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Technological cycle for obtaining wood chipboards. We create our own chipboard production business: equipment and business plan Chipboard production technology

Among the universal composite materials based on wood, it stands out. The production of chipboards is carried out on the technological lines of large wood processing plants and small enterprises.

The essence of the process of obtaining the material is to mix the sawdust mass with an adhesive agent and compress this mixture at high pressure and temperature. Essential mainly in the production of wood-based panels is the use of sawmill waste.

Pressed sheets have high mechanical strength due to the combination of sawdust and resin (adhesive mass) that has solidified to a stone state. For the production of environmentally friendly varieties of material, low-toxic adhesives are used.

Equipment

The technological cycle of production is based on the use of simple and efficient equipment, integrated into a complete system. The use of high-tech lines for the production of slabs is not required, although setting up and maintaining the performance of all units is a complex and non-trivial task.

The chipboard production line includes:

  • mixers - necessary to obtain a homogeneous mixture of sawdust and glue (resinous substances with technological additives and hardeners);
  • molding devices - give a viscous mixture a shape;
  • apparatus for hot pressing and machine tools - are necessary for a complex thermal and mechanical effect on the formed workpiece;
  • coolers - used to accelerate the cooling of hot plates;
  • devices for trimming sidewalls - remove edges from sheets;
  • grinders - give the formed surface smoothness.

All devices work automatically. Current quality control is carried out in parallel with maintaining the system settings at a given level.

On the video - how chipboard is made at the factory:

Manufacturing technology

The raw material for chipboard production is wood chips and wood waste. The working cycle allows the transformation of substandard viscous mass into finished sheets of material.

The main production steps include:

  • collection of raw materials (wood chips and sawdust) at the wood chips exchange (warehouse);
  • material preparation (grinding) in the chipper shop;
  • drying to obtain an optimal state for gluing;
  • sifting chips on automatic sieves and sizing (fineness);
  • mixing large and small fractions of wood chips with each other;
  • adding a binder (resin);
  • the direction of the viscous mass in the molding machine, which determines the shape of the chipboard;
  • pressing under pressure of 20-40 kgf/cm2 at a temperature of 180-220 ºС;
  • plate cooling;
  • trimming edges and sawing to size.

Produced both during the manufacturing process and after receiving finished products. Storage of sheets of material is carried out in blocks stacked on pallets - wooden pallets.

Certificate of conformity

Certification of wood chip products is carried out in three areas:

  • general requirements of regulatory documentation (GOST, TU);
  • fire safety standards;
  • sanitary standards.

The certificate of normative and technical conformity is issued by the state certification body. To check the parameters of wood products according to the requirements of sanitary standards and fire regulations, please contact the relevant territorial authorities.

Features of chipboard lamination

The lamination process consists in applying a resistant melamine film to the surface of the plate, which improves aesthetics and does not require additional processing.

The production of laminated boards is as follows:

  • selection as the source material of the most dense and durable plates with low moisture content;
  • coating with a primer to ensure better adhesion of the laminate;
  • application of several (no more than three) layers of paper impregnated with melamine resin filler. The paper gives the film mechanical strength, and the color of the outer layer forms the appearance of the material. The procedure for applying layers is accompanied by pressing at an elevated temperature;
  • abrupt cooling of the surface, sometimes accompanied by watering.

The surface of the chipboard sheet must be carefully polished before lamination. The slightest residual irregularities will lead to damage to the laminating layer and product defects.

Laminating solid sheets of chipboard at home is quite difficult to perform qualitatively, therefore, most often, ready-made industrial chipboards are purchased for further use.

The video will tell about the features of manufacturing laminated furniture chipboard:

Milling

Obtaining internal curly surfaces and external processing of corners is carried out using milling. The cutter is a serrated cutter having an arbitrary regular shape (cone, trapezium, truncated figures, etc.). Unlike working with harder materials, chipboard is machined through its entire thickness to avoid chipping.

Preparation is carried out, which consists in preliminary cutting out the contours of the planned figures with a circular saw or a jigsaw. Processing is carried out with a manual or stationary milling cutter. In this way, cylindrical and oval holes of any size are obtained, ensuring the aesthetics of the finished product.

Making chipboard at home

The production of wood-based panels can be carried out on a small scale of production or subsidiary farming. The main limitation is the size of the resulting slabs - no more than 50 × 50 cm.

Manufacturing technology is a miniaturized industrial process in which automatic steps are replaced by manual labor:

  • mixing sawdust in a small container (10-15 l);
  • adding a binder and ensuring complete impregnation of the sawdust mass;
  • shaping with little pressure;
  • hot pressing of the workpiece, which requires special equipment;
  • cooling the resulting chipboard fragment in air and trimming the edges.

The gluing of the laminate is carried out in the same baking press that is used to obtain the rough uncut material. There are ready-made coatings for wood-based panels that can be "fry" to the surface with an iron. They improve the appearance of chipboard, but are not fully laminating.

The main layers in the manufacture of the plate

Manufacturers and factories in Russia

The slab business is very profitable because. However, it is associated with the need to purchase expensive equipment and hire qualified personnel. There are small enterprises that produce small batches of chipboard.

The largest and most famous associations (factories) include:

  • "Russian laminate" - located in the Moscow region and has been operating since the beginning of the 90s;
  • "Cherepovets FMK" - is engaged in the production of plywood and chipboard;
  • Flyderer is a Novgorod enterprise, which is a subsidiary of a Polish company;
  • Plitspichprom is a Kaluga manufacturer of a wide range of wood products, including chipboard;
  • "Krasnoyarsk DOK" - offers a large selection of wood materials, using a chipboard production line to increase wastelessness.

The production of chipboards belongs to a technological and cost-effective production line. The increase in the competitiveness of products is due to the improvement of environmental performance and fire safety. Timely control of products allows you to fix deviations from the requirements of the technological regulations in time and minimize the number of defects.

Now many Chinese firms offer in Russia equipment for chipboard plants with a capacity of 10.0 to 100.0 thousand m 3 per year. The cost of this equipment is very attractive, especially against the backdrop of a sharp rise in the price of European equipment due to the depreciation of the ruble.

