MINGHUNG
The production process is a continuous, highly automated operation. Its core objective is to uniformly mix raw wood materials with functional additives (fire retardants, waterproofing agents) and solidify them into boards under high temperature and pressure. The entire process can be divided into the following six main stages:
Stage 1: Raw Material Preparation Section
Purpose: To obtain clean, uniformly sized wood chips.
Process:
1. Chipping: Wood raw material (e.g., small-diameter logs, branches, wood processing residues) is fed into a Chipper and processed into standard-sized wood chips.
2. Screening and Washing: The chips pass through a Screening Station to remove overly fine particles and oversized pieces. They then enter a Washing Drum, which uses hydraulic impact and friction to remove impurities like sand, stones, and metals. Clean chips are fundamental for ensuring subsequent fiber quality and equipment longevity.
Stage 2: Fiber Preparation Section - The "Heart and Functional Injection"
Purpose: To separate the wood chips into individual fibers and simultaneously, uniformly apply the adhesive binder, fire retardant, and waterproofing agent.
Process:
1. Defibration: The clean chips, after pre-steaming, are fed into the Defibrator (Refiner). Under high temperature and pressure, the chips are separated into loose wood fibers.
2. Precision Blending (The Most Critical Step): The fibers exiting the defibrator immediately enter a High-Speed Blender. Here, three sets of precision dosing systems operate simultaneously:
Adhesive System: Injects moisture-resistant Phenolic Resin (PF) or Polymeric Methylene Diphenyl Diisocyanate (PMDI).
Fire Retardant System: Injects liquid or atomized powdered Fire Retardant.
Waterproofing Agent System: Injects Paraffin Emulsion.
The fibers are thoroughly and uniformly mixed with these additives inside the high-speed rotating blender, ensuring each individual fiber is coated. This is the decisive step for achieving uniform fire retardancy and moisture-proof functionality throughout the board.
Stage 3: Mat Forming & Pre-pressing Section
Purpose: To form the blended fibers into a uniform mat and perform initial compaction.
Process:
1. Drying: The resinated moist fibers enter a Drying Duct, where hot air dries them to the optimal moisture content.
2. Forming: The dried fibers are distributed by a Pneumatic Forming Station, laying down a uniform, fluffy "fiber blanket" (the mat) onto a moving steel belt. Specifically designed for the 20mm thickness, the former ensures consistent density from bottom to top, without gradients.
3. Pre-pressing: The loose mat passes through a Pre-press, which performs initial compaction and deaeration, increasing its strength to form a self-supporting "green belt" suitable for entering the hot press.
Stage 4: Hot Pressing & Curing Section - "Shaping and Board Formation"
Purpose: To cure the resin under high temperature and pressure, permanently bonding the fiber mat into a high-density board.
Process:
1. Hot Pressing: The mat enters the core equipment of the line – the Continuous Flat Press. It passes through a long, precisely controlled heated platen section.
Special Process for 20mm Thick Board: The system executes a specific "Temperature-Pressure-Time" profile. This includes: Slower closing speeds and longer low-temperature preheating zones to allow a gentle temperature rise in the board's core, facilitating the escape of internal moisture and air, preventing "blows"; Precise pressure control ensures the board reaches the target density (e.g., >800 kg/m³) without compromising its internal structure.
2. Curing: Under high temperature (approx. 200°C) and pressure, the PF or PMDI resin rapidly cures, firmly bonding the fibers together. The fire retardant and waterproofing agents become permanently fixed within the board's structure.
Stage 5: Finishing & Handling Section
Purpose: To cut the pressed board to size and perform surface treatment.
Process:
1. Cooling & Trimming: The hot board exiting the press enters a Cooler/Conditioning Star for forced cooling and stabilization. Subsequently, it passes through Trimming & Cross-Cut Saws to be cut to the required dimensions, with the irregular edges trimmed off.
2. Sanding: The board enters a Calibrating Sander for precision sanding of both top and bottom surfaces. This is crucial for 20mm thick boards, as it ensures:
Precise final thickness (e.g., 20±0.2mm).
High surface flatness, providing a perfect substrate for subsequent finishing processes like laminating or painting.
Stage 6: Inspection & Packaging
Purpose: To ensure product quality and prepare for storage and transport.
Process: Finished boards are sampled for testing (fire retardancy, moisture resistance, physical/mechanical properties, etc.). Qualified products are automatically stacked, wrapped, and finally sent to storage.
1. Raw Material Handling Equipment:
Chipper: Processes wood raw material into chips.
Chip Screening & Washing System: Ensures chip purity and uniformity.
