Tanzania. Coconut products are utilized in various ways for both food and non-food purposes thus making the coconut palm a very beneficial crop to farmers and communities in general. According to the national census of 1988 nearly 30 per cent of the Tanzanian popUlation lives in coconut growing areas thus emphasizing its importance. In rural areas of the coastal belt of Tanzania, such as Tanga (Pangani) and Zanzibar, coconut-related activities are widely carried out. Traditionally, coconut oil is made from fresh coconuts using the aqueous method and the oil obtained is used for cooking, frying, etc. Also it must be mentioned that coconut milk is widely used in Tanzania for preparation of various dishes. Copra is processed in different locations, such as Pangani and Zanzibar islands. Both kiln and sun drying methods are used in copra making. Most of the copra produced is crushed within the country and the oil is used for consumption and soap making. The sap from the coconut palm is widely used in making beverage obtained from natural fermentation. Although tapping tends to affect the coconut yields, it has proven to be more profitable than selling coconuts. This makes many farmers opt for tapping or both tapping and harvesting nuts. The use of coconut's non-food products is of equal importance. Coir is processed in small scalelhousehold level in Zanzibar, Bagarmoyo, and Pangani and is used for making ropes (for the fishing industry), brooms, brushes, mats etc. 172 3.0 COCOWOOD UTILIZATION Most of the coconut palms in Tanzania were planted during the slave trade and colonial eras, i.e., 1988-1915. It is clear therefore that most ofthese palms are over 60 years. It is estimated that nearly 5 million palms (out of an estimated population of 2.5 million) are over-aged, senile, and therefore suitable for economic cocowood utilization. The age groups of palms found in Tanzania are indicated in the table below: Table 1. Stock and Age Group of Palms in Tanzania as of 1992 Age (Years) No. of Palms (x 1000) Percentage (%) 21 6,318 36 21-40 3,379 20 41-60 3,161 18 61-80 3,683 20 > 80 1,004 6 Total 17,545 100 Source: Possibility for the Utilization of coconut palm wood in Tanzania It is also forecasted that in about 20 years from now, there will be some 3 million more palms that can be felled and used in Tanzania. In recent years, production of cocowood-based products has started to gain popularity. Cocowood utilization ranged from small to medium to large scale. Use of cocowood is aimed at producing high value products both for local use and for export (Mpagalile 1995). It is hoped that with the steady availability of raw materials, cocowood products would become much more popular in the market within the country. The fact that cocowood products are made from trunks of old and unproductive palms, making the process environment friendly, is an added advantage. These and many other activities constitute an important coconut-based industry. In this case, one is not surprised to see that coconut palm is still, after many years of cultivation in this country, a crop accorded special priority by the farmers. However, it is clear that despite this potential, coconut wood in Tanzania is still marginally utilized and this calls for more effort on the promotion side. So far the use of coconut wood has been limited to making doors, windows, window frames, and roofing poles in building construction and carvings. 173 As one step forwards encouraging use of coconut wood in Tanzania, a system of compensating farmers for each coconutpalm cut was devised. The calculations regarding levels of compensation are shown in Table 2 below. Table 2: Calculation of Compensation for the Expropriation of Coconut Palms Age of palm in years Value in Tshs. at an interest rate of 5% below 10 (non-bearing) nil 10 19,050 20 20,600 30 16,050 40 8,900 50 4,450 60 and above 2,200 (1 US$=600T Tanzanian Shillings) Source: Business Times, 1994 The use of cocowood for various purposes will always be influenced by the availability of other natural sources of wood. It is therefore important that while we are looking at various ways of promoting use of cocowood, we also look at the status of other sources of wood. The actual total area of forests and woodlands in Tanzania is not known exactly. Mlowe (1995) analysis ofthe Tanzanian land revealed that 15.5 per cent was managed for wildlife; 7.0 per cent for forestry; and 7.8 per cent for wildlife and forestry simultaneously. Distribution of the land devoted to forestry reserves within the country is shown in the following table (Table 3): Table 3. Status of Forest Reserves in Mainland Tanzania Category Area (OOO'ha) % of Total Plantations 1,04.6 0.75 Closed forests 1,600 11.53 Wood land 11,706 84.34 Mangroves 115.8 0.83 Grassland 353.6 2.55 Total 13,880 100.00 However, it is quite clear that over the years the nation has made a lot of effort in making sure that these natural resources are conserved. One example is the first National 174 Forest Policy in Tanzania enunciated in 1953 and reviewed in 1963. This policy details the manner in which the forest and tree resources of this country will be managed. One of the basic objectives of this policy is to ensure environmental stability and maintenance of an ecological balance, including atmospheric equilibrium, which are vital for sustenance of all life forms, human, animal and plant alike. 4.0 THE COCOWOOD CARVINGS The Makonde people, whose homeland straddles the Tanzania-Mozambique border, carry on the tradition oftheir ancestors as wood carvers. The use of coconut wood in carving has been gaining momentum with the participation of a lot of traditional carving groups in Mtwara, Dar es Salaam, and the Coast region. The carves use the lower part of the coconut palm for their work while the upper soft part of the coconut trunk is usually used in lime kilns. The carving potential of the coconut wood was initially tested by carving groups in the peri-urban centres ofMwenge and Kunduchi in the city ofDar es Salaam. Results of the tests showed that cocowood were good to carve and that woodtumings could be produced without problems with the traditional simple lathe. Famous groups in cocowood carving business include the Mkamba Development Association, Kiparang'anda Handicrafts Group, and Chawasamata of Temeke in Dar es Salaam regIOn. Some of these groups were established back in 1986. They are composed of up to 65 members, about 20 of who are women. Besides carving, other activities ofthe group include pottery, basketry, and weaving mats and carpets. The women members ofthe group mainly work on pottery and weaving. Over the years the group have been using ebony trees for their carving work, as this is their traditional working tree. But having utilized almost all the ebony trees obtainable in their village, the carvers are forced to walk many kilometers to the neighboring villages to buy ebony logs at a much higher price estimated at Tshs. 35,0001= (US $60) per tree. Some groups have started planting ebony seedlings but it will take about 100 years before they can start using the trees. A coconut palm p\anted in 1993 would have given by now a lot of nuts, and thatch fronds and yet be mature for timber harvesting much earlier. It is due to these facts that the groups decided to start using coconut trees for their carving work. The general advantages of cocowood over ebony and the rest of the woods used by the carvers can be summarized as follows: • The price of ebony is increasing with its scarcity while that of old palms is still low. • The conventional trees have very limited uses in their interim phase to wood harvesting while coconut trees have multiple benefits. 175 • The quantities or volume of wood, which could be needed by the carvers, are readily available. 4.1. THE CARVING PROCESS 4.1.1. TOOLS After trees have been felled and logs selected for carving work, arrangements are made to deliver the logs to the workshop. Then carvers start the carving work immediately. Almost all of these carvers don't use any pre-drawn plans for their work. This being a work of art is done directly from the head to the log. Most of the tools used are the basic ones. Tools used by the carvers in the rural as well as in the urban center include wood chisel, carving chisel, hammer, locally made knives, club, hand saws, patasi, locally made file (tupa miti), files and hand drills. In addition locally made simple lathes are used for turning. The initial stages involve cutting chunks of wood from the log until a rough image of the intended figure is obtained. After this stage the finishing work begins. This is a critical stage and a lot of consumables are used. 4.1.2 CONSUMABLE ITEMS Most of these consumable items are used during the finishing phase as already pointed out. It should be emphasized that poor finishing leads to low selling prices. Most of the carvers have realized this and they are now putting much effort on the finishing touches. After obtaining an intended figure from the log, more effort is needed in putting some finishing touches to make the figure recognizable. Sand papering is one of the most important stages. Both wet and dry sand papering is carried out. In general the consumable items used in finishing a carving include sandpaper, wood glue, wood polish, and brushes of different sizes. Some carvers go for the normal shoe polish (black, neutral, or dark tan) because it is cheap and they believe it gives similar results as any other polish. 4.1.3 THEFINISHEDPRODUCTS The carvers are naturally very imaginative and they provide a wide range of products. The most common types of carvings, which are popular and available in the market in different sizes and forms are human and animal skeletons, animals, decorations, plants, kitchenware, devils/ghosts, plays (chess,bao,draft), musical intruments, jewelry boxes, candle and pen holders, flower vases, doors, canoes, dhows, small chests, window, and door frames, to mention a few. 176 4.1.4 QUALITY Very few Makonde carvers have had the opportunity to be exposed to carvings made by individuals and groups elsewhere in the world. One argument is that traders are scared of higher farm gate prices being demanded by the carvers if the latter become aware that the end consumers tend to part with more money if the quality of the product is higher. Another argument is that majority of the carvers can not read nor do they have much time to read articles. Therefore issuing to them written information or designs on product standards required by a given consumer or consumers won't help. The best way would be to issue physical samples. Cocowood carvings, like the rest of the woodcarvings made in Tanzania, are therefore subject to lack of standards. 