The paradox of the Chinese market lies in the fact that, along with the most modern lines, equipment based on the technologies of the 1950s is produced in China. According to the prospectuses of some companies, you can study the history of technical progress in the production of chipboard. But there is a very serious demand for such equipment. So, since 2009, only Kunming Panel Machinery Factory has produced almost 180 simple six- and one-story lines for the production of 4-8 feet (1220-2440 mm) boards!

On fig. 1 shows a general view and diagram of a mini-plant line typical for China for the production of chipboard with a capacity of 10.0 thousand m 3 per year. There are a majority of lines of such capacity in China, and they are used mainly in rural areas for processing waste from logging and woodworking industries located near the slab plant. The products of these slab mini-factories are consumed locally. Everything is quite logical. Transportation costs for the delivery of raw materials and finished boards are minimal. The Chinese are prudent about wood - everything goes into business, starting with branches and branches, shavings and sawdust, and ending with cotton processing waste, bagasse, bonfire, and bamboo.



Rice. 1. General view and scheme of the pallet pressing line with a 5-storey press with a capacity of 10.0 thousand m 3 per year:
1 - forming machine; 2 - loading conveyor; 3 - loading whatnot; 4 - loading traverse; 5 - hot press; 6 - unloading whatnot;
7 - unloading beam

The design of the press is simplified to the limit. The formed carpet is single-layered. No prepress, fan cooler and pallet return conveyor. Serve such equipment 7-10 people. Power consumption - 120-200 kW.

Working principle: the forming machine pours the carpet onto a metal pallet, which is rolled up along the roller conveyor into the loading rack; after filling the bookcase, the traverse pushes all pallets with chipboard briquettes into the press, it closes; after the specified holding time has elapsed, the press opens and pallets with an unedged plate are removed from it by a traverse onto an unloading trolley; the separation of the boards from the pallets, the return of the pallets and the stacking of the boards are carried out manually. Finished slabs are cut to size on a format-cutting machine.

In China, more efficient pallet pressing lines were also produced, which were copies of the Soviet SP-25 lines.

The Chinese ordered the first factories for the production of chipboard in Germany in the late 1980s. Bison has supplied one-story steel belt press lines with a movable forming machine to China. And already in 1983, Xinyang Woodworking Machinery Co., Ltd produced its copy with a capacity of 30 thousand m 3.

Similar lines are being produced now. On fig. 2 shows a general view and diagram of a line manufactured by Shanghai Machine Tool Works Ltd. It works as follows.



Rice. 2. General view (from the side of the forming machine) and a diagram of the steel strip pressing line with a movable forming machine and a one-story hot press: 1 - movable forming machine; 2 - steel tape; 3 - dividing saw; 4 - one-story press; 5 - receiving conveyor;
6 - fan cooler; 7 - sizing saw

The molding machine, moving along the rails, pours a three-layer carpet onto a moving belt. The cross cutting saw cuts the continuous carpet into briquettes. When the press is closed, the forming machine, having reached the hydraulic stops, begins to pour the carpet in the opposite direction onto the already motionless tape. In case of poor-quality filling, the defective carpet passes through an open press and, with the conveyor branch raised, is dumped into the bunker. The finished board is cooled in a fan cooler and then cut to size with a saw.


Rice. Fig. 3. General view and scheme of the line for the palletless method of pressing three-layer plates with a belt-roll press for pre-pressing and a multi-storey hot press: 1 - forming machines for the outer layers; 2 - forming machine of the inner layer; 3 - conveyor;
4 - belt-roll pre-presser; 5 - saw for sawing the edges of the carpet; 6 - dividing saw; 7 - folding conveyor; 8 - pusher;
9 - loading whatnot; 10 - hot press; 11 - unloading whatnot; 12 - fan cooler; 13 - longitudinal saw; 14 - cross saw



1 - top tape; 2 - bottom tape; 3 - tension drum of the upper tape;
4 - tension drum of the lower tape; 5 - pressing rollers;
6 - hydraulic cylinder of the main pressing drum;
7 - driving drum of the upper tape; 8 - driving drum of the lower tape

The most widespread in China are palletless pressing lines with the formation of a carpet on a continuous polymeric tape. The general view of such a line and its scheme are shown in Fig. 3. This technology, known since the 1970s, has proven itself in China. Most Chinese factories are equipped with palletless press lines, essentially the same design. Only the number of forming machines, the format of the manufactured chipboard and the number of press floors vary. The method is simple, as is the operation of equipment well mastered by the Chinese.

Forming machines of the outer and inner layers pour a uniform continuous carpet on the conveyor of the polymer belt. To prevent sticking of the carpet, the tape is sprinkled with talcum powder.

Table 1. Characteristics of the belt-roller
press model TH-MCP manufactured by LINYI
Tianhe Woodworking Machinery Co.,Ltd

Cold pre-pressing of the carpet to give it transport strength is carried out in a belt-roll press. The general view and diagram of the belt-roll press are shown in fig. 4.

The main disadvantage of belt-and-roll presses is a small pre-pressing force and a short impact of pressure on the pressed chipboard carpet - to extend it, Chinese engineers increase the length of the presses and the number of pressing rollers, creating unique designs in their own way.

Characteristics of the press model TH-MCP manufactured by LINYI Tianhe Woodworking Machinery Co., Ltd are shown in Table. one.

The edges of the carpet are sawn with longitudinal saws, and the continuous carpet is sawn into briquettes with a dividing saw. In case of uneven filling, the transfer conveyor rises and the defective briquette is dumped into the bunker located in the pit, where it is crushed in the auger.

The briquettes pass through a system of belt conveyors and are loaded one by one by a pusher onto a shelf, onto pallets made of heat-resistant polymer. The whatnot rises to the upper position, and from it the pallets with briquettes are loaded into the hot press by a loading beam. During the reverse course of the traverse, the briquettes are laid out from the pallets onto the slabs. Simultaneously with loading, the finished uncut slabs are pushed onto the unloading stack. From each floor of the unloading rack, the slabs are fed to the unloading conveyor, from which they go to the fan cooler. From the cooler, the boards are fed to the saw for trimming the longitudinal edges, and then to the saw for trimming the transverse edges.

