MH-CHP
MINGHUNG
This 2500mm wide continuous flat-pressing hot press is the core equipment in modern Medium-Density Fiberboard (MDF) production lines.
1.Continuous Pressing
Working principle: Through two heavy-duty steel belts that wrap around the press machine, the fabricated fiber plates are continuously fed into the high-temperature and high-pressure zone, achieving uniform pressing (different from the periodic multi-layer hot press machine).
Advantages: High production efficiency, low energy consumption, uniform product density, and thickness accuracy of ±0.1mm.
2500mm width
The effective processing width of the pressure machine is 2.5 meters, and it can produce MDF boards with a maximum width of 2.5 meters (the actual finished width is usually slightly smaller and a cutting margin needs to be reserved).
2. Essence of Continuous Flat-Pressing
Core Concept: Eliminates the cyclical "loading-pressing-dwell-depressurizing-unloading" process of traditional multi-opening presses. Enables continuous, uniform passage of the fiber mat through a high-temperature, high-pressure zone.
Physical Process: The formed and pre-pressed fiber mat is gripped between two parallel, high-strength, heat-resistant endless steel belts and fed continuously into a pressing zone where the gap narrows progressively in the machine direction (longitudinal) and the height decreases progressively in the thickness direction. The mat enters at the widest opening (infeed) and exits at the target thickness (outfeed).
Key Forces:
Steel Belt Tension: Provides the fundamental gripping force and transmits driving traction.
Hydraulic Pressure: Applies enormous perpendicular pressure (5-7 MPa or higher) via numerous hydraulic cylinders distributed along the press length and width.
Heat Transfer: Heated press platens (typically circulating thermal oil) conduct heat efficiently through the steel belts into the mat core.
3. Detailed Workflow
3.1 Mat Feeding: The uniformly formed and pre-pressed fiber mat is precisely fed into the press infeed by conveyor.
3.2 Infeed Nip: The upper and lower steel belts grip the mat at the widest opening. The belts are driven by main drive drums.
3.3 Continuous Pressing:
Compression Zone: Immediately upon entry, the mat enters a rapid compression zone. Hydraulic pressure here rises quickly to compress the fluffy mat close to its target thickness, expelling significant air.
Main Pressure/Curing Zone: The longest section. The mat travels at target thickness under constant high pressure (or according to a pressure profile) and constant high temperature (180-220°C). Key processes occur here:
Fiber undergoes plastic deformation under heat and pressure.
Lignin softens, acting as a natural binder.
Added synthetic resins (UF/PF/MDI/etc.) cure, forming a strong bonding network.
Moisture vaporizes and escapes through mat edges and designed venting channels.
Pressure Release Zone: Approaching the outfeed, hydraulic pressure is gradually reduced. This critical stage allows controlled release of internal steam pressure to prevent defects like blisters or delamination. Release rate and gradient require precise control.
3.4 Outfeed Release: The fully pressed and cured mat (now a continuous board) is released by the steel belts at the outfeed.
3.5 Belt Return & Cooling: The released belts loop around return rolls. Cooling systems typically cool them during return to ensure proper temperature at re-entry, preventing pre-curing of the mat surface.
3.6 Board Handling: The continuous pressed board exits the press for downstream processing (cooling, stacking, sawing, sanding).
Project | Typical Value/Explanation |
Effective width | 2500mm |
Design capacity | Typically, a production line with a capacity of 800 - 1500 m³ per day is adopted. |
Work stress | 5 - 7 MPa (peak value in the high-pressure zone) |
Temperature control | 180 - 220℃ (segmented precise temperature control) |
Compression speed | 20 - 120 mm/s (automatically adjusted according to thickness) |
Applicable thickness range | 1.5mm - 40mm (universal pressing for thin plates to thick plates) |
Length of steel strip | 40 - 60 meters (determining the total length of the press machine) |
Width Class | Application Scope | Typical Annual Capacity | Market Positioning |
< 2000mm | Small pilot/lab lines | < 100,000 m³ | Niche/Specialty boards |
2000-2300mm | Mid-scale production | 100,000–200,000 m³ | Standard economic capacity |
2400-2600mm | Large-scale core capacity | 200,000–350,000 m³ | Global new-project standard |
2700-2800mm | Mega-scale lines | 350,000–500,000 m³ | Custom for industry leaders |
> 3000mm | Rare specialty lines | >500,000 m³ | Engineering substrates |
2500mm resides within the critical "Goldilocks Zone" (2400–2600mm)
1. Heavy-Duty Frame & Structure:
Construction: Extremely robust box-type steel structure or pre-stressed frame, capable of withstanding enormous pressing forces (total force up to tens of thousands of tons) without harmful deformation.