4.1.5 FINANCIAL BENEFITS As pointed out earlier there are many advantages of using cocowood for carving. Some are long term and indirect while some are very obvious. The following summary presents the financial benefits from using coconut wood. Since the availability of coconut palms suitable for carving is not a problem, carvers are strongly advised to start using cocowood in their activities. Data Farm gate price for mature palm over 60 years of age 2200 Cutting down the palm 1000 Cutting the lower portion 1000 Cutting the upper portion into pieces of 3 ft each = 1000 Transport of 5 logs to the carver's center 6000 Loading and unloading the logs = 1000 Opportunity cost for labor 220Tshlhour Working hours in 30 days required to finish 5 carvings 360 Consumable required for the finishing work = 3000 Total cost to carve 1 palm tree 121,400 Selling of softer parts for lime making 1700 Selling of 5 pieces of carvings 150000 Return to labor per 1 palm tree 30,300 The above analysis demonstrates that use of coconut palms in carving is highly profitable. The profit can be even greater if the carvers work together as a group like buying raw materials in bulk and finding markets instead of selling their products via agents. 177 4.1.5 PROMOTIONALASPECTS 4.1.5.1 PUBLICITY Majority of the carvers is highly talented in the art of carving but they lack knowledge of the basic business and products promotional issues. However, the carvers have precise ideas on what the whole business venture entails. This therefore calls for the need for a well-planned business promotion. Also majority of the Tanzanians is not fully aware of the suitability and potentials of coconut wood as timber resource; exhibitions have played a very good role. NCDP has been organizing and participating in various local exhibitions to display and educate the general public on the potential uses of coconut wood. Participation in the national farmer's day exhibitions held annually in August and in the World Food Day in October help raise people's awareness and change their attitudes towards cocowood. The exhibitions feature coconut wood products and video films on various uses of coconut wood both from within the country and from abroad. Other international organizations, such as Protrade, have also played an important role in the business promotions by providing manufacturing and marketing expertise. In 1995/96, they sponsored the participation of two local companies, Domus Woodworks Company and Vuyisile Mini Furniture Factory, in an International Furniture Fair in Cologne Germany. 4.1.5.2 TRAINING Majority of carvers in Tanzania has inherited the carving technology from their fathers and forefathers. In this case they are good art-wise but they lack business knowledge. In view of these, on-the-job training for the carvers initiated in 1993. This was recommended during awareness building seminars and workshops for the artisans, carvers, and extension personnel involved in the promotion of the coconut crop. Since 1995, the Sweden-Tanzania Friendship Association (SVETAN) has taken the initiative in training young people. Contents of the training include drawing from models, handicraft:s design drawing, anatomy studies, perspectives in drawing and sculpture, portrait studies, development of samples from drawings, castings, concept of art, marketing, and English. The graduates are not bound to go back to those who nominated them for training, but experience has shown that majority do return to their original groups and provide an on the-job training to their work mates. Follow up training should also be considered to assess the extent of utilization and problems related to the training attended. 178 5.0 PROBLEMS HINDERING USE OF COCONUT WOOD Carvers using cocowood in Tanzania faced some problems which, if solved timely would stir up the development of the industry. These include: • Lack of an accurate system to determine age of the palm before it is felled; • Cracking of some carvings due to improper seasoning and poor finishing of the products; • Lack of awareness by coconut farmers, policymakers, researchers, and developers of the suitability of cocowood as a raw material for carvings; • Hardness of cocowood which makes it difficult for one to utilize the tools and equipment usually used with conventional wood; • Limited training and experience of all people working on cocowood in the country; and • Limited managerial skills on the part ofleaders of the informal as well as formal carvmg groups. 6.0 FUTURE PLANS Tanzania has comparative advantages in the area of wood carving in this region but aggressiveness in marketing our endowment is lacking. Successful promotional efforts should involve coconut farmers, potential and active carvers, petty and large scale traders, and end users of the cocowood carving technology. Assuming all factors remain constant the media should be tapped so that the right information reaches the target group within the shortest possible time. Market information on the possibility of selling cocowood products in the active and potential markets is needed. Aspects of type, quantity and time span between ordering and delivering have to be considered. For the sake of diversification, rural as well as urban carvers should know how to use and process cocowood in the different marketing segments, i.e., construction timber, furniture, furnishing wood, industrial wood, firewood etc. Intensified training for the woodworkers, workshop engineers, and technicians etc. is important for the sustainability of the industry. Short exposures in terms of study tours and farmers field days will be appreciated. Most of the locally produced carvings require a substantial amount of improvement as far as finishing is concerned. Product design as well as machining and surfacing techniques need to be developed further to optimize in-service properties, 179 product acceptance, and production costs. Use of modem equipment will not only ease the activity but also reduce the time span required to finish a given item. 7.0 CONCLUSION As raw material for carvings, coconut wood can ease the pressure on conventional wood that is in the local markets to a higher degree than at present. However, use of all possible media is called for to create an effective awareness among the people. Joint ventures in business should be encouraged whenever it is possible to do so. Cocowood utilization needs to be encouraged now when the private sector is steadily gaining importance in the economic development of Tanzania, both in terms of contributions through privatization ofparastatal organizations and in new investments in various sectors of the economy. Since the current level of cocowood utilization in the country is still low there is a need for further research and promotional work on this. Transfer of technologies that are appropriate for Tanzania should be encouraged as well. Taking into account the method of coconut cultivation and the amount of raw materials available, the introduction of small, medium and large-scale cocowood processing plants would help to improve the situation. ACKNOWLEDGEMENT We Wish to than the Director ofMikocheni Agricultural Research Institute (formerly (NCDP) for granting us the permission to present this paper. The authors are also grateful to the Forest Products Research and Development Institute for the opportunity to participate in this important conference. We are also thankful to the Government of the United Republic of Tanzania for the permission to attend. REFERENCES Barkey and Rwegasira (1988). Coconut Extension Services (Annual Report) Dar es Salaam, Tanzania. National Coconut Development Programme. Beuter, T. (1984). Coconut Marketing Study Phase Ill. A report for Deutche Gesselschaft Technische Zussammenarbeit EIU (1996) Economic Intelligence Unit. Country report, Tanzania. Third Quarter. Mpagalile J. J. (1996). Current Status of Coconut Wood Utilization in Tanzania. National Coconut Development Programme report. 180 PRODUCTION AND COCONUT WOOD UTILIZATION R & D IN THE PHILIPPINES CARLOS B. CARPIO & ERLENE C. MANOHAR Philippine Coconut Authority ABSTRACT The Philippines is currently pursuing an aggressive productivity program through a World Bank Project with a target of replanting 50,000 hectares/year in 20 years to improve production. The unwarranted cutting of an estimated 25 million trees as a major cause of the declining production was reduced through the strict implementation of the Coconut Preservation Act (RA 8048). Likewise, the R & D programs of PCA are intensified to increase productivity that will improve the industry's niche in the global market. The advances in research and the available technologies that can transform coconut lumber of 625,000 trees from replanting to high value products can generate income and improve the economic status of the coconut farmers. This will sustain the long-term development of the coconut industry in all aspects. Concerted efforts and integrated R & D for the coconut industry is a must to assure stable supply for international and domestic consumption, thus, helping the coconut farmers. Keywords: Cocolumber, Coconut Preservation Act, replanting 'Deputy Administrator and Senior Science Research Specialist, Agricultural Research Branch, Philippine Coconut Authority. 