MINGHUNG
This production line is a highly automated and integrated system engineered specifically for manufacturing high-value-added functional panels. Below is a detailed description of the core machinery in the order of the production process:
1. Raw Material Preparation Section
Debarker & Chipper Combo: Processes logs (or small-diameter wood) by debarking and chipping them into uniform wood chips that meet specifications. This is the first critical step in ensuring particle quality.
Flaker: Further processes the wood chips into standardized flakes. It employs high-precision knife discs and a pressure feed system to ensure uniform particle morphology and consistent surface area, which directly impacts the board's mechanical properties and surface quality.
Particle Screening & Re-crushing System: Classifies particles by size via multi-deck vibrating screens. Oversized particles are sent to a re-crusher for reprocessing, while fines can be used in the core layer or as fuel, optimizing the particle size distribution for each layer.
2. Drying, Sorting, and Blending Section
Rotary Drum Dryer: Dries the particles efficiently and uniformly using high-temperature hot air, precisely controlling the moisture content to the required level. It is equipped with an advanced thermal energy system and explosion-proof devices for safety and stability.
Post-Dryer Screen: Re-screens the dried particles to precisely separate fine surface-layer material from coarse core-layer material, preparing for the graduated structure formation.
Ring Blender (Core Equipment): This is the key to achieving flame retardant (FR) and moisture resistant (MR) properties. The system includes multiple precision metering pumps and nozzles:
Resin System: Precisely applies urea-formaldehyde (UF) or melamine-urea-formaldehyde (MUF) resin.
Wax System: Applies molten wax for basic moisture resistance.
Flame Retardant System (Unique): Independent pipelines and nozzles uniformly apply liquid or powder-based eco-friendly flame retardants (e.g., ammonium phosphate, boron compounds) onto the particles.
All components are thoroughly mixed with the particles inside the high-speed rotating blender, ensuring each particle is completely coated.
3. Forming and Pressing Section (Heart of the Line)
Mechanical-Airflow Combination Forming Station: Utilizes multi-head forming technology. Typically employs 4 forming heads:
2 for fine surface-layer particles (top and bottom surfaces).
2 for coarse core-layer particles.
Forms a graduated structure mat (fine-coarse-fine) via precise spreader rolls and airflow, significantly enhancing the board's mechanical strength and surface smoothness.
Continuous Press (CP): The "heart" of the entire production line, representing the highest level of technology. Its advantages include:
High Output & Quality: The mat is continuously conveyed through dozens of meters of pressure zones (preheating, main pressing, pressure holding, pressure relief) by steel belts. The pressure and temperature profiles are precisely controlled, resulting in boards with extremely uniform density and thin pre-cured layers, superior in quality to those from multi-opening presses.
Energy Efficiency: Consumes approximately 20-30% less energy compared to multi-opening presses.
Production Flexibility: Allows online adjustment of board thickness during production (e.g., switching from 20mm to 15mm) without stopping, making it ideal for multi-specification and customized production.
4. Finishing and Sanding/Cutting Section
Cooling and Flipping Unit: Cools and flips the high-temperature boards (>100°C) after pressing to homogenize moisture content and internal stress, preventing warping.
Cross-Cut and Trim Saws: Precisely cuts the continuous board strand to the required panel sizes (e.g., 1220x2440mm, 1830x3660mm) based on order requirements, both transversely and longitudinally.
Stacking and Intermediate Storage System: Automated stacking and conveying provides sufficient conditioning time for the boards to stabilize their properties fully.
Multi-Head Wide-Belt Sander: Typically a heavy-duty sander with 6 or 8 heads. The initial heads are for calibration and coarse sanding to eliminate thickness deviations; the subsequent heads perform fine polishing, ensuring a mirror-smooth surface perfect for further processing like laminating or UV coating.
5. Auxiliary and Control Systems
Thermal Energy Center (TEC): The "powerhouse" of the line. Utilizes process waste (sander dust, bark, fines) and screening residuals as fuel to generate hot gas for the dryer and press, achieving a high degree of energy self-sufficiency and significantly reducing operating costs.