The main disadvantages of palletless pressing lines based on multi-storey presses: high flow binder to ensure the transport strength of the briquettes, rather large allowances for the thickness of the plate and capacity limitation - no more than 80.0 thousand m 3 per year.

Shanghai Chanho Machinery Co., Ltd and Xinyang Woodworking Machinery Co., Ltd. manufacture pressing lines based on single-deck presses with an annual capacity of 30.0 to 80.0 thousand m 3 . In 2005, Xinyang Woodworking Machinery Co.,Ltd manufactured China's first chipboard production line with a capacity of 60.0 thousand m 3 per year based on a large-format single-deck press with a format of pressed board 2440-14630 mm. A general view of a one-story press and a line diagram are shown in fig. 5.


1 - forming machines of the outer layers; 2 - forming machine of the inner layer; 3 - conveyor; 4 - dividing saw; 5 - accelerating conveyor;
6 - one-story hot press; 7 - receiving hopper of defective carpet; 8 - fan cooler; 9 - cross saws; 10 - longitudinal saws

The press is equipped with a unique high-precision hydraulic system that allows you to control the position of the upper press plate relative to the lower one at several points, which makes it possible to continuously adjust the thickness of the pressed plate according to the format and thus reduce the grinding allowance.

The productivity of most lines manufactured in China varies from 10.0 to 100.0 thousand m 3 per year. Almost all equipment, including wood chips and shavings preparation plants, dryers, mixers, main conveyors, are exact or slightly modified copies of equipment from well-known European companies of different years of production.

Cooperation with well-known European companies Dieffenbacher GmbH, Siempelkamp GmbH, IMAL Srl, and others allowed Chinese equipment manufacturers to reach a fundamentally new qualitative level.

Shanghai Wood-Based Panel Machinery Co., Ltd (SWPM) is one of the largest wood-based panel machinery manufacturers in Asia. The history of the enterprise is more than 60 years old, and the first hot presses were produced by the plant in 1958. Following the purchase of the SWPM stake by Dieffenbacher GmbH in 2009, the joint venture became known as D-SWPM. Chinese specialists got access to the latest European scientific developments and technologies, which allowed them to master the production of modern continuous press lines of the ContiPlus type in the shortest possible time. The Chinese took part in the improvement of the manufactured equipment, having received more than 35 patents for various technical solutions.

Until August 2014, D-SWPM has sold more than 40 ContiPlus continuous lines. Lines for the production of boards with a width of 1.22 m and a length of 23.9 to 48.8 m are produced. A general view of the ContiPlus continuous press and a diagram of the D-SWPM production line are shown in fig. 6.


Rice. Fig. 6. General view of the continuous press ContiPlus and scheme of the D-SWPM production line: 1 - forming station; 2 - conveyor;
3 - carpet density meter; 4 - prepresser; 5 - system for removing defective carpet; 6 - press; 7 - transverse and longitudinal saws;
8 - fan cooler; 9 - stacking system

The productivity of the lines is 150.0-200.0 thousand m 3. Finished plate length 2440-4880 mm, thickness 6-40 mm. The maximum pressing speed is 1500 mm/s.

In addition to continuous pressing lines, D-SWPM manufactures lines based on multi-storey presses with a capacity of 30.0-80.0 thousand m 3 per year. The width of the finished slabs is 1220 and 1830 mm, the length is 2440-5490 mm.

Along with equipment for the production of chipboard, lamination lines of various capacities are produced in China. Many enterprises produce the simplest equipment, the quality of which leaves much to be desired. Such lines are made, as a rule, for the domestic market and, in order to reduce the cost, they are equipped with insufficiently reliable hydraulic equipment of local production. More complex and expensive export lines are equipped with Japanese or German-made hydraulics and Japanese electronics.

Many non-automated lamination lines made in China are successfully operated in the Central Asian republics of the former USSR.

Advantages of lines of this type: low cost of equipment, ease of operation, inexpensive expendable materials and accessories. The cost of Chinese-made press gaskets is significantly lower than the cost of press gaskets manufactured by SESA Srl and Sandvik Surface Solutions GmbH, but the quality of manufacturing and coating of gaskets below. During operation of the simplest lines with manual loading and unloading by unskilled personnel, there is a high probability of damage to the gaskets due to careless handling during replacement or if abrasive particles get on the surface of the gaskets. Therefore, the use of inexpensive Chinese gaskets is the best option.

Along with the simplest lamination lines, automated equipment is also produced in China. It is exported to Turkey, Iran, Egypt, India, Pakistan, Malaysia, South Africa and many other countries.

Table 2. Main technical characteristics of lines
lamination by Suzhou Wude Wood-Based
Panel Machinery Co.,Ltd

Table 3. Some Russian enterprises for the production of chipboard,
equipped with equipment made in China

Suzhou Wude Wood-Based Panel Machinery Co., Ltd produces a variety of laminating lines - from the simplest, with manual loading, to the most modern, designed for the simultaneous lamination of two panels. The technical characteristics of Suzhou Wude Wood-Based Panel Machinery Co., Ltd lines are presented in Table. 2, circuit diagrams shown in fig. 7.

So is it worth buying Chinese equipment for the production and finishing of plates? What are its disadvantages and are there any advantages, besides the price?

Russian chipboard manufacturers still have little experience in operating Chinese-made equipment. Information about some of these Russian companies are given in table. 3.

On the lines of these enterprises, chipboard is produced in a palletless way.

A line with a capacity of only 20.0 m 3 per year (about 60 m 3 per day) was installed at the plant of Kazsib LLC. The design of the line is simplified to the limit. The formation of the carpet is carried out in one layer. Naturally, to get high-quality furniture board with a fine-grained surface on such equipment and using such technology is very problematic. Therefore, the enterprise refused to launch the purchased lamination line and limited itself to the production of building boards.