181 1. Situation The coconut industry is the Philippines' leading edge in the world oil market, being one of the world's two largest producers of coconut oil. The industry continues to play a very important role in the economy of the country, accounting for 25 per cent of the cultivated area and over 40 per cent of the value of agricultural exports providing income for at least one-fourth of all the rural families. The coconut, popularly known in the Philippines as "The Tree of Life", is a major source of foreign exchange. Philippine coconut products account for some 65 per cent of world traded coconut products. The Philippines is pursuing an aggressive program on production R & D, particularly in replanting of senile and unproductive palms and removal of the trunks after felling to facilitate replanting operations. This will prevent stems from decaying in the field, thus reducing the possibility of these stems becoming breeding sites of rhinoceros beetles, These same felled trees offer additional income to farmers, if the logs are conv,erted into saleable products. The Philippines' replanting program started in 1976 using the importerl MAW A hybrids. However, these hybrids thrive very well in some parts of Mindanao. In 1991, under the World Bank project, replanting efforts were again pursued using local trees and locally bred materials. Considerable researches have been carried out on various aspects of the properties and potentials of coconut wood after the Coconut Stem Seminar which was held in Tonga in 1976. The second seminar was held at the Philippine Coconut Authority (PCA) -Zamboanga Research Center on October 22-27, 1979. What follows is a list of issues raised and an update on what happened after that, in so far as PCA's Timber Utilization Division (TUD) and PCA's activities are concerned. The issues raised were the following: 1. Many countries need to replenish aging coconut palms; 2. Palm stem utilization is secondary to replanting and replenishment; 3. Government must deal with attitudes of small owners not to fell overmature palms (They must give serious consideration to this by way of incentive schemes); 4. In some countries, coconut wood offers advantages in overseas exchange expenditure; 5. Countries with abundant resources of traditional timbers will have problems in changing preferences for timber uses; 6. There is a great range in the interest and activity in coconut wood utilization country by country; and 7. There is a need for concerted research investigations rather than diffused, duplicated, and wasteful efforts. 182 The Philippine Coconut Authority is the sole government agency mandated by law to develop the coconut and other palm oils. Thus, it is tasked to vigorously develop the industry to its full potential in line with the government's vision for Philippines 2000, and to address these issues in as far as timber utilization is concerned. 2. Production Production in 1995 was 2.6 MT and 1.9 MT in 1992. It was projected to reach 2.1 MT in 1997. About 25 million trees over a five-year period have been cut. To offset the cutting of old or senile trees, PCA embarked on coconut planting and replanting, fertilization, and intercropping program. 3. Problems of the Coconut Industry It is imperative that industry weaknesses and problems be addressed for it to become viable over the long term, sustainable, and globally competitive. These can be realized through, among others, the intensification of agricultural R & D programs and the technology management system to fast track technology utilization. All sectors of the industry must move towards generation of substantial R & D-based information and technologies to address the causes of the following problems. 3.1 Low Farm Productivity Low productivity is a major problem facing the Philippine coconut industry. The average production per hectare/year is less than one metric ton. Four to five MT/year/hectare production is possible through proper utilization of agricultural technologies, hybridization, and fertilization. The Zamboanga Research Center can produce four tons per hectare/year in its farm with proper cultural management practices and balanced nutrition. 3.2 Unwarranted Cutting of Coconut Trees The unwarranted cutting of coconut trees is one of the major problems of the coconut industry. An estimated 25 million trees, about one-half of which were still productive - have been cut in the past few years. There are three principal reasons for this indiscriminate cutting. These are: a) the log ban which made traditional forest lumber very scarce, thereby opening a big demand for coconut lumber; b) low price of coconut; and c) inclusion of coconut land in the Comprehensive Agrarian Reform Program (CARP) coverage, making some landlords, in an effort to evade land reform, cut their coconut trees. These problems have been greatly reduced with the enactment and strict enforcement of RA 8048 known as the Coconut Preservation Act (Annex 1, RA 8048 Primer). 183 3.3 Low Utilization Value of the Coconut The bulk of the country's coconut.products is exported in practically raw form as crude coconut oil, copra meal, copra, desiccated coconut, and young coconuts. Felled logs converted into high value products may soon find a niche in the export market. At present, however, the coconut farmers actually enjoy nothing in terms of added value. The Philippines should exert efforts to process coconut into final and user/consumer products to be able to earn more. 4. Industry Forecast The coconut industry is perceived by some as a sunset industry. There appears to be no concrete basis for this perception considering that coconut is needed everywhere for food, pharmaceuticals, handicrafts, or industry. The aggressive expansion in coconut areas being undertaken by other coconut producing countries such as Indonesia, Vietnam, and Malaysia among others, is proof that the coconut industry will remain a viable and durable industry. Even if the Philippines would double its production, there would still be no problem whatsoever about its domestic and international utilization. 4.1 Domestic Demand The domestic utilization of coconut products is expected to increase in the following areas: coco chemicals, coconut water, coconut milk, coir production, coco shell charcoal, and coco lumber. In particular, domestic use of the latter will be due to a massive Replanting Program and the logs that provide the avenue for the extension promotion of various cocolumber uses. An estimated ten million coconut trees are to be replanted from 1995 to 2000. This could supply a substantial portion of the increasing demand for coconut lumber. 5. The R & D Action Programs of PC A R & D Programs are the key approaches for increasing coconut productivity to ensure consistent supply and improve global competitiveness. Increase in supply of coconut products in the world market need not necessarily cause a decline in prices with improvement in supply position. This would not only strengthen the traditional demand base but also attract new consumers in different end-user sectors (Thampan, 1995). 5.1 Farm Production and Productivity Coconut production in the Philippines has been beset by chronic problems arising from mono culture, which has in turn resulted in low productivity, low income, and underutilized manpower. These - coupled with the senility of coconut trees, the effects of destructive typhoons, conversion of coconut lands to other uses, and the umegulated cutting of coconut trees - have brought coconut production to a very undesirable leveL The World Bank's Small Coconut Farms 184. Development Project (SCFDP) forecasts a 50,000 hectare/year replanting for 20 years to address the problem of declining coconut production through massive planting and replanting nationwide. 5.1.1 Planting and Replanting Project The project earmarked a replanting target of 5,000 ha in the first year rising to about 20,000 ha/year at the end ofthe five-year project. In 1996, the achievement of this program was 8,500 ha of replanting (target was 35,000 ha). PCA should have raised its capacity to produce seednuts to continue the replanting program at the rate of 50,000 ha/year for a period of20 years to achieve the target of replanting of about one million hectares of unproductive coconut palms in the country's major growing areas (Santos, 1997). 5.1.2. Implementation of RA 8048 (Coconut Preservation Act) Another action plan is the enactment of RA 8048 regulating coconut cutting that became rampant due to the ban in cutting of conventional source of lumber, implementation of the Comprehensive Agrarian Reform Progralli, and the expansion in the construction business. The Field Operation Branch of PCA reported an average of 1,698,252 legally cut trees nationwide (Table 1) with the replanting equivalent that stood only at 95,704 during the same period. This is quite alarming considering 2,460 trees being cut/day for a period of 23 months. However, the 1996 reports from Region IV-A (with the highest number of trees cut reported nationwide) reflect that for every coconut tree cut, two trees are being planted (Fig. 1). 5.2 The Agricultural Research Program This program is a major thrust because it directly supports increased· production. It envisions provision of agricultural knowledge and technology to support long-term and stable coconut productivity. In the years ahead, with the concerted efforts and substantial support of the government and the scientific communities, coconut R & D should focus on uncovering new knowledge, in the process generating cost-effective technologies capable of sustaining economic yield of improved planting materials (Magat, 1997). As such, the following breakthroughs and the modernization in its agricultural production and product processing will definitely assure the industry's goal to carve its niche in the global market of coconut products, as well as provide enough supply for domestic consumption. Following are the recent research advances to support the R & D VISIOns. 185 5.2.I.Development of nine coconut hybrids with outstanding basic and chemical features 5.2.2.Development of synthetic variety (Synvar) with the establishment of selfed lines which is the ultimate strategy in mass propagation of improved planting materials 5.2.3. Development of coconut-specific fertilizer grades and compound multi nutrient fertilizers 5.2.4. Development of protocol for coconut cloning that will accelerate mass propagation of promising hybrids 5.2.5. Application of molecular techniques in the aspects of genetic conservation and improvement; and molecular diagnostics for pathogens for safe movement of germplasm and production of disease-free planting materials 5.2.6. The Timber Utilization Division (TUD) was acknowledged by FAO as the only one of its kind in the world such that from 1983 to 1985, it became the International Training Center on Coconut Wood Utilization Program of FAO andPCA. After more than two decades of intensive research undertakings, TUD came up with significant breakthroughs and viable technologies on coconut wood utilization, such as in the aspects of logging of coconut palms, sawmilling of trunks, seasoning and drying, preservation and downstream processing. Its primary goal is to increase farm productivity by converting felled trunks and other logging residues into commercially valuable wood products. Studies to support such goals include the following: a. Wood quality evaluation of different varieties of coconut; b. Cocowood drying and treatment; c. Cocowood preservation; d. Glue-laminated timber; e. Design and fabrication of cocowood furniture component; and f. Utilization of cocowood residues and husks. 