2500mm Challenge: Wider width exponentially increases the difficulty of maintaining frame stiffness and deformation uniformity under massive loads.
2. Hydraulic System:
Zoned Control: The press is divided into multiple independent longitudinal pressure zones (often dozens) along its length. Each zone is driven by one or more cylinder groups. Transverse zones (e.g., 5-7 or more) across the width are also standard. 2500mm presses typically employ finer transverse zoning (e.g., 8-12+ zones) to precisely compensate for belt and platen deflection, ensuring full-width pressure uniformity.
Core Components: High-pressure pump stations, precision servo-proportional valves, accumulators, pressure sensors, displacement sensors (LVDTs).
Control Logic: Based on set pressure profiles and real-time mat thickness (via laser gauges) and pressure feedback, the control system dynamically adjusts cylinder pressure per zone to achieve:
Longitudinal pressure gradient (high at infeed, stable in main zone, decreasing at outfeed).
Transverse pressure uniformity (compensating the "crown effect").
3. Heated Platen System:
Structure: Massive thick steel plates (cast or rolled), internally machined with dense, complex channel networks.
Heating Medium: High-temperature thermal oil (up to 280-300°C) circulates through channels, transferring heat uniformly to the platen surface.
Zoned Temperature Control: Platens have temperature zones along length and width. Achieving high temperature uniformity (±1.5°C or better) is critical at 2500mm width, especially controlling edge effects.
Surface Treatment: High-precision grinding for flatness/smoothness, often with special coatings (chrome, ceramic) for wear resistance, non-stick properties, and heat transfer efficiency.
4. Steel Belt System:
Core Component: Two endless, high-strength specialty alloy steel belts (typically 1.2-2.0mm thick). The hallmark and critical consumable of continuous presses.
Functions: Grip and transport the mat; transfer pressure and heat from platens to the mat; form the pressing gap; impart surface texture (smooth or textured).
2500mm Challenges:
Tension Control: Wider belts make uniform transverse tension control harder. Requires complex tension roll systems and precise closed-loop control to prevent belt tracking issues, wrinkling, or breakage. Typical tension: 100-300 kN/m.
Flatness & Stiffness: Maintaining belt flatness across full length/width under extreme pressure/temperature.
Wear & Heat Resistance: Belts endure high temperature, pressure, friction, and chemical corrosion (resins, additives). Lifespan typically 5-8 years.
Drive & Tracking: Powerful main drives ensure speed stability; sensitive tracking systems (e.g., EPC - Edge Position Control) adjust guide rolls in real-time.
5. Thickness Control System:
Core: High-precision laser thickness gauges (at outfeed/key internal points) scan the pressed board profile (longitudinal & transverse) in real-time.
Feedback Control: Measurement data feeds back to the hydraulic control system, which dynamically adjusts pressure (or piston position) of corresponding cylinders to compensate for thickness deviations. High-resolution transverse scanning is crucial at 2500mm.
Goal: Achieve full-board thickness tolerance within ±0.1mm to ±0.2mm (or better).
6. Lubrication & Cleaning System:
Lubrication: Special high-temperature lubricant (graphite/synthetic) sprayed between belts and platens reduces friction, prevents sticking, and protects surfaces.
Cleaning: Belts pass cleaning stations (brushes, scrapers, vacuum) during return, removing fiber, resin, and lubricant residues to ensure surface quality for the next cycle.
7. Automation & Control System:
Brain: High-performance PLC system integrating all sensors (pressure, temp, position, tension, speed, thickness) and actuators (valves, drives, heaters).
Functions: Full auto start/stop, speed control, pressure profile setting, temperature control, tension control, tracking control, thickness control, recipe storage/optimization, diagnostics/alarms, safety interlocks.
Advanced Features: AI/ML-based process optimization, quality prediction, predictive maintenance, energy management, remote monitoring.
1. Productivity Leap:
Continuous Operation: Eliminates idle time (loading/unloading) of batch presses, approaching 100% theoretical efficiency.
High Speed: Line speeds can exceed 1000 mm/s (depending on thickness), far surpassing multi-opening presses.