Central Control System (PLC + SCADA): The entire line is integrated and controlled via Programmable Logic Controllers (PLC) and a Supervisory Control and Data Acquisition (SCADA) system. From the central control room, operators can monitor and adjust all process parameters (temperature, pressure, speed, resin application rate, flame retardant dosage, etc.), enabling production data visualization, traceability, and optimization. It is the "brain" of automated manufacturing.
The production of flame retardant and moisture resistant particleboard builds upon the standard particleboard process by incorporating functional chemical additives and precise process control. The core process is as follows:
1. Raw Material Preparation: Wood raw material (e.g., twigs, small-diameter wood, wood processing residues) is processed into uniform wood chips by a chipper.
2. Flake Preparation: The wood chips are fed into a flaker to be cut into flakes of designed specifications. The flakes are passed through a screening system to separate fine surface-layer material from coarse core-layer material.
3. Drying: The screened flakes are dried in a dryer (e.g., a rotary drum dryer) by high-temperature hot air to reduce their moisture content to the required range (typically 2-4%).
4. Blending with Additives (Core Step):
Resin Application: The dried flakes are sent to a blender (e.g., a ring blender) where they are uniformly mixed with adhesive (typically urea-formaldehyde UF or melamine-urea-formaldehyde MUF resin) and wax emulsion.
Flame Retardant Application: During blending, liquid or powdered flame retardants are simultaneously and evenly sprayed onto the flakes via an independent, precision metering system.
Moisture Resistant Application: Wax emulsion is applied as the basic water repellent. For higher moisture resistance, modified resins (e.g., MUF) may be used.
5. Forming: The flakes coated with resin and additives are formed into a uniform mat with a "fine-coarse-fine" three-layer graduated structure by the forming station.
6. Pre-pressing and Hot Pressing: The mat is first preliminarily compressed by a pre-press and then enters the hot press (multi-opening press or continuous press). Under high temperature (typically 180-210°C) and high pressure, the adhesive rapidly cures, pressing the flakes into a dense board.
7. Finishing: The pressed board is cooled, conditioned, cut to size, and sanded, resulting in a finished board with precise dimensions and a smooth surface.
1. Achieving Flame Retardancy:
Flame retardancy is primarily achieved by adding flame retardants. Their mechanism of action and production control points are as follows:
Application Method: The core method is the uniform mixing of flame retardants with the flakes during the blending process. This is the most effective and common method, ensuring the flame retardant is distributed throughout the entire board.
Mechanism of Action:
Barrier Formation: The flame retardant melts at high temperatures to form a protective layer that insulates against oxygen and heat.
Cooling by Endothermic Reaction: The decomposition of the flame retardant absorbs heat, lowering the surface temperature of the board and delaying thermal decomposition.
Dilution and Suffocation: Decomposition produces non-flammable gases (e.g., nitrogen, CO₂), diluting the concentration of combustible gases and oxygen.
Chain Reaction Inhibition: Captures free radicals produced by combustion, interrupting the chain reaction of burning.
Common Flame Retardants: Inorganic phosphorus-nitrogen based retardants (e.g., Ammonium Polyphosphate APP), boron-based retardants (e.g., Zinc Borate), etc., which are environmentally friendly and efficient.
Process Control: The dosage and concentration of the flame retardant, as well as the uniformity of its mixture with the flakes, are critical to ensuring consistent and stable flame retardant performance (achieving Class B1 rating).
2. Achieving Moisture Resistance:
Moisture resistance is achieved through a combination of a physical barrier and chemical enhancement:
Wax Water Repellent (Physical Barrier):
Wax emulsion is added during blending. Wax particles uniformly coat the surface of the flakes.
During hot pressing, the wax melts and forms a hydrophobic film on the flake surfaces and in the voids between them, effectively blocking water penetration. This is the foundation for achieving Moisture Resistant (MR) grade.
Resin Modification (Chemical Enhancement):
Using Melamine-Urea-Formaldehyde (MUF) resin instead of standard UF resin. The incorporation of melamine significantly enhances the resin's water and weather resistance, making it less susceptible to hydrolysis by moisture, thereby ensuring the board maintains high mechanical strength even in humid environments.
Process and Structure:
Appropriately increasing hot pressing pressure and temperature makes the board denser, reducing pores accessible to water.
A balanced, stable structure and complete curing also contribute to overall moisture resistance.
