MH-CHP
MINGHUNG
1. Raw Material Handling Stage
Raw Materials: Typically small-diameter logs, branches, wood processing residues (shavings, sawdust), or recycled wood. Stable supply is essential.
Equipment:
Chipper: Chips wood raw material to required specifications. Capacity must match subsequent stages (approx. ~25 tonnes bone-dry wood/hour, requiring more raw material volume accounting for moisture content). Large drum or disc chippers are recommended.
Chip Screening & Washing System: Removes oversized chips, fines, sand, metal, and other impurities.
Chip Storage Silo: Provides buffered storage to ensure continuous feeding.
2. Fiber Preparation Stage (Core Stage)
Equipment:
Refiner (Defibrator): Core equipment. Separates wood chips into individual fibers under high-temperature, high-pressure steam. Requires appropriately sized models. For 150m³/day of 12mm board, one or two parallel large-scale refiners are needed (e.g., capacity around 8-12 tonnes bone-dry fiber/hour, depending on equipment efficiency and operational hours).
Resin Blending System:
Resin (Primarily UF): Precision metering and storage system.
Blender: Uniformly applies resin, hardener, and water repellent (paraffin emulsion) to fibers. Typically uses high-speed paddle blenders.
Fiber Drying System:
Flash Tube Dryer: Rapidly dries resinated wet fibers using hot air (from Energy Center). Drying capacity is a critical bottleneck; it must be sufficiently large and efficient. Needs to process ~8-12 tonnes wet fiber/hour (moisture reduced from ~50% to ~8-12%).
Cyclone Separators / Fiber Recovery System: Separates dried fibers from the air stream.
Fire & Explosion Protection System: The drying system is a high-risk area requiring comprehensive spark detection, deluge suppression, and explosion venting.
3. Forming & Pre-Pressing Stage
Equipment:
Forming Machine: Forms a continuous fiber mat by uniformly distributing dried fibers. For 12mm board, consistent mat formation is crucial. Typically uses mechanical, pneumatic (air), or combination forming. Forming width must match the press.
Pre-Press: Compacts the loose fiber mat for easier transfer into the press and removes some air. Usually a continuous belt pre-press.
4. Hot Pressing Stage (Core Stage)
Equipment:
Hot Press: This is the core and largest investment point of the line. For 150m³/day of 12mm board, a continuous press is the most efficient and mainstream choice.
Type: Continuous Flat Press (e.g., CPS, ContiPress).
Width: Typically requires a width of 2.5 meters (8 feet) or greater (e.g., 2.7m/9ft). Wider presses enable higher throughput.
Length / Opening: Requires sufficient length/number of openings to ensure the 12mm board cures properly at set temperature and pressure (cure time typically 20-40 sec/mm, meaning ~4-8 minutes for 12mm board).
Heating System: High-temperature thermal oil or steam heating.
Pressure Control: Precise control of pressure profiles during different pressing phases.
5. Cooling & Finishing Stage
Equipment:
Discharge Conveying & Cooling Star: Boards exit the press hot and require slow cooling to near ambient temperature (below ~40-50°C) on a star cooler or roller cooling line to prevent warping.
Stacker: Stacks cooled, un-sanded boards ("green boards") for conditioning (stress equalization).
Trimmer / Cross-Cut & Rip Saws: Trims the large panels to standard sizes (e.g., 1220x2440mm, 1830x3660mm) and squares edges. Requires high-precision, high-efficiency sawing.
Sanding Line: Sanding is critical for 12mm MDF. Requires a wide-belt sander (typically 4-head, 6-head, or more) to achieve precise thickness tolerance (e.g., ±0.15mm) and surface finish. Sanding removal is approx. 0.5-1.0mm.
Grading & Inspection Station: Manual or automated inspection for surface quality, thickness, density, etc., for grading.
Bundling/Packaging Machine: Bundles/packages finished boards.
dryer rack
cross-cut saw
sander
6. Auxiliary Systems
Energy Center: Provides heat for production (refiner steam, dryer air, press oil/steam). Primarily fueled by wood waste (bark, sander dust, scrap) via biomass boilers, backed up by gas/oil boilers. Scale must match the entire line's thermal demand.