Rice. 7. Schemes: a - lamination lines with manual paper feed: 1 - roller table; 2 - lifting table; 3 - feeder with vacuum suction cups;
4 - loading mechanism; 5 - press; 6 - unloading mechanism; 7 - lifting table; 8 - roller table; b - automated line:
1 - lifting table; 2 - piece feed mechanism; 3 - brush machine; 4 - stacker of the bottom sheet of paper; 5 - belt conveyor;
6 - stacker of the top sheet of paper; 7 - loading trolley; 8 - press; 9 - unloading cart; 10 - machine for removing overhangs;
11 - fan cooler; 12 - tilter-stacker with vacuum suction cups; 13 - roller table

The technological scheme for the production of chipboard at the plant LLC PK "MDF" is shown in fig. eight.



Rice. 9. Drum sieve sorting of sawmill soft waste and
woodworking

principled technology system when working on such equipment is as follows. Firewood and sawmill waste are fed to a receiving storage table with a transverse chain conveyor, poured onto a belt conveyor, passed through a metal detector and chopped in a drum chipper (loading window size 750 x 400 mm, drum diameter 800 mm, drive power 215 kW). Chips are fed by a belt conveyor to a drum sieve screen to separate the coarse fraction. The conditioned chips are delivered to an inclined belt conveyor that can be moved horizontally, which allows you to pile several piles of chips in the warehouse. From the warehouse, chips are fed into receiving bins with screw discharge conveyors, which unload chips onto belt conveyors that feed them to drum chippers. Soft wood waste (sawdust) is fed by a front-end loader into a receiving hopper, from which it is fed to a drum sieve sorter to separate large fractions, bast, and wood chips. In Russia, drum sorting is not used. In China, such sorting plants are common due to the simplicity of their design (the type of sorting is shown in Fig. 9).

Screened fractions of wood chips and sawdust are delivered to the fuel storage for the boiler house.


b)


a)

Rice. 10. Rotary-tubular chip dryers: a - single-rotor (operated at the PK "MDF" plant); b - two-rotor (operated at the SibPromInvest plant)

Raw shavings are fed by a pneumatic conveying system into raw shaving bins, unloaded by bottom screw conveyors onto belt conveyors and fed into thermal oil rotary-tubular chip dryers. The dryers are heated with thermal oil, the temperature of which is 200 ° C. The initial moisture content of raw chips is 40-60%, the final one is 2-3%.

Dryers of this type have not previously been operated at domestic plants. Rotary tube dryers were used at the dawn of the industrial production of chipboard - in the early 1960s, when specialized equipment for the production of boards was not yet produced, and equipment intended for other industries was used: food, chemical, etc. Later rotary tube dryers have almost universally been superseded by more efficient drum or other types of dryers. However, rotary tube dryers are still being manufactured in China.

The principle of operation of rotary tube dryers is as follows: a bundle of tubes of the rotor, heated from the inside by thermal oil, slowly rotates in a fixed housing and moves the chips to be dried through the dryer along its axis. The blades on the periphery of the rotor lift the chips along the perimeter of the housing, and they fall down through the tube bundle, drying due to contact with the tubes and hot air convection.

From dryers, dry chips are fed by augers to mechanical sorting. The chip fraction for the inner layer is fed by pneumatic transport into the dry chip hopper of the inner layer, the fine fraction is fed into the dry chip hopper of the outer layers. The coarse fraction after regrinding in a fine grinding mill is fed for re-sorting. From the bunker, the chips are poured into the weighing hopper, and from it it is dosed into the high-speed mixer of the inner layer. The pitched chips are fed through the belt conveyor to the screw leveling conveyor for loading the inner layer forming machine.

From the outer layers chip bin, the chips are fed by a belt conveyor to the weighing hopper, and then dosed into the high-speed mixer of the outer layers. The pitched chips are discharged onto a conveyor belt and then fed to the screw screed conveyors loading the outer layer formers, which spread a uniform continuous carpet onto the conveyor belt.

On fig. 11 shows a diagram of the outer layer forming machine. Fractionation of chips and formation of a carpet are carried out mechanically, using rotating knurled rollers.

Compared to the rollers used in the CrownFormer system from Siempelkamp GmbH, as well as in the similar system from IMAL Srl, the Chinese-made rollers have a simplified geometry. However, the quality of carpet formation they provide is quite satisfactory.

In the belt-roller press, cold pressing of the carpet is carried out. The edges of the carpet are sawn with longitudinal saws, and the continuous carpet is sawn into briquettes with a dividing saw.

In case of uneven filling, the transfer conveyor rises and the defective briquette is dumped into the bunker, where it is crushed in the auger. Chips after grinding are fed by pneumatic transport into raw chip bins.


2 - leveling rake; 3 - bottom weight conveyor;
4 - needle dropping roller; 5 - forming rollers

The briquettes pass through the conveyor system and are loaded by a pusher one by one into the loading rack. The whatnot rises to the upper position and the hot press is loaded from it by the loading traverse. Simultaneously with loading, the finished uncut slabs are pushed onto the unloading stack.

Heating of press plates is carried out by thermal oil. From each floor of the unloading rack, the slabs are fed to the unloading conveyor, from which they go to the fan cooler. From the cooler, the boards are directed to a saw for trimming the longitudinal edges, and then to a saw for trimming the transverse edges. The cut-to-size boards are fed to a stacker, from which the packs of boards are transported by forklift to an intermediate holding warehouse before grinding.

A line from Sanda Machinery Co., Ltd (PRC) was installed at the grinding-sorting section. The line consists of a two-head calibrating machine type SM2213/2R, a four-head calibrating and grinding machine type SM2413/2R 2C, a system of conveyors and sorting pockets.

The operation of Chinese-made equipment revealed its main drawback - high binder consumption: 130-140 kg/m 3 . This negatively affects the cost of production and the competitiveness of finished products. However, only at such an expense is the transport strength of the briquette sufficient so that it does not collapse when moving along the conveyor or loading into the press. Most Russian factories in the production of boards consume much less binder - 100-110 kg / m 3, and modern factories, using the technology of continuous pressing in belt presses, the consumption is even less - 65-75 kg/m 3 .