High Capacity: Foundation for large MDF lines (150,000+ m³/year, even 300,000+ m³/year).
2. Superior Product Quality:
Density Uniformity: Continuous, stable pressure/temperature combined with fine zoned control ensures exceptional longitudinal and transverse density distribution and consistent physical/mechanical properties. Transverse density uniformity at 2500mm is a key competitive metric.
Thickness Accuracy: Laser gauging + servo-hydraulic closed-loop control achieves ±0.1mm to ±0.2mm precision.
Surface Quality: Steel belts impart highly consistent surface texture and smoothness (especially for smooth boards).
Internal Bond (IB) Strength: Continuous, controlled pressing and venting promote full resin cure, reduce internal stress, and improve IB.
Low Formaldehyde Emission: Precise temperature/pressure control aids complete resin cure, reducing free formaldehyde.
3. Enhanced Raw Material Utilization:
Width Advantage: A 2500mm effective width allows maximizing usable area when cutting standard sizes (e.g., 1220x2440mm), significantly reducing trim loss. Compared to narrower presses (e.g., 1300mm), utilization can increase by 10%-15%+ – a major cost advantage.
4. Product Flexibility & Market Competitiveness:
Production of Wide Panels: Enables seamless production of jumbo panels (up to ~2500mm wide) for premium furniture (table tops, doors), mouldings, and specialty applications.
Parallel Narrow Board Production: Multiple standard-width boards (e.g., 2 x 1220mm) can be pressed side-by-side on one wide belt, boosting efficiency.
Superior Thin Board Capability: Precise control allows stable production of thin (<3mm) and ultra-thin (<1.5mm) MDF, difficult for multi-opening presses.
Differentiated Products: Facilitates functional gradient boards (e.g., high-density surface, low-density core) and boards with additives (FR, moisture resistance).
5. Energy Efficiency & Environmental Benefits:
Lower Specific Energy Consumption: Continuous operation reduces heat loss. Efficient thermal oil systems and heat recovery (e.g., exhaust gases) lower energy per ton (steam, electricity).
High Automation: Reduces labor and improves the working environment.
Emission Control: More complete curing helps reduce VOC emissions like free formaldehyde.
If you are interested, please feel free to contact us at any time to obtain the quotation.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
This 2500mm wide continuous flat-pressing hot press is the core equipment in modern Medium-Density Fiberboard (MDF) production lines.
1.Continuous Pressing
Working principle: Through two heavy-duty steel belts that wrap around the press machine, the fabricated fiber plates are continuously fed into the high-temperature and high-pressure zone, achieving uniform pressing (different from the periodic multi-layer hot press machine).
Advantages: High production efficiency, low energy consumption, uniform product density, and thickness accuracy of ±0.1mm.
2500mm width
The effective processing width of the pressure machine is 2.5 meters, and it can produce MDF boards with a maximum width of 2.5 meters (the actual finished width is usually slightly smaller and a cutting margin needs to be reserved).
2. Essence of Continuous Flat-Pressing
Core Concept: Eliminates the cyclical "loading-pressing-dwell-depressurizing-unloading" process of traditional multi-opening presses. Enables continuous, uniform passage of the fiber mat through a high-temperature, high-pressure zone.
Physical Process: The formed and pre-pressed fiber mat is gripped between two parallel, high-strength, heat-resistant endless steel belts and fed continuously into a pressing zone where the gap narrows progressively in the machine direction (longitudinal) and the height decreases progressively in the thickness direction. The mat enters at the widest opening (infeed) and exits at the target thickness (outfeed).
Key Forces:
Steel Belt Tension: Provides the fundamental gripping force and transmits driving traction.
Hydraulic Pressure: Applies enormous perpendicular pressure (5-7 MPa or higher) via numerous hydraulic cylinders distributed along the press length and width.
Heat Transfer: Heated press platens (typically circulating thermal oil) conduct heat efficiently through the steel belts into the mat core.
3. Detailed Workflow
3.1 Mat Feeding: The uniformly formed and pre-pressed fiber mat is precisely fed into the press infeed by conveyor.
3.2 Infeed Nip: The upper and lower steel belts grip the mat at the widest opening. The belts are driven by main drive drums.
3.3 Continuous Pressing:
Compression Zone: Immediately upon entry, the mat enters a rapid compression zone. Hydraulic pressure here rises quickly to compress the fluffy mat close to its target thickness, expelling significant air.