Flame retardancy is primarily achieved through the addition of flame retardants during blending for chemical inhibition of combustion. Moisture resistance is achieved by adding wax to create a physical water barrier, often combined with using MUF resin for chemical enhancement. Both rely on the precise and uniform application of additives during the core blending step and subsequent stable hot pressing and curing processes.
Integrated Turnkey Solution: We provide a complete Turnkey Project encompassing everything from raw material handling, particle preparation, drying, blending, forming, pressing, to finishing and cutting, ensuring seamless integration and highly efficient operation.
Customized FR/MR Technology: The core process integrates advanced automatic dosing systems for flame retardant and waterproofing agents, ensuring uniform distribution and precise ratio control. This guarantees the final boards consistently meet Chinese GB Standard Class B1 Flame Retardant and Moisture Resistant (MR) ratings.
High Output & Automation: Utilizing advanced continuous press technology (or large-scale multi-opening press), an intelligent drying system, and a centralized PLC control system, the line achieves full automation, significantly reduces labor costs, and ensures stable production reaching the 100,000 m³ capacity.
Superior End-Product Quality: The high-precision forming station and continuous press ensure exceptional board uniformity and an excellent sanded surface, with minimal density deviation and superior mechanical properties.
Energy Efficiency & Sustainability: The line design includes a thermal energy center (using waste wood as fuel), exhaust gas treatment, and heat recovery systems, minimizing energy consumption and adhering to environmental standards.
Flame Retardant and Moisture Resistant particleboard, due to its combined properties of fire safety and resistance to humidity, breaks through the usage limitations of standard particleboard. It is widely used in fields with specific requirements for safety and environmental conditions.
1. Construction and Interior Decoration
Commercial Space Partitions and Ceilings: Used for partition walls, suspended ceilings, and feature walls in hotels, shopping malls, office buildings, and restaurants. Its flame retardancy meets fire safety codes, and its moisture resistance adapts to various climatic conditions.
Public Facility Interior Fit-outs: Used for interior decoration and furniture manufacturing in crowded places such as hospitals, schools, libraries, museums, stadiums, airports, and train stations, where fire safety is a priority.
Restroom Partitions: Ideal for partitions in public toilets and shower rooms. Its moisture-resistant properties effectively prevent the board from swelling, warping, or molding due to dampness.
2. Furniture Manufacturing
Kitchen and Bathroom Furniture: An ideal substrate for cabinets and vanity units. Its moisture resistance ensures stability in humid environments, while the flame retardancy adds an extra layer of safety for the home.
Laboratory Furniture: Used for manufacturing laboratory workbenches, fume hoods, and storage cabinets. It can resist occasional chemical splashes (when paired with chemical-resistant laminates), and its flame-retardant properties comply with laboratory safety standards.
Office and Commercial Furniture: Used for office partitions, workstations, countertops, display shelves, and storage cabinets, particularly suitable for contract projects that require specific fire ratings.
3. Transportation
Marine Interiors: Used for cabin partitions, wall panels, ceilings, and furniture on cruise ships, ferries, and other vessels. Must meet stringent flame retardant and moisture-resistant (even waterproof) standards.
Vehicle Interiors: Used for wall panels, partitions, luggage racks, and furniture in train carriages, RVs, and buses. The materials require lightness, strength, and flame retardancy.
4. Industrial and Specific Applications
Electronic Components: Used as internal structural supports for products like server racks, audio equipment, and TV back panels, where dimensional stability and resistance to warping are crucial.
Packaging and Display: Used for heavy-duty packaging of high-end industrial products and reusable exhibition displays that demand high stability.
Door Core Material: Serves as the core material for interior doors and fire-rated doors, providing filling support while also contributing flame retardant properties.
The core value of Flame Retardant and Moisture Resistant particleboard lies in its "Safety" and "Stability". It is primarily used in crowded public buildings, humid environments like kitchens and bathrooms, and transportation and specific industrial fields with strict fire protection requirements. It is a high-performance solution that replaces standard particleboard.
If you are new and existing investors planning to establish or upgrade their particleboard plants to produce high-value-added flame retardant and moisture-resistant particleboard.
We provide not only world-class machinery but also comprehensive technical support, installation & commissioning, personnel training, and after-sales service, ensuring your project runs smoothly from conception to production.