6. Conclusion and Recommendations Intensification of agri-industrial R & D effective technology utilization process and meaningful amendments of policies in the coconut industry will practically sustain efforts achieved in the last 25 years of production and R & D cocowood utilization for the growth and development of the coconut industry in all aspects. The replanting program will go on in the next 20 years ifPCA's seed production centers could only produce seednuts that could plant 25,000 ha/year. This means replanting 1 million hectares of the 3 million coconut hectarage in the Philippines or roughly 100 million trees. The current capacity is 6,250 ha/year or 625,000 trees available for cocowood utilization. 186 Since replanting materials consists mainly ofthe hybrids, it is recommended that future cocowood studies be focused on these materials. Coming back to the issues put forward in 1979, we believe that most ofthe issues are being addressed by PCA. However, the need for concerted research efforts rather than diffused, duplicated, and wasteful efforts is still wanting. We believe we can do more to help the farmers and the coconut industry if we integrate all our efforts. Table 1 RA 8048 Updated Summary Report September 1995 to July 1997 (By Region) NO. OF TREES CUT REGION APPLICANTS AVE. TREES CUTIMO. I-IVB 1,819 59,326 2,579 IVA 8,271 543,311 23,622 V 2,572 240,586 10,460 VI 6,187 174,579 7,590 i VII 5,398 104,817 4,557 VIII 7,761 176,585 7,678 IX 1,712 32,286 1,404 I X 5,749 165,754 7,207 I XI 1,225 107,294 4,665 XII 2,322 44,246 1,924 CARAGA 2,322 44,246 1,924 ARMM 316 6,027 262 TOTAL 45,245 1,698,289 73,838 187 REFERENCES DAVID, V.M. 1997. Medium Tenn Coconut Industry Integrated Development Program CY 1996-2000. Philippine Coconut Authority. Diliman, Quezon City, Philippines. p. 1-47. MAGAT, S.S. 1997. Advances in Crop Agronomy, Nutrition, and Fanning Systems of Coconut in the Philippines. Paper presented at the coconut symposium "A Century of the Coconut Industry", Bureau of Soils and Water Management, Quezon City, 28-29 August, 1997. SANTOS, G.A. 1997. The PCA Seed Production Program. Status Report. Philippine Coconut Authority. Diliman, Quezon City. Sept. 16, 1997. P. 1-2. THAMPAN, P.K. 1995. Global Competitiveness of the Coconut Industry. Coconuts Today. Vol. XII, No. 1 October, 1995. Pp. 31-35. COCONUT WOOD PROCEEDINGS. 1979. International Meeting on Coconut Wood. Philippine Coconut Authority. October 22-27. Zamboanga City, Philippines. 188 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION SECONDARY PROCESSING OF COCONUT PALM WOOD by Dieter Fink Application Training And Management GmbH ReutlingenlGermany The following paper on "Secondary Processing of Coconut Palm Wood" is based on experience gained in the course of a research programme "Utilization of Coconut Timber from North Sulawesi, Indonesia" executed on behalf of the Federal Research Centre for Forestry and Forest Products in Hamburg/Germany. In addition, the findings presented in this report reflect practical experiences made in plants in South East Asia and in the Pacific region, where coconut wood is processed. First of all, I must state that, as far as chipping is concerned, cocowood has been the most difficult wood I ever had to do with. Even tropical species with a density in excess of 1 are less demanding than medium and high density cocowood as far as tools, machines and human skills are concerned. Before getting into the matter, I must therefore state that principally the further processing of cocowood is more cost-consuming than traditional species, as subsequent calculations in various plants have shown. This is due to: • high tool wear, • an extremely low machining performance per unit of time and, consequently, I • low processing speeds and a low output, • high investments in highly dimensioned machinery, tools, and extraction • equipment,' • relatively small log diameters/dimensions, • wooden parts of one raw density class featuring small cross sections, and • a lot of grading and sorting work. However, much lower harvesting and transport costs can make up for the high processing costs (the plantations are on relatively even ground and easily accessible, no forest roads are required since there are large distances between the trees). Inthe following I will cover the most important findings regarding • machining of cocowood • gluing • surface finishing 189 APPENDICES Machining properties In the course of the above-mentioned research programme, the following machining methods were explored: • Circular sawing • Band sawing • Planing • Profiling/moulding • Form shaping/moulding • Boring • Mortising/tenoning • Dovetailing • Swing chisel mortising • Sanding (wide faces, edges, profiles) • Lathe-turning The results of the study were verified and complemented in various plants where cocowood is processed. All cutting edge materials used for its machining were studied, with the exception of mono- and polycrystalline diamonds and ceramics for cutting edges or knives. Besides aluminum oxide (AL20 3) as conventional sanding material, we also tested zirconia alumina, which is normally used to grind metals. Both the surface and the edge quality were visually evaluated directly after the machining process to see whether there are any splinters (tom out vascular bundles) and raised grains. The reference species were popular (compared with cocos M.D.) and dark red meranti (compared with cocos H.D.) In addition, we measured the cutting edge wear and the dulling of the cutting edge where this was technically possible. The suitability for machining and the surface quality depends on various factors; • the material • the process • the tool and • the machine To come straight to the point: our studies revealed that the absolute value of the feed per tooth fZ, plays an outstanding role, compared to the other parameters. It is much more important than, for instance, cutting with feed or cutting against feed method, which usually plays a major role when processing conventional species, among others, because of the pre-splitting effect, which is more or less strong when processing conventional speCIes. 190 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION In the following, the relevant results of our findings are summarized: • Carbide-tipped cutting tools are the prerequisite for economical and good quality processing on an industrial scale. Stellite-tipped circular saws, for instance, can provide good results when cutting logs. And stellite can also be used for planing operations to achieve satisfactory results. • The cutting material, the density of the cocowood, and the feed per tooth fZ, as the most important process parameter, must be well-matched. • As far as cocowood is concerned, the feed per tooth fZ has a greater influence on the processing quality than the cutting with feed or cutting against feed factor. • Profiling vertically to the fibres should be avoided, if possible. • For large cutting depth or chip removal volumes, multiple processing steps or passes are necessary. • End-face planing (hogging) ensures, compared to peripheral flat planing or conventional planing, better surface qualities. • Boring in all fibre directions brings satisfactory results, even when using HSS bits. Conclusion: dowelled joints are ideal for cocowood. • Narrow band sawing using carom-vanadium sawblades is very problematic when cutting.curved workpieces; the average life-distance is 3 m per sawblade. Therefore, hardened band-saw blades are strongly recommended. • Mortising, tenoning, and dovetailing are possible. However, there are extremely strong cutting forces, as well as splinters at the tool exit side. Good counter-stops are therefore necessary. Better: to avoid these processes and to use dowelled joints, provided that the stability of the joint is good enough. • When using aluminum oxides (AL20 3) for the abrasive particles, sanding is highly problematic because ofthe very short lifespan of the sanding belts. Recommendation: 1. Sanding process: across the grain 2. Sanding process: with the grain Use sanding belts with zirconia alumina. Lathe-turning does not pose any problems when processing cylindric workpieces, even when HS cutters are used. Note: Avoid highly profiled lathe-turned components with a profile base narrowing to a point. The cutting tool tip (lance) should always have a certain radius and should not taper to a point. 1 91 APPENDICES Concluding, the following can be stCJJedregarding the above-mentioned processing methods: ./ . • high blade wear, even when using carbide-tipped tools, and, consequently high tool costs • due to relatively small feed per tooth rates, the output is smaller than with conventional specIes • high cutting forces with coco's HD • high amount of dust and fine particles • polluting the direct environment • tool dulling ~ good dust extraction equipment is necessary •. machines, drives, bearings and guides must be adequately dimensioned ~ industrial processing of cocowood requires "best" machines and tools • wet cocowood is easier to machine than dry cocowood. Recommendation: 1. pre-processing in "wet" condition 2. kiln-drying to the required final moisture content 3. final processing Attention: Dimensional changes and possibly surface cracks have to be taken into consideration! 