Main Pressure/Curing Zone: The longest section. The mat travels at target thickness under constant high pressure (or according to a pressure profile) and constant high temperature (180-220°C). Key processes occur here:
Fiber undergoes plastic deformation under heat and pressure.
Lignin softens, acting as a natural binder.
Added synthetic resins (UF/PF/MDI/etc.) cure, forming a strong bonding network.
Moisture vaporizes and escapes through mat edges and designed venting channels.
Pressure Release Zone: Approaching the outfeed, hydraulic pressure is gradually reduced. This critical stage allows controlled release of internal steam pressure to prevent defects like blisters or delamination. Release rate and gradient require precise control.
3.4 Outfeed Release: The fully pressed and cured mat (now a continuous board) is released by the steel belts at the outfeed.
3.5 Belt Return & Cooling: The released belts loop around return rolls. Cooling systems typically cool them during return to ensure proper temperature at re-entry, preventing pre-curing of the mat surface.
3.6 Board Handling: The continuous pressed board exits the press for downstream processing (cooling, stacking, sawing, sanding).
Project | Typical Value/Explanation |
Effective width | 2500mm |
Design capacity | Typically, a production line with a capacity of 800 - 1500 m³ per day is adopted. |
Work stress | 5 - 7 MPa (peak value in the high-pressure zone) |
Temperature control | 180 - 220℃ (segmented precise temperature control) |
Compression speed | 20 - 120 mm/s (automatically adjusted according to thickness) |
Applicable thickness range | 1.5mm - 40mm (universal pressing for thin plates to thick plates) |
Length of steel strip | 40 - 60 meters (determining the total length of the press machine) |
Width Class | Application Scope | Typical Annual Capacity | Market Positioning |
< 2000mm | Small pilot/lab lines | < 100,000 m³ | Niche/Specialty boards |
2000-2300mm | Mid-scale production | 100,000–200,000 m³ | Standard economic capacity |
2400-2600mm | Large-scale core capacity | 200,000–350,000 m³ | Global new-project standard |
2700-2800mm | Mega-scale lines | 350,000–500,000 m³ | Custom for industry leaders |
> 3000mm | Rare specialty lines | >500,000 m³ | Engineering substrates |
2500mm resides within the critical "Goldilocks Zone" (2400–2600mm)
1. Heavy-Duty Frame & Structure:
Construction: Extremely robust box-type steel structure or pre-stressed frame, capable of withstanding enormous pressing forces (total force up to tens of thousands of tons) without harmful deformation.
2500mm Challenge: Wider width exponentially increases the difficulty of maintaining frame stiffness and deformation uniformity under massive loads.
2. Hydraulic System:
Zoned Control: The press is divided into multiple independent longitudinal pressure zones (often dozens) along its length. Each zone is driven by one or more cylinder groups. Transverse zones (e.g., 5-7 or more) across the width are also standard. 2500mm presses typically employ finer transverse zoning (e.g., 8-12+ zones) to precisely compensate for belt and platen deflection, ensuring full-width pressure uniformity.
Core Components: High-pressure pump stations, precision servo-proportional valves, accumulators, pressure sensors, displacement sensors (LVDTs).
Control Logic: Based on set pressure profiles and real-time mat thickness (via laser gauges) and pressure feedback, the control system dynamically adjusts cylinder pressure per zone to achieve:
Longitudinal pressure gradient (high at infeed, stable in main zone, decreasing at outfeed).
Transverse pressure uniformity (compensating the "crown effect").
3. Heated Platen System:
Structure: Massive thick steel plates (cast or rolled), internally machined with dense, complex channel networks.
Heating Medium: High-temperature thermal oil (up to 280-300°C) circulates through channels, transferring heat uniformly to the platen surface.
Zoned Temperature Control: Platens have temperature zones along length and width. Achieving high temperature uniformity (±1.5°C or better) is critical at 2500mm width, especially controlling edge effects.
Surface Treatment: High-precision grinding for flatness/smoothness, often with special coatings (chrome, ceramic) for wear resistance, non-stick properties, and heat transfer efficiency.
4. Steel Belt System:
Core Component: Two endless, high-strength specialty alloy steel belts (typically 1.2-2.0mm thick). The hallmark and critical consumable of continuous presses.
Functions: Grip and transport the mat; transfer pressure and heat from platens to the mat; form the pressing gap; impart surface texture (smooth or textured).