2. Fiber Preparation & Functionalization Equipment:
Defibration System: One of the hearts of the production line, responsible for separating chips into fibers.
Precision Resin/Additive Application System:
Adhesive (PF/PMDI) storage, metering, and delivery units.
Fire Retardant preparation, storage, and high-precision metering/pumping system.
Paraffin emulsion storage and metering system.
High-Speed Blender: The key equipment for achieving uniform mixing of fibers and additives.
fiber
glue machine
3. Forming & Pre-pressing Equipment:
Fiber Drying Duct: Equipped with a thermal energy system for drying fibers.
Pneumatic Forming Station: Optimized specifically for thick boards to ensure uniform mat formation.
Pre-press: Performs initial compaction of the mat.
dryer
forming machine
pre press
4. Hot Pressing & Curing Equipment:
Continuous Flat Press: The core and highest-value equipment of the entire line. Utilizes computer-controlled heated platens and multiple hydraulic cylinders to apply continuous pressure and heat to the board, resulting in high production efficiency and stable board quality. The preferred choice for producing 20mm thick boards.
5. Finishing & Handling Equipment:
Cooler/Conditioning Star: Allows the board to cool uniformly.
Trimming & Cross-Cut System: Includes edge trimmers and cross-cut saws for sizing length and width.
Calibrating Sander: Ensures final board thickness and surface flatness.
dryer rack
cross-cut saw
sander
6. Auxiliary & Control Systems:
Central Automated Control System (PLC + SCADA): The "brain" of the production line, centrally monitoring and regulating all process parameters.
Thermal Energy Plant: Provides the steam and thermal oil required for production.
Dust Extraction & Environmental Protection System: Collects process dust and treats exhaust gases to ensure environmental compliance.
Hydraulic System: Provides power for various pressing equipment.
PLC
energy center
hydraulic system
The core technology of this production line lies in how it efficiently, stably, and uniformly integrates both fire-retardant and moisture-proof functionalities into the core of the 20mm thick board.
1. Precision Dosing System for Dual-Function Additives
Fire-Retardant Dosing System:
Technology: Employs an independent, high-precision metering and atomization system for fire retardants (e.g., phosphorus-nitrogen based, Aluminum Trihydroxide, Magnesium Hydroxide). Typically, liquid or powdered retardants are applied simultaneously or sequentially with the adhesive binder during the fiber preparation stage via dedicated pipelines and nozzles.
Advantage: Ensures uniform distribution of the fire retardant throughout the fiber mass, which is crucial for achieving a high overall fire rating (e.g., Chinese GB 8624 B1 grade, EU EN 13501-1 B-s1, d0 class, US UL standards). Avoids issues of uneven distribution and compromised physical properties associated with post-production impregnation or spraying.
Moisture-Proof Agent Dosing System:
Technology: Similar to the fire retardant system, it features an independent, precision metering and dosing system for paraffin emulsion. The paraffin is accurately applied to the fiber surfaces before drying to form a stable hydrophobic film.
Coordinated Control: The central control system precisely coordinates the application ratios of fire retardant, moisture-proof agent, and adhesive resin to prevent interference and ensure stability of the final product's performance.
2. Dedicated Adhesive System
To achieve excellent moisture resistance and durability, this production line preferentially uses Phenolic Resin (PF) or Polymeric Methylene Diphenyl Diisocyanate (PMDI) as the primary binder. The cured adhesive layer formed by these resins is inherently water-insoluble and chemically stable, perfectly meeting the durability requirements for both moisture and fire resistance.
3. Process Optimization for 20mm Thick Board
Forming Station: Utilizes a high-precision mechanical or pneumatic forming head, specially designed for the 20mm thick mat to ensure extremely uniform fiber distribution from the surface to the core, preventing density gradients and subsequent warping.
Hot Pressing System:
Key Equipment: Employs a Continuous Press or a Multi-Opening Hot Press with specific pressure control programs.
Process Control: Implements a customized "Temperature-Pressure-Time" pressing profile for the 20mm thick board. Features longer preheating zones and slower closing speeds to ensure the core temperature reliably reaches the resin curing point, while preventing steam-related defects like "blows" caused by trapped vapor. Pressure control is precise, ensuring adequate board density without over-pressing that can create sealed steam layers.
4. High Automation and Intelligent Control
Central Control Room (PLC + SCADA): The entire line is centrally managed by computers, which monitor and record all process parameters in real-time (e.g., fiber moisture content, additive flow rates, press platens temperature and pressure, line speed).