192 INTERNATIONALCONFERENCE ON COCOWOOD UTILIZATION Gluing Gluing is not only necessary in case of constructive joints such as doweled joints, but also with a view to the relatively small cross sections of a density group. In addition, gluing is required to achieve larger dimensions, for instance when producing solid wood panels and ~cantlings. Basically" all types of glue designed for gluing wood can be used to glue coconut palm wood. This includes PVA adhesive, urea, melamine and phenol-form-aldehyde adhesives, as well as epoxide and polyurethane adhesives. The choice of the adhesives depends mainly on the conditions of use (interior/exterior use, climate resistance) and on the machining conditions Goint gluing, assembly gluing, fitting tolerance of the components, wood moisture content). In principle it can be stated that coconut wood has a very good gluability. Pre-conditions for gluing Cocos nucifera • The cocowood must be dried to the final wood moisture content corresponding to the subsequent application climate. • The surfaces that are to be glue-bonded must be smooth and dust-free, and there must be no vascular bundles projecting from the surface, as they impede the required joint fit. • Wood joints must be machined to an accurate fit and must have sufficiently large adhesion surfaces appropriate to the joint strength requirements (dowels versus double mortise and tenon). • A sufficient amount of glue must be applied. The basic parenchrymatic tissue of coconut palm wood has a high absorbency that takes up the adhesive rapidly and thus leads to a starved glue line. This effect occurs especially with cross-grain wood surfaces and with Cocos nucifera LD. Remedies include high-viscosity adhesives (based on PVA) or a double application of adhesive to these critical surfaces. Note: Dowel holes may have a high proportion of cross-grain surfaces. Special instructions regarding the technique for glue-bonding Cocos nucifera The use of glue-bonded profiles for full-width glue bonding may have advantages in certain applications (strengths, reduction ofthiclmess misalignment). Care should be taken to ensure that glue-bonded profiles do not taper to a point, since otherwise there may be machining problems and less accurate fits as a result of projecting vascular bundles. For this reason, finger joints are not recommended. 193 APPENDICES It is absolutely possible for the various layers to have different densities when manufacturing laminate scantlings and boards made of multiple layers. Thus, in three layer panels the facing layer can be made of Cacas nu~iferaHD and the core layer of Ca cos nucifera MD. This must be seen as a great advantage for the economic use of coconut wood, since the yield factor can be improved considerably as a result ofthe ability to use medium and low density wood. Surface finishing A well-sanded wood surface is a pre-condition for high surface quality. The fine sanding of Cacas nucifera should be carried out with 1001120 grit, parallel to the grain, and at a low pressure. Staining Cacos nucifera absorbs stain very well. The variations in the colour of the wood of the kind that often occur with Cacas nucifera can be evened out very well by staining. Because of its properties, the parenchyma absorbs the stain more strongly during staining than the vascular bundles, which lead to a negative staining pattern in the case of very dark stain shades (i.e., the vascular bundles appear paler than the parenchyma.) Prime and top coating The prime and top coating of Cacos nucifera. MD can cause problems if the coating material is not properly formulated because the parenchymatic tissue is softer than the fully curedlhardened coat layer. In the event of mechanical stress, the brittle coat cracks or "whitens" because of the soft substrate. This effect can be avoided by using elastically formulated PU (polyurethane) paints. Fibres raising after application of the prime coat, especially with water-based materials, must be removed by intermediate sanding. Coconut palm wood can be treated with all of the finishing systems that are suitable for finishing/painting wood, provided that the material is formulated "elastically". Final remarks The industrial use of cocowood requires professional approach and processing. This already begins with the design of the end product. Not all of the design and construction principles and methods of realisation, which are known from conventional species, are applicable to cocowood. As outlined before, the processing costs are relatively high due to high tool wear, a low output per time unit, and the relatively high requirements regarding the machine and tool design. The proportion ,of manual work during secondary processing should be kept low, since the tools that can be used here are not very efficient. Nevertheless, realization 194 INTERNATIONALCONFERENCE ON C_OCOWOOD UTILIZATION of processing quality that meets international standards is a challenge, in particular for up-market products such as furniture and interior decoration items. But despite this, I would like to encourage potential wood processing companies to use this valuable and aesthetic raw material in an economically sensible way. Meanwhile, sufficient positive experience and know-how are available to help avoid mistakes and to enable manufacturers to process and market this material in a profitable way. In the future, there will be a shortage of wood in this part of the world. In the long run, wood from plantations such as rubberwood and gmelina, which are heavily used today, is not the perfect solution. The market depends on change. It is high time for cocowood to come in. 195 NETWORKINGIINFORMATION DISSEMINATION ON TECHNOLOGIES DEVELOPED FOR COCOWOOD INDUSTRY! ABSTRACT More than 90 countries in the tropical regions grow coconut and millions of people depend on coconut for their food, shelter and employment. The development of the coconut industry is thus very essential for improving the welfare of those people. APCC has long realized the key role of information in boosting the coconut industry. It has taken various efforts to make coconut information available and easily accessible. Meanwhile, APCC is determined to be a leading coconut information provider in line with its efforts to develop the coconut industry especially in the Asian and Pacific region. The paper describes APCC's activities on the networking/information dissemination on technologies developed for the coconut industry in general and coconut wood in particular for more than two and a half years of its existence. Before I come to the subject of my paper today which is "NetworkinglInformation Dissemination on the Technologies Developed for the Cocowood Industry, let me say a few words about APCC. APCC (Asian and Pacific Coconut Community) is the first intergovernmental commodity organization established in 1969 in the region under the auspices of the then ECAFE now ESCAP.. Present membership numbers to 14 , seven from Asia and seven from the Pacific. Theyare: FSM, Fiji, India, Indonesia, Malaysia, PNG, Philippines, Solomon Islands, Sri Lanka, Thailand, Vanuatu, Vietnam, Samoa and Palau as associate member. Members of the APCC account for 86% and 90% of the world's total coconut production and exports, respectively. Realizing that lack of information or its proper dissemination as a constraint for the development of the coconut industry, information activities has consistently been given priority by the APCc. One of the recently revised 15 functions deal mainly on information and another relating to information. I Paper presented by Mrs. 1. c. Suharto, Publication Officer, APCC at the International Conference on Cocowood Utilization, 27-29 October 1997, Manila, Philippines. . 196 Function 1 - provide a forum to promote friendship among its member states and associate members and for the various interest groups of the coconut industry to exchange expertise, information and thereby identify common problems with a view to formulate policies and programme taking into account the experience of member states, other coconut producing countries and related commodities and, Function 10 - to collect, analyze, package information on all aspects of coconut and related products and disseminate such information as necessary to meet the various needs of the industry. COCOWOOD - A NEW PRODUcr As we all know, coconut is a multi-product crop. The technologies developed and the level of adoption for each product, however, vary from every producing country to another. More often this is a result oflack or inadequate information dissemination, most especially for a new product and technology. Coconut timber utilization is not an exception. Although there have been some attempts earlier in this regard,. unfortunately, very little of these technologies have so far been transferred and applied especially out of the country where the technologies were generated and developed. So being a new product, the need to publish and disseminate the technologies developed, is now considered more urgent and necessary. Aware of the need, APCC's has been actively involved in bridging the information gap relative to the promotion of coconut wood utilization. Its activities could be traced back to the late 70s which were undertaken either through collaborative involvement with related agencies or on its own. PROMOTION AcrIVITIES APCC's collaborative involvement with the PCAlFAO/GTZ on the conduct ofa seminar on Coconut Wood Utilization in Zamboanga City, Philippines in 1979, resulted in the resolution for inclusion ofR & D project on cocowood utilization in the Second Window of the UNCTAD-IPC. The 1980 Session, though felt that there was no immediate need for any decision on this issue, other than to manifest a strong interest of APCC countries in this activity and the potential benefit to be derived by the coconut industry from a successful breakthrough in coconut wood utilization technology. The 1981 Session, meanwhile, endorsed the Regional Coconut Wood Training Development Project which emphasized both training on coconut wood processing as well as further development for maximizing commercial utilization of the entire coconut stem. An output of the project is the Technical Report on the Mechanical Properties of Coconut Palm Wood based on the work of V. K. Sulc, a wood technologist. In 1985 APCC, in collaboration with UNIDO, had drawn up a project proposal entitled, "Coconut Wood Utilization" with the immediate objective to promote the industrial use of coconut palm stems generated from the replanting schemes in the region. Components 197 under the project, among others, were training, conduct of seminars, fH~ldvisits and the study of existing research activities. The Session endorsed the project proposal and had requested the APCC Executive Director to make official request to UNDP for funding. However, due to lack of funds, the project proposal did not take off the ground. PALMWOOD UTILIZATION PROJECf Increased role played by the APCC on information dissemination took place under the IDRC funded project on Palmwood Utilization in 1980. The various activities undertaken under the component on Coconut Wood included, the issuance of special issue of CORD (acronym for Coconut Research and Development) on the subject of Coconut Wood Utilization, production of video documentary titled, New Phases of the Coconut Industry, highlighted the different technologies involved in the commercialization of coconut lumber. CORD's "Special Edition on Cocowood Utilization" incorporated 6 articles which dealt mostly on research results undertaken. Among them are: • Evaluation of some chemicals for the control of blue stain fungus and pinhole borer or freshly-sawn coconut timber • The production and properties of coconut stem charcoal in Thailand • Coconut stem utilization in Indonesia • Coconut stem utilization in Sri Lanka • Design & development of coconut palm roof shingles • Exposure tests of surface treated sawn lumber • Book review: How to process coconut palm wood APCC's Executive Director's participation at the Regional Experts' Meeting on Coconut Wood Utilization held in Los Banos, Laguna, Philippines, in 1995 was APCC" another involvement in this activity. The meeting has recommended, among others: a) for the APCC to become the regional center for networking but should expand its concern to include countries in the Mrican region and link with other existing networks, and b) for the APCC to prepare a data gathering instrument and gather data through its focal points for the preparation of a ''Directory of Specialists trainers, traders and organizations concerned with cocowood. APCC, however, is still in communication with relevant agencies regarding the implementation of this activity. Meanwhile, by making use of its already developed infrastructure, via the different media including print and electronic, APCC's activities in promoting transfer of coconut timber technologies have definitely been intensified in the intervening years. 