2500mm Challenges:
Tension Control: Wider belts make uniform transverse tension control harder. Requires complex tension roll systems and precise closed-loop control to prevent belt tracking issues, wrinkling, or breakage. Typical tension: 100-300 kN/m.
Flatness & Stiffness: Maintaining belt flatness across full length/width under extreme pressure/temperature.
Wear & Heat Resistance: Belts endure high temperature, pressure, friction, and chemical corrosion (resins, additives). Lifespan typically 5-8 years.
Drive & Tracking: Powerful main drives ensure speed stability; sensitive tracking systems (e.g., EPC - Edge Position Control) adjust guide rolls in real-time.
5. Thickness Control System:
Core: High-precision laser thickness gauges (at outfeed/key internal points) scan the pressed board profile (longitudinal & transverse) in real-time.
Feedback Control: Measurement data feeds back to the hydraulic control system, which dynamically adjusts pressure (or piston position) of corresponding cylinders to compensate for thickness deviations. High-resolution transverse scanning is crucial at 2500mm.
Goal: Achieve full-board thickness tolerance within ±0.1mm to ±0.2mm (or better).
6. Lubrication & Cleaning System:
Lubrication: Special high-temperature lubricant (graphite/synthetic) sprayed between belts and platens reduces friction, prevents sticking, and protects surfaces.
Cleaning: Belts pass cleaning stations (brushes, scrapers, vacuum) during return, removing fiber, resin, and lubricant residues to ensure surface quality for the next cycle.
7. Automation & Control System:
Brain: High-performance PLC system integrating all sensors (pressure, temp, position, tension, speed, thickness) and actuators (valves, drives, heaters).
Functions: Full auto start/stop, speed control, pressure profile setting, temperature control, tension control, tracking control, thickness control, recipe storage/optimization, diagnostics/alarms, safety interlocks.
Advanced Features: AI/ML-based process optimization, quality prediction, predictive maintenance, energy management, remote monitoring.
1. Productivity Leap:
Continuous Operation: Eliminates idle time (loading/unloading) of batch presses, approaching 100% theoretical efficiency.
High Speed: Line speeds can exceed 1000 mm/s (depending on thickness), far surpassing multi-opening presses.
High Capacity: Foundation for large MDF lines (150,000+ m³/year, even 300,000+ m³/year).
2. Superior Product Quality:
Density Uniformity: Continuous, stable pressure/temperature combined with fine zoned control ensures exceptional longitudinal and transverse density distribution and consistent physical/mechanical properties. Transverse density uniformity at 2500mm is a key competitive metric.
Thickness Accuracy: Laser gauging + servo-hydraulic closed-loop control achieves ±0.1mm to ±0.2mm precision.
Surface Quality: Steel belts impart highly consistent surface texture and smoothness (especially for smooth boards).
Internal Bond (IB) Strength: Continuous, controlled pressing and venting promote full resin cure, reduce internal stress, and improve IB.
Low Formaldehyde Emission: Precise temperature/pressure control aids complete resin cure, reducing free formaldehyde.
3. Enhanced Raw Material Utilization:
Width Advantage: A 2500mm effective width allows maximizing usable area when cutting standard sizes (e.g., 1220x2440mm), significantly reducing trim loss. Compared to narrower presses (e.g., 1300mm), utilization can increase by 10%-15%+ – a major cost advantage.
4. Product Flexibility & Market Competitiveness:
Production of Wide Panels: Enables seamless production of jumbo panels (up to ~2500mm wide) for premium furniture (table tops, doors), mouldings, and specialty applications.
Parallel Narrow Board Production: Multiple standard-width boards (e.g., 2 x 1220mm) can be pressed side-by-side on one wide belt, boosting efficiency.
Superior Thin Board Capability: Precise control allows stable production of thin (<3mm) and ultra-thin (<1.5mm) MDF, difficult for multi-opening presses.
Differentiated Products: Facilitates functional gradient boards (e.g., high-density surface, low-density core) and boards with additives (FR, moisture resistance).
5. Energy Efficiency & Environmental Benefits:
Lower Specific Energy Consumption: Continuous operation reduces heat loss. Efficient thermal oil systems and heat recovery (e.g., exhaust gases) lower energy per ton (steam, electricity).
High Automation: Reduces labor and improves the working environment.
Emission Control: More complete curing helps reduce VOC emissions like free formaldehyde.
If you are interested, please feel free to contact us at any time to obtain the quotation.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