Dust Collection System: Large central dust collection system (primarily baghouse filters), covering all dust generation points (chipping, screening, sanding, forming) to meet environmental standards.
Compressed Air System: Supplies instrument and control air.
Electrical Control System: Plant-wide PLC/DCS automation for centralized monitoring and process control.
Hydraulic System: Provides power for the press, pre-press, etc.
Water Treatment System: Treats process wastewater (if generated, e.g., from refining).
VOCs Abatement System: Treats organic emissions from drying, pressing, etc. (increasingly stringent environmental requirement).
Daily Output: 150 m³
Operating Hours: Based on 24-hour operation (accounting for maintenance/shift changes, effective production time ~22 hours).
Hourly Output: 150 m³ / 22 hours ≈ 6.82 m³/hour
Board Density: Assumed standard density ~750 kg/m³
Hourly Bone-Dry Fiber Demand: 6.82 m³/h 750 kg/m³ ≈ 5,115 kg/h (approx. 5.1 tonnes/hour). Accounting for production losses, sanding allowance, etc., the refiner system design capacity should be 6-7 tonnes bone-dry fiber/hour or higher.
Drying Capacity: Assuming wet fiber moisture ~50%, wet fiber quantity: 5,115 kg/h / (1 - 0.5) = 10,230 kg/h (approx. 10.2 tonnes/hour). The dryer must handle this flow rate to target moisture.
Press Capacity: With 2.5m width and 12mm thick board, target line speed: 6.82 m³/h / (2.5m 0.012m) ≈ 227 meters/hour. The continuous press must achieve or exceed this speed while ensuring proper curing.
A complete medium-sized MDF production line requires a large investment. For a 12mm board line with a daily output of 150m³, the core equipment (hot grinding, laying, continuous press machine, sanding line) accounts for approximately 60-70% of the total investment, while the auxiliary equipment and systems account for about 30-40%.
We can design matching mechanical equipment according to your different needs, such as different raw materials, different production capacity, and different panel thicknesses. After understanding your situation, our team can design a suitable quotation for you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
1. Raw Material Handling Stage
Raw Materials: Typically small-diameter logs, branches, wood processing residues (shavings, sawdust), or recycled wood. Stable supply is essential.
Equipment:
Chipper: Chips wood raw material to required specifications. Capacity must match subsequent stages (approx. ~25 tonnes bone-dry wood/hour, requiring more raw material volume accounting for moisture content). Large drum or disc chippers are recommended.
Chip Screening & Washing System: Removes oversized chips, fines, sand, metal, and other impurities.
Chip Storage Silo: Provides buffered storage to ensure continuous feeding.
2. Fiber Preparation Stage (Core Stage)
Equipment:
Refiner (Defibrator): Core equipment. Separates wood chips into individual fibers under high-temperature, high-pressure steam. Requires appropriately sized models. For 150m³/day of 12mm board, one or two parallel large-scale refiners are needed (e.g., capacity around 8-12 tonnes bone-dry fiber/hour, depending on equipment efficiency and operational hours).
Resin Blending System:
Resin (Primarily UF): Precision metering and storage system.
Blender: Uniformly applies resin, hardener, and water repellent (paraffin emulsion) to fibers. Typically uses high-speed paddle blenders.
Fiber Drying System:
Flash Tube Dryer: Rapidly dries resinated wet fibers using hot air (from Energy Center). Drying capacity is a critical bottleneck; it must be sufficiently large and efficient. Needs to process ~8-12 tonnes wet fiber/hour (moisture reduced from ~50% to ~8-12%).
Cyclone Separators / Fiber Recovery System: Separates dried fibers from the air stream.
Fire & Explosion Protection System: The drying system is a high-risk area requiring comprehensive spark detection, deluge suppression, and explosion venting.
3. Forming & Pre-Pressing Stage
Equipment:
Forming Machine: Forms a continuous fiber mat by uniformly distributing dried fibers. For 12mm board, consistent mat formation is crucial. Typically uses mechanical, pneumatic (air), or combination forming. Forming width must match the press.