198 PuBLICATIONS To date, APCC has a total of 120 publications comprising of regular, ad hoc, series and serials. The regular ones are: COCOMUNITY - Newsletter semimonthly Statistical Yearbook - Annual CORD - J oumal semiannual COCOINFO International - Journal semiannual Both COCOMUNITY and the Statistical Yearbook have been uninterruptedly published since 1972 and 1982, respectively. CORD acronym for Coconut Research and Development was launched 15 years ago, to assist in dissemination of information on coconut research and development. Only original articles are published in the journal. COCOINFO International started four years ago with the objective to assist mainly the processing and marketing sub-sectors. All of the above, except the Statistical Yearbook, frequently incorporate articles on coconut wood. Prepared in 1981 APCC in collaboration with UNIDO is a seven set document on coconut processing technology information that included: oil refining, desiccated coconut, domestic food processes and coconut coir fiber. With the lapse oftime while some of them needed updating and new technologies which had to be documented, accordingly, new technologies on energy values, waste heat unit, activated carbon, etc. were produced. It should be noted that during that time, coconut wood was not yet significantly utilized. With the emergence of new technologies and the increased interest on coconut wood, APCC has already initiated action to have the technologies produced along the UNIDO's format and the expert to undertake this assignment has already been identified. PROVIDE A FORUM In keeping with the functions earlier mentioned APCC organizes regular, ad hoc seminars, workshops and other meetings. APCC's annual technical meeting called the COCOTECH is a regular forum, which is open to interest groups of the industry. It deliberates on a topic, which is of current interest. In its 1996 meeting which deliberated on Technology Transfer and Application in Relation to the Coconut Industry, was a paper on Coconut Wood Processing and Utilization while at the 1991 meeting where it delved on the theme, Small-Scale Processing of Coconut Products, a paper titled, "Portable Sawmill-Our Guide to Economic and Practical Approach to Forest Utilization", discussed the basic machinery to process coconut palm from a standing tree to a finished product suitable for everyday needs. 199 PROVIDE TRAINING APCC being aware that ecological advances made in relation to the coconut industry varies from country to country arrange training programme under the TCDC concept to facilitate the transfer. Every attempt is made to get some donor agency to fund the air travel, which is the biggest cost component. The other costs are generally shared by the beneficiary and benefactor countries. Currently there is a training programme on cocowood utilization for which APCC has sought ESCAP and UNIDO's assistance, which is pending at the moment. APCC also arrange training programs and visit to other countries upon request by both members and non-member countries as well. In this case, the bulk of the expenses have to be borne by the benefiting party. COCONUTmwORMATIONNETWORK An ITC Geneva funded project titled, ''Development of a Computer Based Market Intelligence System for Coconut Producing Countries in Collaboration with the Asian and Pacific Coconut Community", in 1987 ushered in the computerization era at the APCC Secretariat. The project, among others, has provided the necessary infrastructure like computers, modems, etc. to the Secretariat. It was however, in 1992 under the IDRC Canada funded project on Integrated Coconut Information Programme that put in place a coherent information network within the 14 APCC member countries and two related organizations. The network has become the nucleus for the production, collection, retrieval and distribution of coconut information. Specifically, the programme has established contact points called Coconut Information Specialists in each of the 14 APCC member countries. The network has significantly strengthened the capacity of each member country to collect, package, disseminate and exchange information on the coconut industry which is consistent with the overall objective the APCC which is to promote, coordinate and harmonize the activities of the coconut industry. Initially for three years the project was extended for a year in view of its importance to the industry. Under this phase, the program has provided e-mail and Internet access and connectivity to APCC member countries and associated institutions to constitute an electronic network of coconut producing countries in Asia and the Pacific. Through the programme, coconut related information likewise has been packaged and web pages have been developed for APCC publication and activities. (For details please visit us at E-mail: apcc(alindo.net.id; Home Page: http://www.apcc.org.sg.) These have been widely disseminated through PanAsia NetworkingProgramme(p AN) web server in Singapore. As of this writing, a total of9 APCC member countries have already installed their mail and Internet facilities while the rest are expepted to finish their installations in a month or two. A number of them too have developed and are operating their homepage. Next month, the Documentalist of the APCC Secretariat is making advisory visits1tp some skills of the National Coconut Information Specialists to operate electronic mail, World Wide Web 200 facilities, the Hypertext Markup Language (HTML) for developing a home page etc. However, there are still a number of activities envisaged under the project such as; use of virtual conference software to initiate special discussions and electronic conference, Internet phone, access to consultants databases, coconut equipment manufacturers, coconut product suppliers, etc. to name a few. The network is initially being operated within the APCC member countries. With the 1996 APCC Session decision to extend its membership to coconut producing countries outside the region, which will include Africa, South and Central American countries, this should enable a more global scope of the coconut information network. Establishing linkages within and outside the region would further facilitate transfer of technologies on the coconut industry in general and on coconut wood in particular. 201 RAW MATERIAL SOURCE AND ACQUISITIONl RN.PALOMAR PCA-ZamboangaResearchCenter San Ramon,Zamboanga City, Philippines ABSTRACT The coconut growing countries of the world share the common problem declining palm productivity due to, among other things, increasing proportion of old and unproductive palms. A large-scale replanting program is envisioned to replace old and senile palms with hybrid and high yielding coconut varieties as a positive approach to the problem of low palm productivity. Readily available coconut wood resource from senile palms in the Asian and Pacific Coconut Community (APCC) consisting of 14 member-countries and other coconut regions has been estimated at 214.28 million cubic meters of mill able .. logs. Of this volume, Indonesia and the Philippines account for 32.48% and 32.34%, respectively, or a combined wood resource of about 65% of the total logs available in· the coconut producing countries of the world. In the Philippines, the estimated total coconut area is 3~08 million hectares and about 30% of the coconut stands are considered old and senescent. Of the 15 regions, Southern Tagalog has the largest area of 517.36 thousand hectares followed by Southern Mindanao and Bicol with 501.31 thousand and 372.57 thousand hectares, respectively. Of the three major geographical divisions of the country, Mindanao has the largest coconut. area of more than 1.59 million hectares while Luzon and the Visayas have 913.18 thousand and 571.01 thousand hectares, respectively. Coconut log acqUISItIon in the Philippines should be in accordance with Republic Act No. 8048 known as the Coconut Preservation Act of 1995 which prohibits, among other things, cutting of coconut trees that are younger than 60 years old. 1 Paper presented during the International Conference on Cocowood Utilization on 27-29 October 1997 at the Holiday Inn, Manila, Philippines 202 INTRODUCTION The coconut is an important perennial crop that grows well in a wide range of tropical environments and extends over a large proportion of the coasts and islands geographically located between 20 degrees north and 20 degrees south of the equator and in altitude below 600 meters. The palm thrives best in well-drained soils with a well-distributed annual rainfall ranging from 1,300 mm to 2,300 mm and a mean temperature of27 degrees centigrade. It has a strong columnar stem that supports a whorl of fronds in its apex, which develops a single growing point known as the bud. Its roots emerge from an underground root bulb located below the basal section of the stem. Its fibrous root system consists of primary roots wherein secondary and tertiary roots as well as numerous rootlets emanate for moisture and nutrient uptake. As a monocot, the palm's life support system flows through the fibrovascular bundles, which are denser at the outside portion and becoming scarce at the core when viewed in cross-section of the stem. All growth is considered primary as the stem is devoid of vascular cambium. Hence, no secondary thickening of the stem is possible unlike dicotyledonous plant. Under normal conditions, a healthy palm has an average of 40 fronds. The oldest frond supports bunches of harvestable nuts followed by a few sustaining developing bunches and newly-opened and developing inflorescence. The others are young, open and newly opened leaves and spears. A typical tall coconut variety reaching 70 years old and over are considered mature and unproductive. It can reach a height of 25 meters or more with 30 to 40 centimeters in diameter at breast height. Variations in height and diameter from one tree to another or between locations are the results of the growing conditions of the individual palm during the early stages of its life. Taper is about 5 mm per meter. Mature stem gives a maximum wood volume of one cubic meter. The many uses of coconut wood have been successfully demonstrated ranging from novelties to building construction materials. Coconut wood is no doubt a good material for the manufacture of high value and export-quality finished products, which include furniture, decorative interior walls, parquet, wares and curio items. In view of the increasing demand for timber, coupled with diminishing commercial wood species, coconut wood will become an extremely valuable commodity. 