Please contact us for a quotation.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
This production line is a highly automated and integrated system engineered specifically for manufacturing high-value-added functional panels. Below is a detailed description of the core machinery in the order of the production process:
1. Raw Material Preparation Section
Debarker & Chipper Combo: Processes logs (or small-diameter wood) by debarking and chipping them into uniform wood chips that meet specifications. This is the first critical step in ensuring particle quality.
Flaker: Further processes the wood chips into standardized flakes. It employs high-precision knife discs and a pressure feed system to ensure uniform particle morphology and consistent surface area, which directly impacts the board's mechanical properties and surface quality.
Particle Screening & Re-crushing System: Classifies particles by size via multi-deck vibrating screens. Oversized particles are sent to a re-crusher for reprocessing, while fines can be used in the core layer or as fuel, optimizing the particle size distribution for each layer.
2. Drying, Sorting, and Blending Section
Rotary Drum Dryer: Dries the particles efficiently and uniformly using high-temperature hot air, precisely controlling the moisture content to the required level. It is equipped with an advanced thermal energy system and explosion-proof devices for safety and stability.
Post-Dryer Screen: Re-screens the dried particles to precisely separate fine surface-layer material from coarse core-layer material, preparing for the graduated structure formation.
Ring Blender (Core Equipment): This is the key to achieving flame retardant (FR) and moisture resistant (MR) properties. The system includes multiple precision metering pumps and nozzles:
Resin System: Precisely applies urea-formaldehyde (UF) or melamine-urea-formaldehyde (MUF) resin.
Wax System: Applies molten wax for basic moisture resistance.
Flame Retardant System (Unique): Independent pipelines and nozzles uniformly apply liquid or powder-based eco-friendly flame retardants (e.g., ammonium phosphate, boron compounds) onto the particles.
All components are thoroughly mixed with the particles inside the high-speed rotating blender, ensuring each particle is completely coated.
3. Forming and Pressing Section (Heart of the Line)
Mechanical-Airflow Combination Forming Station: Utilizes multi-head forming technology. Typically employs 4 forming heads:
2 for fine surface-layer particles (top and bottom surfaces).
2 for coarse core-layer particles.
Forms a graduated structure mat (fine-coarse-fine) via precise spreader rolls and airflow, significantly enhancing the board's mechanical strength and surface smoothness.
Continuous Press (CP): The "heart" of the entire production line, representing the highest level of technology. Its advantages include:
High Output & Quality: The mat is continuously conveyed through dozens of meters of pressure zones (preheating, main pressing, pressure holding, pressure relief) by steel belts. The pressure and temperature profiles are precisely controlled, resulting in boards with extremely uniform density and thin pre-cured layers, superior in quality to those from multi-opening presses.
Energy Efficiency: Consumes approximately 20-30% less energy compared to multi-opening presses.
Production Flexibility: Allows online adjustment of board thickness during production (e.g., switching from 20mm to 15mm) without stopping, making it ideal for multi-specification and customized production.
4. Finishing and Sanding/Cutting Section
Cooling and Flipping Unit: Cools and flips the high-temperature boards (>100°C) after pressing to homogenize moisture content and internal stress, preventing warping.
Cross-Cut and Trim Saws: Precisely cuts the continuous board strand to the required panel sizes (e.g., 1220x2440mm, 1830x3660mm) based on order requirements, both transversely and longitudinally.
Stacking and Intermediate Storage System: Automated stacking and conveying provides sufficient conditioning time for the boards to stabilize their properties fully.
Multi-Head Wide-Belt Sander: Typically a heavy-duty sander with 6 or 8 heads. The initial heads are for calibration and coarse sanding to eliminate thickness deviations; the subsequent heads perform fine polishing, ensuring a mirror-smooth surface perfect for further processing like laminating or UV coating.
5. Auxiliary and Control Systems
Thermal Energy Center (TEC): The "powerhouse" of the line. Utilizes process waste (sander dust, bark, fines) and screening residuals as fuel to generate hot gas for the dryer and press, achieving a high degree of energy self-sufficiency and significantly reducing operating costs.