Quality Traceability System: Production data for each board can be traced, providing a basis for quality analysis and troubleshooting, ensuring consistent and stable product quality.
5. Energy Saving and Environmental Design
Heat Recovery: Recovers waste heat from the hot press and dryer system to preheat fresh air, significantly reducing energy consumption.
Dust Removal and Exhaust Gas Treatment: Equipped with high-efficiency baghouse dust collectors and specialized treatment for exhaust gases containing fire-retardant components, ensuring emissions comply with environmental standards.
Product Performance:
Fire Retardancy: Meets GB 8624 B1 grade or equivalent international standards, effectively retarding flame spread.
Moisture Proofness: Meets or exceeds EN 622-5 standards, with low thickness swelling, suitable for humid environments.
Physical Properties: Uniform structure, high Internal Bond strength, excellent Modulus of Rupture, suitable for load-bearing structures.
Thickness Accuracy: Tight tolerance on the 20mm thickness, high surface flatness.
Application Fields (High-End Markets):
Building Interiors: Wall panels, partitions, ceilings in hospitals, schools, shopping malls, hotels, convention centers.
Public Transportation: Interior panels (wall panels, luggage racks, floor substrate) for high-speed rail, subways, buses.
Shipbuilding: Marine cabin panels, furniture for cruise ships, ferries.
Specialty Furniture: Laboratory workbenches, fume hoods, archival storage furniture, data center room partitions.
Safety Facilities: Fire door core stock, backing boards for fire escape route signs.
High Technical Barrier: Producing thick boards with combined fire-retardant and moisture-proof functionalities involves high technical thresholds, resulting in fewer competitors and extremely high product value-added.
Regulatory Compliance: Enables customers to manufacture products that comply with increasingly stringent global building fire safety and environmental regulations, capturing market opportunities.
Turnkey Solution: Provides a complete production solution for "dual-protection" thick boards from raw material to finished product, eliminating the need for external functional treatment and ensuring better quality control.
Excellent Return on Investment (ROI): Although the initial investment is relatively high, the profit margin for these specialty boards is far greater than for standard MDF, offering investors substantial economic returns.
✅ Transform Your Production Now!
Request Your Customized Quote & Technical Proposal:
Call +86 18769900191, +86 15805496117, +86 18954906501 or 【Live Chat】
Get a productivity upgrade plan within 24h
The production process is a continuous, highly automated operation. Its core objective is to uniformly mix raw wood materials with functional additives (fire retardants, waterproofing agents) and solidify them into boards under high temperature and pressure. The entire process can be divided into the following six main stages:
Stage 1: Raw Material Preparation Section
Purpose: To obtain clean, uniformly sized wood chips.
Process:
1. Chipping: Wood raw material (e.g., small-diameter logs, branches, wood processing residues) is fed into a Chipper and processed into standard-sized wood chips.
2. Screening and Washing: The chips pass through a Screening Station to remove overly fine particles and oversized pieces. They then enter a Washing Drum, which uses hydraulic impact and friction to remove impurities like sand, stones, and metals. Clean chips are fundamental for ensuring subsequent fiber quality and equipment longevity.
Stage 2: Fiber Preparation Section - The "Heart and Functional Injection"
Purpose: To separate the wood chips into individual fibers and simultaneously, uniformly apply the adhesive binder, fire retardant, and waterproofing agent.
Process:
1. Defibration: The clean chips, after pre-steaming, are fed into the Defibrator (Refiner). Under high temperature and pressure, the chips are separated into loose wood fibers.
2. Precision Blending (The Most Critical Step): The fibers exiting the defibrator immediately enter a High-Speed Blender. Here, three sets of precision dosing systems operate simultaneously:
Adhesive System: Injects moisture-resistant Phenolic Resin (PF) or Polymeric Methylene Diphenyl Diisocyanate (PMDI).
Fire Retardant System: Injects liquid or atomized powdered Fire Retardant.
Waterproofing Agent System: Injects Paraffin Emulsion.
The fibers are thoroughly and uniformly mixed with these additives inside the high-speed rotating blender, ensuring each individual fiber is coated. This is the decisive step for achieving uniform fire retardancy and moisture-proof functionality throughout the board.
Stage 3: Mat Forming & Pre-pressing Section
Purpose: To form the blended fibers into a uniform mat and perform initial compaction.
Process:
1. Drying: The resinated moist fibers enter a Drying Duct, where hot air dries them to the optimal moisture content.
2. Forming: The dried fibers are distributed by a Pneumatic Forming Station, laying down a uniform, fluffy "fiber blanket" (the mat) onto a moving steel belt. Specifically designed for the 20mm thickness, the former ensures consistent density from bottom to top, without gradients.
