A combination of fax and mail questionnaires were used to estimate consumption of wood based products by the U.S. cabinet industry and evaluate current management issues affecting the cabinet industry. Group 1 companies (>$20 million in sales) were contacted and sent a fax questionnaire. A random sample of 1034 Group 2 companies (<$20 million in sales and >10 employees) were sent a mail questionnaire. A total of 19 usable questionnaires were received from Group 1 companies and 217 usable questionnaires were received from Group 2 companies. Group 1 respondents averaged 1,108 employees and $125.81 million in sales. Group 2 respondents averaged 27 employees and $2.31 million in sales. A shortened questionnaire (questionnaire 2, one page) was sent to half of the Group 2 sample frame resulting in twice the response rate as that of the long questionnaire (questionnaire 1, three pages). Results indicated that the cabinet industry used an estimated 484 million board feet of hardwood lumber. Nearly 95% of the hardwood lumber purchases were grade 1 common or better. The most common used species were red oak (44%) and hard maple (24%). An estimated 58 million board feet of components and 68,344 doors were also purchased by cabinet manufacturers in 1999. Softwood lumber use was estimated at 25 million board feet, consisting primarily of white (49%) and southern yellow (36%) pine. The most commonly used panel products were particleboard and hardwood plywood, at an estimated 1,044 million square feet (1/2 inch basis) and 279 (3/8 inch basis) million square feet respectively. Other panel products used by the industry were medium density fiberboard, hardboard, and softwood plywood. Approximately 156 (any thickness) million square feet of veneer was used. Lumber purchases were primarily direct from sawmills (66%) for Group 1 companies and from wholesalers/distributors (53%) for Group 2 companies. Panel product purchases followed the same trend with Group 1 companies buying primarily direct from manufacturers (44%) and the majority of Group 2 purchases coming from wholesalers/distributors (84%). Group 1 companies sold their products through factory sales people (54%) and to home improvement/building supply centers (37%). Group 2 companies sold their products through factory sales people (77%) and to builders and remodelers (62%). The largest proportion of cabinet types sold by both Groups 1 and 2 were face frame kitchen cabinets (74% and 38% respectively). Companies from both groups reported producing certified (green) products. The majority of companies indicated they purchased some parts from outside sources. Companies from both groups reported considering alternative materials to substitute for wood. Products that were mentioned include strawboard, urban waste MDF, and plastic mouldings. Concerns rated highest by cabinet companies were finding qualified employees, increasing raw material prices, keeping qualified employees, and wood quality. / Master of Science

This study was undertaken to determine the use and quantities of new and recovered wood materials utilized by the United States pallet and container industry in 1999. Wood use trends were identified by comparing the results of this study with that of three previous studies (1992, 1993, and 1995) conducted by Virginia Tech and the United States Forest Service. Also, information was gathered on firm employment, plant operations, and production. A mail survey of 3,507 manufacturers of wood pallets and/or containers in the United States was used to obtain primary data. It was found that the pallet and container industry consumed an estimated 6.54 billion board feet of solid wood in 1999, of which 4.41 billion was hardwood and 2.13 billion was softwood. It was further estimated that 3.7 billion board feet of the hardwood was purchased or processed as lumber and cants, and an additional 707 million board feet as hardwood parts. Approximately 51% of the hardwood consumed was a mixture of hardwood species. Oak accounted for 31% of the hardwood used by the industry. For softwood, an estimated 1.52 billion board feet was consumed in the form of lumber and cants, and another 610 million board feet as parts. Southern Pine (48% of the total softwood volume) and Spruce-Pine-Fir (25%) were the solid softwoods most commonly used by the pallet and container industry. Of the estimated 289 million square feet of wood panels that went into the production of pallets and containers, nearly 208 million square feet of it was softwood plywood, followed by oriented strand board (77 million square feet), and hardwood plywood (5 million square feet). The pallet and container industry produced approximately 429 million new pallets in 1999. Approximately 80% of these pallets were stringer type and 12% were block type. The pallet industry was responsible for the recovery of 299 million pallets in 1999. Furthermore, it was estimated that the pallet industry returned to service nearly 218 million pallets through either repair or recycle. Of the wood use trends identified, the most significant are the large increases in pallet recovery, repair, and recycling during the 1990s. The production of landscape mulch has become the leading use of ground or chipped pallets. A small increase was seen in new pallet production. Increases in new wood use were modest, and primarily limited to softwood parts and oriented strand board. The use of Southern Pine by the pallet and container industry continues to grow relative to other softwood species and in terms of total volume used. / Master of Science