Central Control System (PLC + SCADA): The entire line is integrated and controlled via Programmable Logic Controllers (PLC) and a Supervisory Control and Data Acquisition (SCADA) system. From the central control room, operators can monitor and adjust all process parameters (temperature, pressure, speed, resin application rate, flame retardant dosage, etc.), enabling production data visualization, traceability, and optimization. It is the "brain" of automated manufacturing.
The production of flame retardant and moisture resistant particleboard builds upon the standard particleboard process by incorporating functional chemical additives and precise process control. The core process is as follows:
1. Raw Material Preparation: Wood raw material (e.g., twigs, small-diameter wood, wood processing residues) is processed into uniform wood chips by a chipper.
2. Flake Preparation: The wood chips are fed into a flaker to be cut into flakes of designed specifications. The flakes are passed through a screening system to separate fine surface-layer material from coarse core-layer material.
3. Drying: The screened flakes are dried in a dryer (e.g., a rotary drum dryer) by high-temperature hot air to reduce their moisture content to the required range (typically 2-4%).
4. Blending with Additives (Core Step):
Resin Application: The dried flakes are sent to a blender (e.g., a ring blender) where they are uniformly mixed with adhesive (typically urea-formaldehyde UF or melamine-urea-formaldehyde MUF resin) and wax emulsion.
Flame Retardant Application: During blending, liquid or powdered flame retardants are simultaneously and evenly sprayed onto the flakes via an independent, precision metering system.
Moisture Resistant Application: Wax emulsion is applied as the basic water repellent. For higher moisture resistance, modified resins (e.g., MUF) may be used.
5. Forming: The flakes coated with resin and additives are formed into a uniform mat with a "fine-coarse-fine" three-layer graduated structure by the forming station.
6. Pre-pressing and Hot Pressing: The mat is first preliminarily compressed by a pre-press and then enters the hot press (multi-opening press or continuous press). Under high temperature (typically 180-210°C) and high pressure, the adhesive rapidly cures, pressing the flakes into a dense board.
7. Finishing: The pressed board is cooled, conditioned, cut to size, and sanded, resulting in a finished board with precise dimensions and a smooth surface.
1. Achieving Flame Retardancy:
Flame retardancy is primarily achieved by adding flame retardants. Their mechanism of action and production control points are as follows:
Application Method: The core method is the uniform mixing of flame retardants with the flakes during the blending process. This is the most effective and common method, ensuring the flame retardant is distributed throughout the entire board.
Mechanism of Action:
Barrier Formation: The flame retardant melts at high temperatures to form a protective layer that insulates against oxygen and heat.
Cooling by Endothermic Reaction: The decomposition of the flame retardant absorbs heat, lowering the surface temperature of the board and delaying thermal decomposition.
Dilution and Suffocation: Decomposition produces non-flammable gases (e.g., nitrogen, CO₂), diluting the concentration of combustible gases and oxygen.
Chain Reaction Inhibition: Captures free radicals produced by combustion, interrupting the chain reaction of burning.
Common Flame Retardants: Inorganic phosphorus-nitrogen based retardants (e.g., Ammonium Polyphosphate APP), boron-based retardants (e.g., Zinc Borate), etc., which are environmentally friendly and efficient.
Process Control: The dosage and concentration of the flame retardant, as well as the uniformity of its mixture with the flakes, are critical to ensuring consistent and stable flame retardant performance (achieving Class B1 rating).
2. Achieving Moisture Resistance:
Moisture resistance is achieved through a combination of a physical barrier and chemical enhancement:
Wax Water Repellent (Physical Barrier):
Wax emulsion is added during blending. Wax particles uniformly coat the surface of the flakes.
During hot pressing, the wax melts and forms a hydrophobic film on the flake surfaces and in the voids between them, effectively blocking water penetration. This is the foundation for achieving Moisture Resistant (MR) grade.
Resin Modification (Chemical Enhancement):
Using Melamine-Urea-Formaldehyde (MUF) resin instead of standard UF resin. The incorporation of melamine significantly enhances the resin's water and weather resistance, making it less susceptible to hydrolysis by moisture, thereby ensuring the board maintains high mechanical strength even in humid environments.
Process and Structure:
Appropriately increasing hot pressing pressure and temperature makes the board denser, reducing pores accessible to water.
A balanced, stable structure and complete curing also contribute to overall moisture resistance.