One way to reduce the consumption of resin can be the use of liquid lignosulfonates in the binder, which increase the stickiness and transport strength of the briquettes. Another way is the synthesis of resins with high stickiness directly at the factory. LLC PK MDF managed to master the synthesis of resins with high stickiness from urea-formaldehyde concentrate KFK-85.

Chip fires often occurred during the operation of the dryers at SibPromInvest LLC. There have been cases of pops and wood dust explosions. Although the pneumatic transport system for dry chips from dryers was equipped with modern equipment for detecting sparks manufactured by GreCon (Germany), the fire extinguishing system turned out to be ineffective, and additional hatches had to be made in the pipelines of the pneumatic transport system to eliminate frequent fires.

Similar problems were observed at the Kazsib enterprise. In addition, it turned out that when drying chips with a moisture content above 60%, the productivity of the dryer dropped sharply, so the rotary dryer at this enterprise was replaced by a drum dryer.

Fires and explosions are also not uncommon during the operation of drum dryers, however, the causes of chip ignition in them are different than in rotary tube dryers.

The main causes of fires in rotary dryers include the sticking of dust and resinous substances on the inner surface of the dryer and the rotor tube with subsequent ignition, the presence of pockets (deposits) of dust and resinous substances outside the mixing radius with overdried and even charred chips. In addition, the temperature of the pipes in the dry chip zone is almost the same as at the feed end, and already dried chips with a moisture content of 1-3% come into contact with the rotor pipes, the temperature of which is 220 ° C, and this can lead to chip ignition. During the operation of dryers at SibPromInvest, thermal oil leaks were also noted at the places where the rotor tubes were welded into the dryer.

The only way to reduce the number of fires is to regularly clean dryers and air ducts from wood particles and wood dust adhering inside.


Rice. 12. General view of the lamination line based on a short cycle press
type YL1200-3, operated by LLC PK MDF

Rotary dryers also have a number of advantages. This is high efficiency, since the coolant circulates in a closed circuit and there is no heat loss along with the exhaust gas-air mixture, as in drum dryers. During the operation of rotary dryers, the emissions of drying products into the atmosphere are minimal. There is no direct contact between the drying agent and the chips, and its surface is not contaminated by combustion products. The dryers are heated by thermal oil boilers operating on coal and bark and wood waste, which is economically feasible in non-gasified regions of Russia.

PK MDF LLC also operates a lamination line based on a 1200-ton YL1200-3 short cycle press manufactured by Wuxi City Xunma Hydraulic Pneumatic Co., Ltd (Fig. 12).

Heating of plates is carried out by thermal oil of the MT-300 brand from an electric boiler with a power of 250 kW. Pressing modes do not differ from those adopted on automatic lines. Cycle time - from 18 to 30 s depending on the color and density of the film. Press temperature - 190-200 °C. The productivity of the line is 50-70 sheets per hour.

As a conclusion

The following advantages of Chinese-made equipment for the manufacture of chipboard can be distinguished: low cost, ease of maintenance and operation, high maintainability.

The disadvantages include: high consumption of binder for the lines of the non-pallet pressing method, low productivity of rotary tube dryers when drying chips with a moisture content above 60%; the fragility of some components and parts.

In general, Chinese equipment, with a competent approach to procurement and selection of a manufacturer, can serve as a completely reasonable alternative to European-made equipment for a plant with a capacity of 60.0-100.0 thousand m 3. Mini-factories with an annual capacity of 10.0-20.0 thousand m 3 are too primitive and are only suitable for manufacturing building board. And from an economic point of view, the acquisition of such plants is inexpedient.

Alexander FILIPPOVICH, chief technologist,
Viktor NEMOKAEV, commercial director,
Alexey KIPRIYANOV, Ch. power engineer
LLC PK "MDF"

In pursuit of super-profitable and often overly technologically complex industries, novice businessmen often simply do not pay attention to the simplest materials that different reasons seem to them outdated, unused and unattractive for investment.

Such materials include, for example, chipboard, or chipboard. Many people generally consider this material to be just an attempt to recycle woodworking waste and are surprised to learn that special chippers and chippers are often used in chipboard factories to produce so-called non-commercial wood from non-commercial wood. technological chips - i.e. the main component of chipboard.

But chipboard is used very widely: furniture manufacturers use laminated board in the manufacture of doors, sides, facades, and polished board - for various hidden elements; builders and finishers also widely use wood board- mainly for creating various floorings; in addition, manufacturers of trucks and wagons make partitions and bulkheads from chipboard. Although, of course, the main consumer of this material is furniture production.

But why not produce some more technologically advanced material - the same laminated chipboard or even blanks for modular furniture? The answer is simple - the production of the starting material is much cheaper and technologically (and hence in investment plan) is inexpensive. The production of chipboard requires much less equipment, and the cost of materials, than the manufacture of its derivatives - for example, laminated chipboard.

It is obvious that starting a chipboard production can turn out to be a very profitable business, especially if there is access to cheap raw materials - sawmill waste. The sales market is practically unlimited, so there will be no problems with this.

Technology and equipment for chipboard production

Chipboard is obtained by hot pressing a mixture of chips and thermosetting resin. In general terms, the technology is as follows - the chips are mixed with a binder, and placed in molds, where it is glued together under the influence of high pressure and temperature. Then the finished slab is removed, cooled, cut and polished.

The chipboard production process itself can be divided into several stages: preparation of raw materials, obtaining chips, mixing chips with glue, forming a carpet, pressing and gluing boards, cooling and trimming edges, grinding ends and faces.

By and large, the first two stages are optional if you use imported material. If not, then you will have to purchase a crusher or chipper (160-460 thousand rubles, depending on the type, power, etc. characteristics), as well as a chipper (about 1280 thousand rubles).

As you can see, some additional costs, although small, will still be required, so it makes sense to think about the advisability of working on finished or requiring preparation of raw materials.

However, this issue, due to its financial miserliness, is rather resolved when studying suppliers: are there any relevant manufacturers of technological chips in your city.

Chips are mixed with glue in special mixers (235 thousand yuan per unit), where chips and heated resin with hardeners and other additives are fed. At the same time, it must be remembered that the weight fractions of chips and resin are strictly regulated, and from a violation of their ratio in any direction, a deterioration in the physical and mechanical properties of the product may occur.