3. Pre-pressing: The loose mat passes through a Pre-press, which performs initial compaction and deaeration, increasing its strength to form a self-supporting "green belt" suitable for entering the hot press.
Stage 4: Hot Pressing & Curing Section - "Shaping and Board Formation"
Purpose: To cure the resin under high temperature and pressure, permanently bonding the fiber mat into a high-density board.
Process:
1. Hot Pressing: The mat enters the core equipment of the line – the Continuous Flat Press. It passes through a long, precisely controlled heated platen section.
Special Process for 20mm Thick Board: The system executes a specific "Temperature-Pressure-Time" profile. This includes: Slower closing speeds and longer low-temperature preheating zones to allow a gentle temperature rise in the board's core, facilitating the escape of internal moisture and air, preventing "blows"; Precise pressure control ensures the board reaches the target density (e.g., >800 kg/m³) without compromising its internal structure.
2. Curing: Under high temperature (approx. 200°C) and pressure, the PF or PMDI resin rapidly cures, firmly bonding the fibers together. The fire retardant and waterproofing agents become permanently fixed within the board's structure.
Stage 5: Finishing & Handling Section
Purpose: To cut the pressed board to size and perform surface treatment.
Process:
1. Cooling & Trimming: The hot board exiting the press enters a Cooler/Conditioning Star for forced cooling and stabilization. Subsequently, it passes through Trimming & Cross-Cut Saws to be cut to the required dimensions, with the irregular edges trimmed off.
2. Sanding: The board enters a Calibrating Sander for precision sanding of both top and bottom surfaces. This is crucial for 20mm thick boards, as it ensures:
Precise final thickness (e.g., 20±0.2mm).
High surface flatness, providing a perfect substrate for subsequent finishing processes like laminating or painting.
Stage 6: Inspection & Packaging
Purpose: To ensure product quality and prepare for storage and transport.
Process: Finished boards are sampled for testing (fire retardancy, moisture resistance, physical/mechanical properties, etc.). Qualified products are automatically stacked, wrapped, and finally sent to storage.
1. Raw Material Handling Equipment:
Chipper: Processes wood raw material into chips.
Chip Screening & Washing System: Ensures chip purity and uniformity.
2. Fiber Preparation & Functionalization Equipment:
Defibration System: One of the hearts of the production line, responsible for separating chips into fibers.
Precision Resin/Additive Application System:
Adhesive (PF/PMDI) storage, metering, and delivery units.
Fire Retardant preparation, storage, and high-precision metering/pumping system.
Paraffin emulsion storage and metering system.
High-Speed Blender: The key equipment for achieving uniform mixing of fibers and additives.
fiber
glue machine
3. Forming & Pre-pressing Equipment:
Fiber Drying Duct: Equipped with a thermal energy system for drying fibers.
Pneumatic Forming Station: Optimized specifically for thick boards to ensure uniform mat formation.
Pre-press: Performs initial compaction of the mat.
dryer
forming machine
pre press
4. Hot Pressing & Curing Equipment:
Continuous Flat Press: The core and highest-value equipment of the entire line. Utilizes computer-controlled heated platens and multiple hydraulic cylinders to apply continuous pressure and heat to the board, resulting in high production efficiency and stable board quality. The preferred choice for producing 20mm thick boards.
5. Finishing & Handling Equipment:
Cooler/Conditioning Star: Allows the board to cool uniformly.
Trimming & Cross-Cut System: Includes edge trimmers and cross-cut saws for sizing length and width.
Calibrating Sander: Ensures final board thickness and surface flatness.
dryer rack
cross-cut saw
sander
6. Auxiliary & Control Systems:
Central Automated Control System (PLC + SCADA): The "brain" of the production line, centrally monitoring and regulating all process parameters.
Thermal Energy Plant: Provides the steam and thermal oil required for production.
Dust Extraction & Environmental Protection System: Collects process dust and treats exhaust gases to ensure environmental compliance.
Hydraulic System: Provides power for various pressing equipment.
PLC
energy center
hydraulic system
The core technology of this production line lies in how it efficiently, stably, and uniformly integrates both fire-retardant and moisture-proof functionalities into the core of the 20mm thick board.
1. Precision Dosing System for Dual-Function Additives
Fire-Retardant Dosing System:
Technology: Employs an independent, high-precision metering and atomization system for fire retardants (e.g., phosphorus-nitrogen based, Aluminum Trihydroxide, Magnesium Hydroxide). Typically, liquid or powdered retardants are applied simultaneously or sequentially with the adhesive binder during the fiber preparation stage via dedicated pipelines and nozzles.
