MH
MINGHUNG
This process is specifically designed to meet the demanding requirements of industrial shelving for high strength, high stiffness, and high durability. The core focus is on achieving high density, high strength, and consistent quality. The entire highly automated process follows the "face-core-face" three-layer principle, with the following detailed steps:
 | Phase I: Raw Material Preparation & Handling |
1. Debarking & Chipping: Logs are debarked using a drum debarker (bark affects appearance and bond strength) and then fed into a large drum chipper to produce uniform process chips.
2. Chip Screening & Storage: Chips are graded by a multi-deck swing screen, separating oversize chips, accept chips, and fines. Oversize chips are reduced in a re-crusher and recycled. Accept chips are conveyed to large storage silos to ensure continuous and stable production.
3. Particle Preparation & Classification:
Flaking: Accept chips are fed into a ring flaker to produce particles of specified thickness.
Milling: Particles are sent through a particle mill to roughen their surfaces, increasing the specific surface area for better glue adhesion.
Classification: Particles are precisely separated into fine face material and coarser core material via an airflow sifter. This is the foundation for the three-layer structure, ensuring a smooth surface and a strong interior.
| Phase II: Drying & Blending |
4. Particle Drying: Face and core particles are dried separately in large rotary drum dryers using hot air supplied from the energy center. Moisture content is precisely controlled to the process range of 2-4%, preparing them for efficient blending.
5. Particle Blending - 【Key to High Strength】:
Dried face and core particles are sent to separate high-speed ring blenders.
High-pressure spraying technology is used to uniformly apply a significant amount of MDI resin (Isocyanate) to the particles. MDI is crucial for high load-bearing boards—it is formaldehyde-free, offers extremely high bond strength, and effectively bonds wood and any potential reinforcement materials.
Wax and other agents are added simultaneously to impart moisture resistance.
| Phase III: Forming & Pre-pressing |
6. Layered Forming: The resinated face and core particles are formed into a continuous, uniform, endless mat with a "fine-coarse-fine" sandwich structure by the multiple spreading heads of a mechanical forming station. Precise forming technology ensures a density profile across the board's thickness, resulting in very high Modulus of Rupture (MOR) and Modulus of Elasticity (MOE).
7. Pre-pressing: The fluffy mat enters a continuous belt pre-press where it is initially compacted at room temperature. This expels air, increases mat strength for handling, and forms a sturdy "mat band" for transport into the press.
| Phase IV: Pressing & Curing |
8. Continuous Pressing - 【Core Process】: The mat band enters an extra-long continuous flat press. Under high temperature (200-220°C) and pressure, the mat moves through the press at a constant speed, curing the MDI resin rapidly.
Key Advantage: The continuous press produces boards with an extremely uniform density profile, low internal stress, and excellent dimensional stability. The mechanical properties (e.g., Internal Bond - IB) are far superior to those from discontinuous presses, fully meeting the safety requirements for shelf load-bearing capacity.
| Phase V: Finishing & Processing |
9. Cooling & Trimming: Pressed boards are evenly cooled in a cooler stacker to stabilize dimensions and relieve internal stress. They are then precisely cut to required sizes by cross-cut and edge-trimming saws.
10. Sanding: Boards pass through a 6-8 head heavy-duty calibrating sander to remove the pre-cured layer and correct minimal thickness deviations, achieving the precise 16mm thickness and an extremely smooth, flat surface.
11. Inspection & Packaging: Boards undergo 100% quality monitoring via online systems (e.g., X-ray density gauges) to ensure density, thickness, and mechanical properties comply with shelf board standards like DIN EN 312 P5. Qualified products are automatically stacked, packaged, labeled, and stored for shipment.
Plant-Wide Auxiliary Systems:
Energy Center: Uses waste materials from the process (bark, sander dust, sawdust) as fuel to generate thermal energy for drying and pressing, achieving energy self-sufficiency and environmental benefits.
Central Dust Extraction System: Collects dust from all processes, ensuring a clean and safe production environment.
Central Control System (DCS/PLC): Automation system (e.g., Siemens-based) integrated into a control room for precise control and intelligent management of all process parameters (temperature, pressure, speed, moisture content). This is the fundamental guarantee for achieving the annual output of 300,000 m³ with highly stable quality.
Claim Your Free PB Line Layout! Get end-to-end plant design from strand preparation to sanding. Receive 3D factory plan within 30 days.