The formation of the carpet is carried out with the help of forming machines; they place the resinous shavings into the mold. Pressing and gluing chipboards is carried out in special thermal presses. The total price of the twin forming machine and 8-layer press is only 1,536,000 yuan per set. After the blank sheet is produced, it is cut to the specified dimensions using an automatic sheet cutting machine (88,000 yuan per unit) and fed to polishing.

Chipboard grinding is the final stage of machining in the production process, and the grade depends on the quality of surface grinding: according to GOST 10632-89, first-grade boards should not have recesses (protrusions) or scratches, paraffin, dust-tar or resin stains, chipped edges, chipped corners , under-grinding, surface waviness.

Slabs of the second grade may not be polished at all, but they are used only in construction - for furniture production it is sanded boards that are required, although often chipboard manufacturers purchase second-grade boards and grind them themselves.

For grinding chipboard sheets, grinding machines are used, the choice of which takes into account such parameters as the processing width, the number of grinding heads (usually 2, 4 or 6 grinding heads) and power. According to these parameters, there is a spread in prices - from 440 to 995 thousand rubles.

The above equipment for the production of chipboard is the main one. Additional include vibrating screens; various types of roller, belt, spiral and chain conveyors connecting different units; roller lifting table for laying finished chipboard sheets in packs; ventilation system for removing dust during grinding and some other specific devices (loaders; stackers, etc.).

As you can see, the list of equipment for chipboard production is quite small. However, in addition to equipment, production facilities are also required.

To deploy a full-fledged chipboard production, about 1800 square meters are required. m of the actual production area plus at least 600 sq. m of warehouse space - and this is not counting utility rooms, offices, sanitary and others.

Business prospects for the production of chipboard

Prospects for the production of chipboard are determined by the very specifics of this production. As you may have noticed, sanding, coating and other forms of finishing greatly increase the selling price of boards.

Ideally, first-class slabs are better not to be sold at all, but to be laminated or veneered on their own. This will of course require low cost, however, the sale of such plates occurs at prices much more expensive than usual.

In addition, on the basis of the production of chipboard, it is also possible to organize the production of related materials: MDF, fiberboard, etc., not to mention furniture production.

Laminated chipboard (LDSP) is the main component for the production of cabinet furniture, which authentically imitates natural wood, but much cheaper.

Cheapness due to the use woodworking waste- shavings.

The production of laminated chipboard has several basic technologies.

  • what is chipboard;
  • how the production of chipboard differs from the production of chipboard;
  • what documents regulate the quality of chipboard in Russia;
  • what equipment is used for lamination;
  • How is edging tape made?
  • how to laminate chipboard yourself.

chipboard is ordinary wood chipboard that we talked about lined with a decorative coating.

The coating can be either one-color and smooth, or multi-colored or imitating the texture of wood.

Key features such as:

  • bending strength;
  • ability to hold a screw;
  • density;
  • moisture resistance classes;
  • formaldehyde emission class;
  • flammability

fully correspond to the same characteristics of the source material.

The thickness of the laminated material depends on its purpose. For the manufacture of cabinet furniture, most often take chipboard with a thickness 16 mm, however, table tops are often made from slabs thick 25–38 mm.

Chipboard for wall, floor and ceiling cladding is made of chipboard with a thickness of 8–12 mm.

A laminating layer with a three-dimensional pattern increases the thickness of the chipboard, because such the pattern is created by pressing the base layer, pushing the contours of the pattern on it.

outdoor the film only follows the contours this drawing.

How is chipboard made?

For the manufacture of laminated chipboard, ordinary polished chipboards are used, so they are produced at a chipboard plant, by connecting the lamination area.

Moreover, 3 technologies are used to cover the source material with a laminating film:

  • lamination;
  • laminating;
  • smooth lamination.


lamination

When laminating 1-2 layers of specially prepared paper are glued onto the base, and the first layer - the base - is made as thick as possible so that the pattern can be pushed through it.

The thickness of the base, depending on the depth of the pattern, can reach 0.5–1 mm, the thickness of the second layer is tenths or even hundredths of a mm.

On top of these layers, another one is laid, made of transparent paper and a mixture of various resins, which when heated, they turn into a strong film, reliably protecting the decorative surface.

The main layer is laid on the prepared chipboard surface and pressed down with a hot stamp with a suitable pattern.

The surface temperature of the stamp is 150–220 degrees, due to which the resin impregnating the main layer is mixed with the resin that glues the chips in the chipboard and, paper becomes an inseparable part of the plate.

Then, in the same way, a decorative layer with a suitable pattern and an outer layer protecting the board from damage are glued.

At some enterprises, all layers of the coating are first connected to each other, then dried and, only after that, they are attached to the chipboard.

With this technology, the coating is made in the form of a tape. A pattern is formed on it using a cylinder with an installed matrix, similar to the formation of a pattern during laminating.

Difference with caching in that the tape is fastened without glue, heating the resins impregnating the paper until melted and mixed with the resin in the chipboard.

Laminating

When laminating, first prepare facing material, for which all layers are laid in order and a pattern is printed on them using a cold press.

At the same time, the uncured resin of the various layers is mixed, due to which the coating turns into a wide and long tape.

If a drawing is used to print cylindrical die, then it becomes possible to ribbons of any length.

Many small businesses producing 3D textured laminate prefer do not spend money on expensive equipment necessary for the manufacture of the tape, and buy ready-made material.

The finished tape is sent to the dryer, then wound into rolls, which are delivered to the laminating area. There, the facing material is cut to size and laid on a plate lubricated with special glue, then pressed down with a press and heated until the glue is completely polymerized.

Thanks to this technology veneer goes faster, after all no need to heat each layer of coating separately so the company can produce more products.

The disadvantage of this technology is that the glued lining holding on much weaker than real lamination.

Smooth lamination

This technology similar to caching, however, is a full-fledged lamination, because when heated, the resin of the coating and the plates are mixed, forming a single material. In addition, in the strip preparation area no press to create a pattern.