203 The proportion of old and senescent palms is inevitably increasing in almost all coconut growing countries. As a result, progressive decline in nut production is experienced which affects both the livelihood of the farmers and the economies of the countries. Replacing these senile palms with hybrid and early-bearingvarieties is generally desired. It has been recognized that the most effective and proper way of disposing the felled trunks is to convert them to saleable finished wood products. This system would not only provide proper trunk disposal as a phytosanitary measure at replanting time but would also give economic benefits to the farmers in the form of additional income, make available alternative construction material, and would generate investment and employment opportunities for the entrepreneurs and for people living in the rural areas, respectively. RAW MATERIAL SOURCE The estimated available wood resource in coconut producing countries indicating the area under coconut, percentage of ageing palms and volume of millable logs and sawn lumber is presented in Table 1. Table 1. Estimated available wood resource in coconut producing countries. Area under Percentage of Volume of Volume of Coconut Ageing Millable Sawn Country (*000 HA.) Palms** Logs*** Lumber**** (*000 cu. m) (*000 cu.m.) l.APCC Countries 10,353.00 31.79 195,526.25 58,957.88 F.S. Micronesia 17.00 30.00 382.50 114.75 Fiji 64.00 35.00 1,680.00 504.00 I India 1,669.00 10.00 12,517.50 3,755.25 . Indonesia 3,712.00 25.00 69,600.00 20,880.00 Malaysia 290.00 40.00 8,700.00 2,610.00 I PapuaNewGuinea 260.00 30.00 5,850.00 1,755.00 Philippines 3,080.00 30.00 69,300.00 20,790.00 Solomon Islands 59.00 40.00 1,770.00 531.00 Sri Lanka 419.00 20.00 6,285.00 1,885.50 Thailand 412.00 35.00 10,815.00 3,244.50 Vanuatu 96.00 45.00 3,240.00 972.00 Vietnam 186.00 25.00 3,487.50 1,046.25 Western Samoa 75.00 45.00 2,531.25 759.38 Palau -- -- 14.00 35.00 367.50 110.25 2.0ther Countries 824.00 30.00 17,756.25 5,326.88 I Africa 461.00 30.00 10,372.50 3,111.75 America 254.00 25.00 4,762.50 1,428.75 Asia 64.00 30.00 1,440.00 432.00 Pacific 45.00 35.00 1,181.25 354.38 TOTAL 11,177.00 30.90 214,282.50 64,284.76 *Source: 1995 APCC Coconut Statistical Yearbook **Rough Estimate ***Estirnated at 100 trees per hectare with log volume of 0.75 cubic meter per tree. ****Estimated at 30 percent sawn lumber 204 The coconut growing countries listed above account for a total of more thanll.17 million hectares planted to coconut. The estimated percentage of ageing palms range from 10% to 45% with India and Vanuatu including Western Samoa having the lowest and highest proportion of old palms, respectively. Indonesia, which accounts for the biggest area under coconut, has 25% senile trees while the Philippines, which comes next in terms of coconut area, has 30% ageing palms. The rest of the coconut producing countries have 20% to 35% senile trees. Based on the volume of millable logs, a total of about 214.28 mi11ion cubic meters of round timber would be readily available for economic utilization producing approximately 64.28 million cubic meters of sawn coconut lumber. Of this volume, Indonesia and the Philippines account for 20.88 million and 20.79 million cubic meters of sawn lumber, respectively, or a combined wood resource of 41.67 million cubic meters which represents more than 64% of the expected total lumber production of the coconut growing countries. The 14 member-countries of the Asian and Pacific Coconut Community (APCC) have available wood resource of 196.52 million cubic meters representing about 92% of the world's total millable logs. In the Philippines, the coconut area and estimated volume of millable logs and sawn lumber by region are presented in Table 2. Of the 15 regions, Southern Tagalog has the largest coconut area of 517,360 hectares followed by Southern Mindanao with 501,310 hectares. The third largest coconut area is the Bicol region with 372,570 hectares while the fourth is Western Mindanao with 371,080 hectares. Tablt;" 2. Coconut area and estimated volume of millable logs and sawn lumber by region in the three major geographical divisions in the Philippines. Coconut Area" Volume of"" Volume of""" REGION ('000 Hectares) Millable Logs Sawn Lumber ('000 cu. m.) ('000 cu.m.) Cordillera Autonomous Region 0.25 5.63 1.69 Iloeos 13.39 301.28 90.38 Cagayan Valley 7.34 165.15 49.55 Central Luzon 2.27 51.08 15.32 Southern Tagalog 517.36 11,640.59 3,492.18 Bieol 372.57 8,382.82 2,514.85 Luzon 913.18 20,546.55 6,163.97 Western Visayas 112.16 2,523.60 757.08 Central Visayas 135.31 3,044.48 913.34 Eastern Visayas 323.54 7,279.65 2,183.90 Visavas 571.01 12,847.73 3,854.32 Western Mindanao 371.08 8,349.30 2,504.79 Northern Mindanao 211.62 4,761.45 1,428.44 Southern Mindanao 501.31 11,279.47 3,383.83 Central Mindanao 98.44 2,214.90 664.47 Autonomous Region InMuslim Mindanao 187.76 4,224.60 1,267.38 Caraga 225.60 5,076.00 1,522.80 Mindanao 1,595.81 35,905.72 10,771.71 Philippines 3,080.00 69,300.00 20,790.00 *Source: 1995 Coconut Industry Statistics, PCA **Estimated atlOO trees per hectare with log volume of 0.75 cubic meter per tree ***Estimated at 30% sawn Lumber recovery 205 Of the three major geographical divisions in the country viz. Luzon, Visayas and Mindanao, the latter has the largest coconut area of 1.595 million hectares which is about 50% of the total Philippine coconut area, followed in descending order by Luzon (913,180 hectares) and the Visayas (571,010 hectares). In terms of available wood resource, Mindanao has 35.90 million cubic meters of millable logs while Luzon and Visayas have 20.54 million cubic meters, respectively. RAw MATERIAL ACQUISITION Republic Act No. 8048 known as Coconut Preservation Act of 1995 was enacted by Philippine Congress to regulate the unabated and indiscriminate cutting of coconut trees. The Law prohibits the cutting of coconut trees except in the following cases and only after a permit had been issued by the Philippine Coconut Authority: 1. When the tree is sixty (60) years old. 2. When the tree is no longer economically productive. 3. When the tree is disease-infested. 4. When the tree is damaged by typhoon or lightning. 5. When the land devoted to coconut production is converted, in accordance with law, into residential, commercial or industrial areas. 6. When the land devoted to coconut production is converted into other agricultural uses or other agriculture-related activities in pursuance to a conversion duly applied for by the owner and approved by the proper authorities. Provided that no conversion is allowed by the PCA until after it has been verified and certified that for a period of at least three (3) years, the majority of the coconut trees have become senescent and economically unproductive or where the coconut farm is not adaptable to sound management practices on account of geographical location, topography, drainage and other conditions rendering the farm economically unproductive. 7. When the tree will cause hazard to life and property. An application to permit to cut is required with a fee of twenty-five pesos (PHP25.00) pre tree payable to the PCA. Ten pesos (PHPI0.00) of the fee will be retained as PCA's share to finance the replanting program. Ten pesos (PHPlO.00) and five pesos (PHP5.00) will be given to the municipal and the barangay unit concerned, respectively, for the repair and rehabilitation of roads which have been damaged by the continuous passage of heavy vehicles used for transporting coconut lumber. Currently, plantation owners sell their old and unproductive coconut trees atPHP400.00 to PHP800.00 per tree depending on the size of the stem. 206 REFERENCES Asian and Pacific Coconut Community. 1995. Coconut Statistical Yearbook. Jakarta, Indonesia. Congress of the Philippines. 