Flame retardancy is primarily achieved through the addition of flame retardants during blending for chemical inhibition of combustion. Moisture resistance is achieved by adding wax to create a physical water barrier, often combined with using MUF resin for chemical enhancement. Both rely on the precise and uniform application of additives during the core blending step and subsequent stable hot pressing and curing processes.
Integrated Turnkey Solution: We provide a complete Turnkey Project encompassing everything from raw material handling, particle preparation, drying, blending, forming, pressing, to finishing and cutting, ensuring seamless integration and highly efficient operation.
Customized FR/MR Technology: The core process integrates advanced automatic dosing systems for flame retardant and waterproofing agents, ensuring uniform distribution and precise ratio control. This guarantees the final boards consistently meet Chinese GB Standard Class B1 Flame Retardant and Moisture Resistant (MR) ratings.
High Output & Automation: Utilizing advanced continuous press technology (or large-scale multi-opening press), an intelligent drying system, and a centralized PLC control system, the line achieves full automation, significantly reduces labor costs, and ensures stable production reaching the 100,000 m³ capacity.
Superior End-Product Quality: The high-precision forming station and continuous press ensure exceptional board uniformity and an excellent sanded surface, with minimal density deviation and superior mechanical properties.
Energy Efficiency & Sustainability: The line design includes a thermal energy center (using waste wood as fuel), exhaust gas treatment, and heat recovery systems, minimizing energy consumption and adhering to environmental standards.
Flame Retardant and Moisture Resistant particleboard, due to its combined properties of fire safety and resistance to humidity, breaks through the usage limitations of standard particleboard. It is widely used in fields with specific requirements for safety and environmental conditions.
1. Construction and Interior Decoration
Commercial Space Partitions and Ceilings: Used for partition walls, suspended ceilings, and feature walls in hotels, shopping malls, office buildings, and restaurants. Its flame retardancy meets fire safety codes, and its moisture resistance adapts to various climatic conditions.
Public Facility Interior Fit-outs: Used for interior decoration and furniture manufacturing in crowded places such as hospitals, schools, libraries, museums, stadiums, airports, and train stations, where fire safety is a priority.
Restroom Partitions: Ideal for partitions in public toilets and shower rooms. Its moisture-resistant properties effectively prevent the board from swelling, warping, or molding due to dampness.
2. Furniture Manufacturing
Kitchen and Bathroom Furniture: An ideal substrate for cabinets and vanity units. Its moisture resistance ensures stability in humid environments, while the flame retardancy adds an extra layer of safety for the home.
Laboratory Furniture: Used for manufacturing laboratory workbenches, fume hoods, and storage cabinets. It can resist occasional chemical splashes (when paired with chemical-resistant laminates), and its flame-retardant properties comply with laboratory safety standards.
Office and Commercial Furniture: Used for office partitions, workstations, countertops, display shelves, and storage cabinets, particularly suitable for contract projects that require specific fire ratings.
3. Transportation
Marine Interiors: Used for cabin partitions, wall panels, ceilings, and furniture on cruise ships, ferries, and other vessels. Must meet stringent flame retardant and moisture-resistant (even waterproof) standards.
Vehicle Interiors: Used for wall panels, partitions, luggage racks, and furniture in train carriages, RVs, and buses. The materials require lightness, strength, and flame retardancy.
4. Industrial and Specific Applications
Electronic Components: Used as internal structural supports for products like server racks, audio equipment, and TV back panels, where dimensional stability and resistance to warping are crucial.
Packaging and Display: Used for heavy-duty packaging of high-end industrial products and reusable exhibition displays that demand high stability.
Door Core Material: Serves as the core material for interior doors and fire-rated doors, providing filling support while also contributing flame retardant properties.
The core value of Flame Retardant and Moisture Resistant particleboard lies in its "Safety" and "Stability". It is primarily used in crowded public buildings, humid environments like kitchens and bathrooms, and transportation and specific industrial fields with strict fire protection requirements. It is a high-performance solution that replaces standard particleboard.
If you are new and existing investors planning to establish or upgrade their particleboard plants to produce high-value-added flame retardant and moisture-resistant particleboard.
We provide not only world-class machinery but also comprehensive technical support, installation & commissioning, personnel training, and after-sales service, ensuring your project runs smoothly from conception to production.
Please contact us for a quotation.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