Our contacts:
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
This process is specifically designed to meet the demanding requirements of industrial shelving for high strength, high stiffness, and high durability. The core focus is on achieving high density, high strength, and consistent quality. The entire highly automated process follows the "face-core-face" three-layer principle, with the following detailed steps:
| Phase I: Raw Material Preparation & Handling |
1. Debarking & Chipping: Logs are debarked using a drum debarker (bark affects appearance and bond strength) and then fed into a large drum chipper to produce uniform process chips.
2. Chip Screening & Storage: Chips are graded by a multi-deck swing screen, separating oversize chips, accept chips, and fines. Oversize chips are reduced in a re-crusher and recycled. Accept chips are conveyed to large storage silos to ensure continuous and stable production.
3. Particle Preparation & Classification:
Flaking: Accept chips are fed into a ring flaker to produce particles of specified thickness.
Milling: Particles are sent through a particle mill to roughen their surfaces, increasing the specific surface area for better glue adhesion.
Classification: Particles are precisely separated into fine face material and coarser core material via an airflow sifter. This is the foundation for the three-layer structure, ensuring a smooth surface and a strong interior.
| Phase II: Drying & Blending |
4. Particle Drying: Face and core particles are dried separately in large rotary drum dryers using hot air supplied from the energy center. Moisture content is precisely controlled to the process range of 2-4%, preparing them for efficient blending.
5. Particle Blending - 【Key to High Strength】:
Dried face and core particles are sent to separate high-speed ring blenders.
High-pressure spraying technology is used to uniformly apply a significant amount of MDI resin (Isocyanate) to the particles. MDI is crucial for high load-bearing boards—it is formaldehyde-free, offers extremely high bond strength, and effectively bonds wood and any potential reinforcement materials.
Wax and other agents are added simultaneously to impart moisture resistance.
| Phase III: Forming & Pre-pressing |
6. Layered Forming: The resinated face and core particles are formed into a continuous, uniform, endless mat with a "fine-coarse-fine" sandwich structure by the multiple spreading heads of a mechanical forming station. Precise forming technology ensures a density profile across the board's thickness, resulting in very high Modulus of Rupture (MOR) and Modulus of Elasticity (MOE).
7. Pre-pressing: The fluffy mat enters a continuous belt pre-press where it is initially compacted at room temperature. This expels air, increases mat strength for handling, and forms a sturdy "mat band" for transport into the press.
| Phase IV: Pressing & Curing |
8. Continuous Pressing - 【Core Process】: The mat band enters an extra-long continuous flat press. Under high temperature (200-220°C) and pressure, the mat moves through the press at a constant speed, curing the MDI resin rapidly.
Key Advantage: The continuous press produces boards with an extremely uniform density profile, low internal stress, and excellent dimensional stability. The mechanical properties (e.g., Internal Bond - IB) are far superior to those from discontinuous presses, fully meeting the safety requirements for shelf load-bearing capacity.
| Phase V: Finishing & Processing |
9. Cooling & Trimming: Pressed boards are evenly cooled in a cooler stacker to stabilize dimensions and relieve internal stress. They are then precisely cut to required sizes by cross-cut and edge-trimming saws.
10. Sanding: Boards pass through a 6-8 head heavy-duty calibrating sander to remove the pre-cured layer and correct minimal thickness deviations, achieving the precise 16mm thickness and an extremely smooth, flat surface.
11. Inspection & Packaging: Boards undergo 100% quality monitoring via online systems (e.g., X-ray density gauges) to ensure density, thickness, and mechanical properties comply with shelf board standards like DIN EN 312 P5. Qualified products are automatically stacked, packaged, labeled, and stored for shipment.
Plant-Wide Auxiliary Systems:
Energy Center: Uses waste materials from the process (bark, sander dust, sawdust) as fuel to generate thermal energy for drying and pressing, achieving energy self-sufficiency and environmental benefits.
Central Dust Extraction System: Collects dust from all processes, ensuring a clean and safe production environment.
Central Control System (DCS/PLC): Automation system (e.g., Siemens-based) integrated into a control room for precise control and intelligent management of all process parameters (temperature, pressure, speed, moisture content). This is the fundamental guarantee for achieving the annual output of 300,000 m³ with highly stable quality.
Claim Your Free PB Line Layout! Get end-to-end plant design from strand preparation to sanding. Receive 3D factory plan within 30 days.
Our contacts:
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