Pre-Press: Compacts the loose fiber mat for easier transfer into the press and removes some air. Usually a continuous belt pre-press.
4. Hot Pressing Stage (Core Stage)
Equipment:
Hot Press: This is the core and largest investment point of the line. For 150m³/day of 12mm board, a continuous press is the most efficient and mainstream choice.
Type: Continuous Flat Press (e.g., CPS, ContiPress).
Width: Typically requires a width of 2.5 meters (8 feet) or greater (e.g., 2.7m/9ft). Wider presses enable higher throughput.
Length / Opening: Requires sufficient length/number of openings to ensure the 12mm board cures properly at set temperature and pressure (cure time typically 20-40 sec/mm, meaning ~4-8 minutes for 12mm board).
Heating System: High-temperature thermal oil or steam heating.
Pressure Control: Precise control of pressure profiles during different pressing phases.
5. Cooling & Finishing Stage
Equipment:
Discharge Conveying & Cooling Star: Boards exit the press hot and require slow cooling to near ambient temperature (below ~40-50°C) on a star cooler or roller cooling line to prevent warping.
Stacker: Stacks cooled, un-sanded boards ("green boards") for conditioning (stress equalization).
Trimmer / Cross-Cut & Rip Saws: Trims the large panels to standard sizes (e.g., 1220x2440mm, 1830x3660mm) and squares edges. Requires high-precision, high-efficiency sawing.
Sanding Line: Sanding is critical for 12mm MDF. Requires a wide-belt sander (typically 4-head, 6-head, or more) to achieve precise thickness tolerance (e.g., ±0.15mm) and surface finish. Sanding removal is approx. 0.5-1.0mm.
Grading & Inspection Station: Manual or automated inspection for surface quality, thickness, density, etc., for grading.
Bundling/Packaging Machine: Bundles/packages finished boards.
dryer rack
cross-cut saw
sander
6. Auxiliary Systems
Energy Center: Provides heat for production (refiner steam, dryer air, press oil/steam). Primarily fueled by wood waste (bark, sander dust, scrap) via biomass boilers, backed up by gas/oil boilers. Scale must match the entire line's thermal demand.
Dust Collection System: Large central dust collection system (primarily baghouse filters), covering all dust generation points (chipping, screening, sanding, forming) to meet environmental standards.
Compressed Air System: Supplies instrument and control air.
Electrical Control System: Plant-wide PLC/DCS automation for centralized monitoring and process control.
Hydraulic System: Provides power for the press, pre-press, etc.
Water Treatment System: Treats process wastewater (if generated, e.g., from refining).
VOCs Abatement System: Treats organic emissions from drying, pressing, etc. (increasingly stringent environmental requirement).
Daily Output: 150 m³
Operating Hours: Based on 24-hour operation (accounting for maintenance/shift changes, effective production time ~22 hours).
Hourly Output: 150 m³ / 22 hours ≈ 6.82 m³/hour
Board Density: Assumed standard density ~750 kg/m³
Hourly Bone-Dry Fiber Demand: 6.82 m³/h 750 kg/m³ ≈ 5,115 kg/h (approx. 5.1 tonnes/hour). Accounting for production losses, sanding allowance, etc., the refiner system design capacity should be 6-7 tonnes bone-dry fiber/hour or higher.
Drying Capacity: Assuming wet fiber moisture ~50%, wet fiber quantity: 5,115 kg/h / (1 - 0.5) = 10,230 kg/h (approx. 10.2 tonnes/hour). The dryer must handle this flow rate to target moisture.
Press Capacity: With 2.5m width and 12mm thick board, target line speed: 6.82 m³/h / (2.5m 0.012m) ≈ 227 meters/hour. The continuous press must achieve or exceed this speed while ensuring proper curing.
A complete medium-sized MDF production line requires a large investment. For a 12mm board line with a daily output of 150m³, the core equipment (hot grinding, laying, continuous press machine, sanding line) accounts for approximately 60-70% of the total investment, while the auxiliary equipment and systems account for about 30-40%.
We can design matching mechanical equipment according to your different needs, such as different raw materials, different production capacity, and different panel thicknesses. After understanding your situation, our team can design a suitable quotation for you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