1995. Republic Act No. 8048. Coconut Preservation Act of 1995. Palomar, R. N. 1996. Country Brief Coconut Wood Utilization in the Philippines. Paper presented during-the Regional Experts' Meeting on Coconut Wood Utilizatio~ FPRDI, College, Laguna, 01-07 February 1996. Philippine Coconut Authority.1995. Coconut Industry Statistics. Market Research and Promotion Division, Market Development Department. Santos, G. A.1991. Varietal Improvement. In Cocobased-Farming Systems: State of the Knowledge and Practice, DA-BAR, Quezon City. r' 207 N C co ~ Cl) 0 0 I- N U 'I W tn 0:: I ' is 0 c: ~ CU 0 C. I ' --(J (J Cl) -- s.. ~ -- CU C D.. o DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MRS. JOSEPHINE C. Publication Asean and Pacific Coconut Tel. No. 62-21-5221712 to SUHARTO Officer Community 13 3rd Floor, Lina Building Fax No. 62-215221714 Jin Rasuna Said Jakarta Indonesia PROF. OR. DIETER Professor Doctor APPLICA no Training and Tel. No. (49) 7121-939750 FINK Management GinbH Unter den Linden A5 72762 Reutlingen, Germany MR. KAVEINGA Chief Executive Tonga Timber limited Tel. No. 29813 FA'ANUNU Officer P.O. box 21 Nuku'alofa, Fax No.29778 Tonga DR. JOSEPH Head Post Harvest Research Tel. No. 00-255-51- MPAGALlLE Institute 700552 P.O. Box 6226 Dar es Fax No. 00255-51-75549 Salaam, Tanzania DR. IVAN EASTIN Associate University of Washington Fax No. 206-685-3091 Professor Seattle, Wasgington U.S.A. PROF. DR. ARNO Professor Dr. Federal Research Center for Tel. No. +49-40-73962600 FRUEHWALD Forestry and Forest Products Fax No. +49-40-73962480 leuschnerstrasse 91 D 21031 Hamburg MR. D.M. SUGATH Assistant Director Market Development and Tel. No. 329749; 421027-8 DISSANAYAKE Research Fax No. 94-1-447602 Coconut Development and Research 11 Duke street, Columbo 1 Sri Lanka II,' . !i'- MR. DON LlONEL Manager Overseas Operations Tel. No. +441944 563091 JAYANETTI TRADA Fax No. +441494 565487 Hugdenden Valley High Wycombe HP14 4ND United Kingdom 211 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. GUY Yayasan Social Tel. No. (0382) 21401 JACQUEMIN Pembangunan Masyarakat Fax No. 62-382-21102 (YASPEM) JL Gajah Mada P.O. Box 121 Maumere 26112 Flores NNT-Indonesia MR. STAFFAN Director Scan Za Carpentry Tel No. +0812 750151 LUNDH Workshop Fax No. +255-54-30107 P.O. Box 352 Zanzibar, Tanzania MR. TORSTEN S. Consultant Brookdeich 164 a Tel. No. ++49-40 7203969 KILlAN D-21029 Hamburg, Fax No. ++49-40 7208230 Germany E-mail 101517.442@coml2userve. corn MR. ROBERT F. President Silahis Arts and Arti Facts Tel. No. 1331-9313-1493 LANE 2353 Sunrise Street Fax no. 0912-330-5501 Concorde Tambo, Paranaque, Philippines MR. EBERHARD Consultant GERMAC Machineries Tel. No. 9280106 JUNGINGER Corp. Fax No. 9229302 110 Timog A venue Quezon City, Philippines MR. FREDERIC Manager Cocowood of the Tel. No. (2) 924-58-51 to BILET Philippines-UniMasters 52 60 Times street Fax No. (2) 924-00-85 Quezon City, Philippines MRS. MARGARETHA Consultant Silahis Arts and Crafts Tel. No. 818-1787 GLOOR The Makati Tuscany Apt. 21 C 6751 AyaJa Avenue, Makati, Metro Manila, Philippines MR. WOLFGANG MPIZKoJa Tel. No. 49-221-5062-420 ROHDE Germany Fax. No. 5062413 E-mail: Rhode@Mpiz- Kolen.MPG.De 212 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. PETER BIWER Padans, Indonesia Tel. No. 0751-32768 MR. ROBERT Bureau of Industry BLUME Metro Manila, Philippines DR. DOUGLAS Project Manager International Tropical Tel. No. (81-45) 223-1110 PATTIE Timber Organization Fax. No. (045)223-1111 (lITO), 5th Floor, Pacifico- Yokohama Bldg. International Organizations Center 1-1-1, Minati-mirai, Nishi- ku Yokohama 220 Japan MR. DOMINIQUE Project Manager Common Fund for Tel. No. (3120) 66 46 409 LELlEVRE Commodities (CFC) Fax. No. (3120) 67 60 231 Willemshuis, Stadhouderskade 55 1072 AB Amsterdam DR. ACHILLES Associate Department of Economics Tel. No. 536-2505 COSTALES Professor College of Economics and Fax. No. 536-3641 Management UP Los Bafios, College, Laguna, Philippines MR. RODOLFO M. Philippine Coconut Tel. No. 522-1714 MADRAZO Authority Zamboanga City, Philippines MR. RICK MARQUEZ Dept. of Science and Tel. No. 837-21-91-96 Technology Science Technology Information Institute Bicutan, Metro Manila, Philippinis MR. TEDDY Dept. of Science and Tel. No. 837-21-91-96 AMANTE Technology Science Technology Information Institute Bicutan, Metro Manila, Philippines MR.ANTONIO Cedarwood Tel. No. 6462328 GOMEZ Philippines 213 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. GERONIMO T. Finance Officer Provident Tree Fann Tel. No. 532-3071 to 82 MANALO Incorporated Punta, Sta. Ana. Manila, Philippines MR. LUT F. LOPEZ Provident Tree Fann Tel. No. 532-3071 to 82 Incorporated Punta, Sta. Ana. Manila, Philippines MS. FE LOO Department of Environment Tel. No. 9201761 and Natural Resources Quezon City, Philippines MR. ROLENDO Division Chief III Philippine Coconut Tel. No. 991-5087 PALOMAR Authority Fax. No. 991-6369 Zamboanga Research Center P.O. Box 356 San Ramon, Zamboanga City, Philippines MR. JUANITO President Fancy Panels Enterprises Tel. No.(082) 238-0554 CALOLOT Km. 15, Panacan Fax. No.(082) 2380280 Davao City, Philippines MR. FRANCISCO Senior Manila Electric Company Tel. No. 631-5652 BUHAIN Superintendent 31FTSB, Meralco Center Fax. No. 1662-8745 Ortigas Avenue Pasig City, Philippines MR. FLORENTINO G. President Furniture Ville Inc. Tel.No.0912-301-9881 TORRES Pio Production Center Fax. No. 045-910-075 Porac, Pampanga, Philippines MR. BENJAMIN General Manager JERMOND International, Tel. No. (062)991-7946 DIMAANO Inc. Fax.No. (062)992-0133 Summer Hill Subdivision Pasocana, Zamboanga City, Philippines MR.CARLOS Deputy Philippine Coconut TeI.No.920-0415;426- CARPIO Administrator Authority 1398 Quezon City, Philippines Fax. No. 920-0415 214 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. DOMINGO Davao Etnokraft Tel. No. 299-2728 LADAO Matina, Davao City, Philippines MR. MARCELO MARBOZA Handicraft Tel.No.0918-802-9486; ZAMORA Baranggay Tubuan II 812-7065 By-Pass Silang, Cavite, Philippines DR. EMMANUEL D. Director Forest Products R.esearch Tel.No. (049)536-3630 BELLO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 DEPUTY DIRECTOR Assistant Project Forest Products Research Tel.No. (049)536-3630 DOMINADOR S. Leader, ITTO 3 and Development Institute Fax.No. (049)536-3630 ~ ALONZO (FPRDI) College, Laguna 4031 ENGR. ROMULO C. Project Leader, Forest Products Research Tel.No. (049)536-3630 EALA ITT03 and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. EDNA B. BAUZA Subject Matter Forest Products Research Tel.No. (049)536-3630 Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. MA. SALOME R. Subject Matter Forest Products Research Tel.No. (049)536-3630 ROMAN Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 FOR. ROBERT A. Subject Matter Forest Products Research Tel.No. (049)536-3630 NATIVIDAD Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 ., I FOR. CATALlNO L. Subject Matter Forest Products Research Tel.No. (049)536-3630 PABUAYON Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MR. DANTE B. Subject Matter Forest Products Research Tel.No. (049)536-3630 PULMANO Specialist, ITTO and Development Institute Fax.Nb. (049)536-3630 (FPRDI) College, Laguna 4031 215 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. VICTOR G. Subject Matter Forest Products Research Tel.No. (049)536-3630 REVILLEZA Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. LOLlTA V. Subject Matter Forest Products Research Tel.No. (049)536-3630 VILLAVELEZ Specialist, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 DR. JUSTO P. ROJO Conference Forest Products Research Tel.No. (049)536-3630 Session I and Development Institute Fax.No. (049)536-3630 Chairman, ITTO (FPRDI) College, Laguna 4031 ENGR. ARNALDO P. Conference Forest Products Research Tel.No. (049)536-3630 '''" MOSTEIRO Session III and Development Institute Fax.No. (049)536-3630 Chairman, ITTO (FPRDI) College, Laguna 4031 MS. YOLANDA U. Conference Forest Products Research Tel.No. (049)536-3630 ROBILLOS Moderator, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MR. WILFREDO M. Conference Forest Products Research Tel.No. (049)536-3630 AMERICA Session IV and Development Institute Fax.No. (049)536-3630 Chairman, ITTO (FPRDI) College, Laguna 4031 DR. MAGDALENA Y. Conference Forest Products Research Tel.No. (049)536-3630 GIRON Session V and Development Institute Fax.No. (049)536-3630 Chairman, ITTO (FPRDI) College, Laguna 4031 ENGR. WIVIO M. Study Leader, Forest Products Research Tel.No. (049)536-3630 TORDILLA ITT03 and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 ENGR. FELlX C. Guest Observer Forest Products Research Tel.No. (049)536-3630 MOREDO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 216 DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER DR. FLORENTINO O. Consultant, ITTO Forest Products Research Tel.No. (049)536-3630 TESORO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 DR. FLEURDELlZ M. Guest Observer, Forest Products Research Tel.No. (049)536-3630 LAURICIO FPRDI and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 OR. MARINA A. Conference Forest Products Research Tel.No. (049)536-3630 ALlPON Coordinator. and Development Institute Fax.No. (049)536-3630 ITT03 (FPRDI) College, Laguna 4031 , .. MS. GRECELDA A. Study Leader, Forest Products Research Tel.No. (049)536-3630 ( EUSEBIO ITT03 and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. CAROLINA C. Chairman, Forest Products Research Tel.No. (049)536-3630 CANAPI Committee on and Development Institute Fax.No. (049)536-3630 Registration, (FPRDI) ITT03 College, Laguna 4031 MS.CAROLYN Study Leader, Forest Products Research Tel.No. (049)536-3630 MARIE C. GARCIA ITT03 and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MR.PERLAA. Member Forest Products Research Tel.No. (049)536-3630 CENTENO Committee on and Development Institute Fax.No. (049)536-3630 Promotion, ITTO (FPRDI) College, Laguna 4031 MS. RIZALlNA K. Chairman, Forest Products Research Tel.No. (049)536-3630 ARARAL Committee on and Development Institute Fax.No. (049)536-3630 Promotion ITTO (FPRDI) College, Laguna 4031 MS. ZENAIDA R. Member Forest Products Research Tel.No. (049)536-3630 REYES Committee on and Development Institute Fax.No. (049)536-3630 Secretariat, ITTO (FPRDI) College, Laguna 4031 217 \ \ DIRECTORY NAME POSITION ADDRESS CONTACT NUMBER MR. RODRIGO E. Member Forest Products Research Tel.No. (049)536-3630 CORTEZ Committee on and Development Institute Fax.No. (049)536-3630 Physical (FPRDI) Arrangement, College, Laguna 4031 ITTO 3 MR. EDGARC. Chairman Forest Products Research Tel.No. (049)536-3630 DEOMANO Committee on and Development Institute Fax.No. (049)536-3630 Exhibits, ITTO 3 (FPRDI) College, Laguna 4031 MR. EDUARDO M. Member Forest Products Research Tel.No. (049)536-3630 ATIENZA Committee on and Deve}opment Institute Fax.No. (049)536-3630 Exhibits, ITTO 3 (FPRDI) College, Laguna 4031 "\ ~ t MR. MELANIO C. Training Forest Products Research Tel.No. (049)536-3630 ABINA IConsultant, and Development Institute Fax.No. (049)536-3630 ITT03 (FPRDI) (Computer College, Laguna 4031 Maintenance) MS. LlLIBETH D. Science Research Forest Products Research Tel.No. (049)536-3630 SANTOS Assistant, ITTO 3 and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. MA. TERESA J. Science Research Forest Products Research Tel.No. (049)536-3630 NIMEDEZ Assistant, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. GINA V. DE Science Research Forest Products Research Tel.No. (049)536-3630 CASTRO Assistant, ITTO and Development Institute Fax.No. (049)536-3630 (FPRDI) College, Laguna 4031 MS. LYDIAC. Accounting Forest Products Research Tel.No. (049)536-3630 NASAYAO Clerk, and Development Institute Fax.No. (049)536-3630 ITT03 (FPRDI) College, Laguna 4031 218