To create a smooth surface, it is enough to lay 2 layers, the lower of which will be made from paper, and the top one is made of a special film, which, when heated, forms durable and transparent coating.

Due to the fact that large chipboard manufacturers are constantly looking for ways to increase the manufacturability of production and reduce costs, various changes are constantly being made to this process, the essence of which manufacturers keep secret. After all, any improvement in the quality of the laminating coating, as well as cost reduction, makes their products more competitive.

Documents regulating quality

The main document regulating the quality and characteristics of chipboard in Russia is GOST R 52078-2003, which you can find at this link.

There is also international standard EN 14322:2004, which is in many ways similar to the Russian one. You can find him.

These standards differ from those adopted for chipboard only by the requirements for the laminating coating. In everything else they completely identical.

Besides, there are various specifications(technical conditions), which are developed by both manufacturers of laminated chipboard and furniture manufacturers. Specifications prescribe those requirements that are not included in generally accepted standards or, for some reason, are knocked out of them.

For example, in TU can be prescribed non-standard product sizes, and also indicated detailed composition of the adhesive, which differs from what the company uses in the production of conventional chipboard.

Equipment: plant and its components

In most cases, for laminating chipboard, a multifunctional device is used, which is called laminator. Its basis is powerful press with steam or oil heating of the plate, as well as with the possibility of installing matrices with the required pattern.

The laminator can be large, capable of handling maximum sheet sizes, as well as medium or small. If a large press is installed, then after cooling, the laminated sheet enters the cutting machine, which is completely similar to that used in the production of chipboard.

In addition, the laminator can be one or two sided, that is, stick the film only with front side or simultaneously process the front and back planes.

Medium-sized presses are designed for laminating already cut boards, the size of which complies with the requirements of GOST R 52078-2003 and EN 14322:2004.

The small press is designed for laminating finished parts, such as input and interior doors or furniture items. Therefore, the enterprise you should choose a laminator based on the range products.

In addition, along with a large or medium laminator, a tape laying line is often used, which also performs several functions:

  • determines the quality of preparation of the chipboard surface for further processing;
  • lays the tape on the slab and orients it correctly;
  • cut off excess tape.

In factories where small laminators are installed, this operation is usually performed by a specially trained highly qualified worker stacking and cutting the tape by hand. Most often, this is done in furniture factories, when they have to make parts that, for some reason, cannot be cut from a whole sheet.

Similarly, they act in large woodworking workshops or industries that manufacture not only furniture, but also various carpentry products.

The laminator can be used not only for lamination, but also for general gluing, so it makes no sense to spend money on a special line.

Often, after cooling, medium and small slabs are fed to a sawing machine, which cuts 1–2 mm of the slab, forming a smooth edge. Such a machine is equipped with large-diameter circular saw blades with hard alloy soldering or diamond-coated.

They move the plates along the entire line using belt conveyors and vacuum lifters, and all operations are automatic.

The cost of the equipment depends on many factors, so most of the enterprises that produce such lines and individual machines voice the price only after the customer provides specific requirements for configuration and performance.

On Aliexpress and other sites you can find individual devices and entire lines with an indication of the approximate cost excluding delivery and installation.

Medium single-sided laminator for 1220*2440 mm boards can be purchased for 100-200 thousand US dollars, and a 60-120 cm wide laminating tape supply line will cost 18–25 thousand US dollars.

Edge tape

In the manufacture of laminated chipboard, only the front and back surfaces are laminated, and edges remain uncoated. Therefore, enterprises producing laminated chipboard, along with it, also supply edging tape, which is used for self-laminating the ends.

The color of the tape is fully consistent with the color of the plate, so after sticking the tape, the entire plate becomes one-color.

The tape for edging, that is, pasting the edges, is made noticeably thinner than the one used when facing particle boards in production. Indeed, in the conditions of a furniture workshop it is impossible to create such a high pressure and most craftsmen manage with an ordinary iron, warming up the tape laid on the edge.

How to laminate chipboard yourself?

Not always Chipboard, which can be purchased in stores, matches the color or pattern, so you can veneer the plate yourself.

Good for this different kinds decorative films that are sold in hardware stores.

Films are self-adhesive and conventional.

To apply a self-adhesive film, a thin protective coating is removed from it and placed on a chipboard sheet cleaned of dirt and dust, then rolled with a roller, removing air bubbles.

To apply a regular film, use a special adhesive recommended by the film manufacturer, then wait 2-5 minutes and carefully apply the film, do not allowing wrinkles to appear.

Such methods allow you to stick on chipboard only those drawings that are in the store, so you can use the method that was used in the days of the USSR when chipboard was in huge short supply.

A thin layer of primer (PVA diluted with water in a ratio of 5:1) was applied to the chipboard surface cleaned from dust and dirt. Then, the desired drawing was made on sheets of landscape paper and PVA was primed on the reverse side.

After 2-4 days, when the glue had completely hardened, the sheets with the pattern were laid out on the surface of the chipboard in such a way as to bring the pattern together. Then each sheet was heated with an iron.

If all the sheets were correctly laid and heated, then after cooling they formed a continuous pattern that completely covered the entire surface of the plate.

However the shift of any of the sheets led to a violation of the pattern and spoiled the whole picture, therefore, for greater reliability, they tried to get not landscape, but printing paper, which was larger than the plate.

The finished drawing was covered with furniture or parquet varnish in 2-3 layers and a home-made laminate was obtained. with low coating strength, but with the necessary pattern.

Related videos

On this video you can see the work of the chipboard production plant:

Conclusion

The production of chipboard is difficult process, which includes many operations, therefore, to turn ordinary particle boards into laminated ones, it is necessary site with good facilities.

After reading the article, you learned how the lamination process takes place and whether you can do it yourself.

In contact with

Almost any construction business is profitable and, with a competent approach to business, regardless of seasonality, quickly pays off. And especially promising here is not even the provision of services to the population, but the direction of the production of high-tech materials that are in demand among consumers. Such business ideas include the manufacture of chipboard (chipboard). The production of laminated chipboard will be in demand among buyers if the process is thought through to the smallest detail and lucrative contracts are concluded with customers. Chipboard - practical, relatively inexpensive, eco-friendly material, which has been occupying a leading position in the construction niche for many years. It is actively used in the manufacture of furniture, in the construction of roofs and floors, in the construction of interior and room partitions.