Advantage: Ensures uniform distribution of the fire retardant throughout the fiber mass, which is crucial for achieving a high overall fire rating (e.g., Chinese GB 8624 B1 grade, EU EN 13501-1 B-s1, d0 class, US UL standards). Avoids issues of uneven distribution and compromised physical properties associated with post-production impregnation or spraying.
Moisture-Proof Agent Dosing System:
Technology: Similar to the fire retardant system, it features an independent, precision metering and dosing system for paraffin emulsion. The paraffin is accurately applied to the fiber surfaces before drying to form a stable hydrophobic film.
Coordinated Control: The central control system precisely coordinates the application ratios of fire retardant, moisture-proof agent, and adhesive resin to prevent interference and ensure stability of the final product's performance.
2. Dedicated Adhesive System
To achieve excellent moisture resistance and durability, this production line preferentially uses Phenolic Resin (PF) or Polymeric Methylene Diphenyl Diisocyanate (PMDI) as the primary binder. The cured adhesive layer formed by these resins is inherently water-insoluble and chemically stable, perfectly meeting the durability requirements for both moisture and fire resistance.
3. Process Optimization for 20mm Thick Board
Forming Station: Utilizes a high-precision mechanical or pneumatic forming head, specially designed for the 20mm thick mat to ensure extremely uniform fiber distribution from the surface to the core, preventing density gradients and subsequent warping.
Hot Pressing System:
Key Equipment: Employs a Continuous Press or a Multi-Opening Hot Press with specific pressure control programs.
Process Control: Implements a customized "Temperature-Pressure-Time" pressing profile for the 20mm thick board. Features longer preheating zones and slower closing speeds to ensure the core temperature reliably reaches the resin curing point, while preventing steam-related defects like "blows" caused by trapped vapor. Pressure control is precise, ensuring adequate board density without over-pressing that can create sealed steam layers.
4. High Automation and Intelligent Control
Central Control Room (PLC + SCADA): The entire line is centrally managed by computers, which monitor and record all process parameters in real-time (e.g., fiber moisture content, additive flow rates, press platens temperature and pressure, line speed).
Quality Traceability System: Production data for each board can be traced, providing a basis for quality analysis and troubleshooting, ensuring consistent and stable product quality.
5. Energy Saving and Environmental Design
Heat Recovery: Recovers waste heat from the hot press and dryer system to preheat fresh air, significantly reducing energy consumption.
Dust Removal and Exhaust Gas Treatment: Equipped with high-efficiency baghouse dust collectors and specialized treatment for exhaust gases containing fire-retardant components, ensuring emissions comply with environmental standards.
Product Performance:
Fire Retardancy: Meets GB 8624 B1 grade or equivalent international standards, effectively retarding flame spread.
Moisture Proofness: Meets or exceeds EN 622-5 standards, with low thickness swelling, suitable for humid environments.
Physical Properties: Uniform structure, high Internal Bond strength, excellent Modulus of Rupture, suitable for load-bearing structures.
Thickness Accuracy: Tight tolerance on the 20mm thickness, high surface flatness.
Application Fields (High-End Markets):
Building Interiors: Wall panels, partitions, ceilings in hospitals, schools, shopping malls, hotels, convention centers.
Public Transportation: Interior panels (wall panels, luggage racks, floor substrate) for high-speed rail, subways, buses.
Shipbuilding: Marine cabin panels, furniture for cruise ships, ferries.
Specialty Furniture: Laboratory workbenches, fume hoods, archival storage furniture, data center room partitions.
Safety Facilities: Fire door core stock, backing boards for fire escape route signs.
High Technical Barrier: Producing thick boards with combined fire-retardant and moisture-proof functionalities involves high technical thresholds, resulting in fewer competitors and extremely high product value-added.
Regulatory Compliance: Enables customers to manufacture products that comply with increasingly stringent global building fire safety and environmental regulations, capturing market opportunities.
Turnkey Solution: Provides a complete production solution for "dual-protection" thick boards from raw material to finished product, eliminating the need for external functional treatment and ensuring better quality control.
Excellent Return on Investment (ROI): Although the initial investment is relatively high, the profit margin for these specialty boards is far greater than for standard MDF, offering investors substantial economic returns.
✅ Transform Your Production Now!
Request Your Customized Quote & Technical Proposal:
Call +86 18769900191, +86 15805496117, +86 18954906501 or 【Live Chat】
Get a productivity upgrade plan within 24h