Our business valuation:

Starting investments - from 8,000,000 rubles.

Market saturation is average.

The complexity of starting a business is 7/10.

The production and sale of chipboard, despite the simplicity of the technology and the availability of equipment, will be associated with many problems, the main of which is high competition. Surely, in every region there is a woodworking enterprise engaged in the production of particle boards. And therefore, in order not to waste money on launching production, it does not hurt to first analyze a specific sales market. There are a lot of potential customers, and a couple of wholesale consumers will be enough for a small enterprise to stay afloat.

So, how to open a chipboard production in Russia that is competitive and profitable?

What assortment to offer consumers?

Chipboard production as a business will only make a profit when any client who contacts the company finds what he was looking for. Given this, it is important to establish production different kind, properties and price category.

Experts distinguish many classifications of chipboard. The main one is gradation by the number of layers:

  • single layer
  • three-layer,
  • multilayer.

By appearance and the quality of the raw materials used, chipboards are divided into grades:

  • Grade 1. Material with even edges and a smooth surface.
  • Grade 2. Material with minor violations of the integrity of the structure - scratches, chips.
  • Grade 3. The material can be attributed to defective products.

To offer customers material suitable for different types works, it is important to think over the recipes of plates that differ in density:

  • low density - up to 550 kg / m 3,
  • medium density- 550-750 kg / m 3,
  • high density - over 750 kg / m 3.

It’s great if the chipboard manufacturing process involves finishing the material with polymer films, veneer, plastic or paper.

It is important to think over the assortment at the initial stages of starting a business, since many subsequent steps will depend on this - the purchase of raw materials, the purchase of equipment.

Description of the chipboard manufacturing process

Technological scheme for the production of chipboard

Even if a small do-it-yourself chipboard production is planned, it is important to study in detail the material production technology. The quality of the finished product will also depend on the quality of the technological stages.

The main advantage of this direction is the simplicity of the technology. All stages of the production chain are interconnected, and it will not be difficult to understand them even for a person far from the industrial sphere.

The main raw materials that will be supplied to the workshop are sawdust, small wood waste. The components used are widely available and inexpensive. And to make chipboard production less expensive, it would be nice to arrange direct supplies of raw materials from local woodworking enterprises. It is quite natural that the closer the supplier, the cheaper the cost of raw materials.

It is a common practice when furniture factories rent out production waste at a lower cost (or even completely free of charge), and in return receive high-quality chipboard from an entrepreneur at an attractive price. Here is such a barter turns out.

Chipboard production technology is hot pressing. The scheme is this:

  • The raw material is dosed and mixed with a binder - a thermosetting resin.
  • The mixture is poured into special molds.
  • Forms with a mixture are subjected to high pressure and elevated temperature.
  • The resulting plates are taken out of the molds, if necessary, they are additionally processed - they are cut, polished, pasted over with decorative materials.

Despite the fact that the production of furniture chipboard is very simple, when organizing a full-fledged workshop, you should hire a qualified technologist who will strictly control the quality of input raw materials and all technological modes. No control over production process cannot be dispensed with, because here, as in many other areas, the rule applies - the better the product, the more profit it will bring.

Technical equipment of the workshop

Production line for the production of chipboard

After the assortment has been thought out and the technology has been studied, you can proceed to the next stage of organizing a business - to buy equipment for the production of chipboard. And this stage is one of the most important, because it is the most expensive.

It will be difficult to organize a home business for the production of chipboards, because the financial investments here are quite large - not every aspiring entrepreneur will be able to start a workshop without attracting outside investment.

The "middle" line for the production of chipboard includes the following machines and devices:

  • Mixers with dispensers.
  • Forming machines.
  • Thermopresses.
  • Coolers.
  • Machine for trimming finished boards.
  • Grinding machine.

The designated equipment implies the use of ready-made components for the production of chipboard - sawdust and shavings. But if it is planned to organize a full-cycle plant (that is, with grinding boards and logs), then additional component lines will have to be provided - crushers and a sieve.

The price of equipment for the production of chipboard is quite high, and the final cost of the devices will depend on their capacity, degree of automation and configuration. For example, a fully automated line, where all production steps are carried out without human intervention, and with a capacity of up to 150 sheets per shift, will cost at least 17,000,000 rubles. But even lines of lower productivity (up to 50 sheets per day) will be too expensive for many entrepreneurs - at least 8,000,000 rubles.

Given the considerable cost of equipment, it makes sense to think about some savings options:

  • Used equipment costs 2 or even 3 times cheaper than new.
  • By leasing the line, you can avoid the huge initial investment.
  • Chinese machines can cost significantly less than equipment from European brands.

Profitability of the chipboard production business

Many entrepreneurs have already proven in practice that a mini-plant for the production of chipboard, with well-established distribution channels, brings consistently high incomes to its owner.

The sooner you manage to establish sales to wholesale customers, the sooner all costs will pay off. At first, it will be difficult for a young enterprise to enlist the support of large wholesalers. But even here it is quite possible to achieve success, for example, by slightly lowering the prices for the supplied products.

Before starting to calculate the profitability of the enterprise in the business plan, it is necessary to present those capital expenditure items that will have to be incurred to open the enterprise. According to minimal estimates, the launch of a small workshop will require costs in the amount of ≈8,000,000 rubles.

This includes the following items of expenditure:

  • Purchase and installation of equipment on site.
  • Purchase of raw materials.
  • Preparation and rental of premises.
  • Company registration.

And these costs will increase significantly if you buy a machine for the production of chipboard of greater power. But for starters, a line of low productivity will suffice.

Speaking about the profitability of a mini-factory, it is hardly possible to give exact figures, because everything here is strictly individual, given the prices for finished goods in each region and sales volumes. On average, chipboard is sold at a price of 6500-10000 rubles / m 3. The cost of the same material varies between 4000-6000 rubles.

In the absence of problems with sales, the company can go to zero after 2 years. And these are excellent indicators of profitability.