Medium Density Fiber Board Manufacturing Process.pptx

Medium Density Fiber Board Manufacturing Process

1. Chipper Plug Feed Screening Chip Bin Wood yard Digester Dryer Defibrator Fibre Bin Mat Forming Prepressing Hot Pressing Cooling Wheel RB Stacking For Min. 72 Hrs Sanding Grading Warehouse Process Flow Chart Dispatch

2. PROCESS FOR MANUFACTURING ARCHIDPANEL Eucalyptus wood storage area where we keep timber for air dry purpose. Timber Arrival moisture is variable based on seasonal harvesting , During summer average arrival moisture in the range of 48 – 50 %, In winter average arrival moisture in the range – 53 – 55% Optimum moisture for process is 35 % 1. WOOD YARD

3. 2. CHIPPER for chipping the wooden logs After chipping through chipper discharge conveyor, the material transfer to bunker area for storage .

4. 3. SCREENING Before reaching the refiner the chips are Screened by a Brook Screen to remove unsuitable sized chips. The material through Bucket elevator come to screening and here the screening of material can be done and to remove unwanted chips which is below 5mm and above 40 mm Here the screening of chips can be done and we can put <5mm chips in Bunker for fuel to energy plant and we can separate >40mm chips also for energy plant ,besides this only b/w 5mm to 40mm chips we use for production and passes it on refiner area through the tubular conveyor After Screening chips are once again scanned for metal detection. Contaminated & waste chips are removed

5. 3. Chip Bin – Chips are come at refining process ,Which starts with the chips entering a Pre-steaming bin where steamed channelized from the in- house energy plant is injected into the bin under atmospheric pressure to soften and equalize the moisture level in the chips. Here all material store at surge bin area ,here we are doing Pre steaming of wooden chips from steam , We can Equalize moisture of chips here and we can store chips here

6. 4.PLUG FEED SCREW- Chips are discharged into a plug screw where they are compressed and the water is removed along with unnecessary linin & natural oils present in the timber the plug screwed then transports the chips to a digester also Known as The Preheater. Here the washing of chips has been done with water to vanish all the natural resin from the wood chips and to create a plug

7. 5.PREHEATER PREHEATER( DIGESTER)- In preheater cooking of chips has been done , it is also called the digester. The Preheater cooks the wood chips under high steam pressure for approximately 5 to 6 minutes which quickly increases the chips temperature & softens the natural resin that bonds the wood- fiber together. Inner temperature of preheater is 175°-180°c , we are using Y( RAYS) for checking the level of the of preheater

8. 6.DISCHARGE SCREW- Discharge screw is used to discharge material to ribbon screw .here we using ribbon screw to transmit fiber to defibrator 7. DEFIBRATOR - Defibrator has feeder is a fast rotating ribbon type screw ,which gives a uniform feeding to the housing basically in the form of a raw material. H ere the steam from preheater comes at defibrator ,here in this wax is added at defibrator for water proofing In Defibrator there is a stator and rotor here stator is fixed and rotor rotates and there is segment which together crush the chips from preheater and make it fiber here

9. 8. BLOW LINE – Here the fiber after defibrator come to blow line and here the mixing of resin & Color. DRYER STAGE 1 – HOT Gases from Energy plant comes to here and it will dry fiber and maintain moisture . 9. Dryer When the Resin-coated Fibre is transported through Blow line into cyclone ,where through a vortex motion wood fiber is separated from the moisture or air in the 1 st stage of Drying process ,Fiber exiting at the bottom of the cyclone than enters the 2 nd stage drying processes where the moisture of the fiber is measured to accurately control the dryer temperature

10. 10.FIBRE BIN – The material from DDC (Dryer discharge conveyor) put into the fibre bin which enables the operator to maintain a buffer quantity for providing a constant flow of fibre to the mat forming station and there are impact rollers to put material upward , Mat height centre for mat height and weighting scale DRYER STAGE 2- fiber will come from 1 st stage cyclone and put into DDC (Dryer discharge conveyor) .

11. 11. MAT FORMING STATION The matt forming station spread the fiber onto a conveyor forming a continuous fiber mattress according the desired thickness of the final product the spreading controls of the forming station use a scalper system to achieve a critical optimum cross panel mat density , the mat than measured format density as well as format moisture to ensure accurate forming of the mat

12. 12. PRE PRESS – PREPRESS system mat is than prepressed to remove air out of the fiber mattress from fiber and mat uniform , initial press is done and unwanted air from fiber get out and we make initial thickness of board here Provide pre compression mat width is trimmed and travels under a metal detection device while the mat forming is constantly monitored any deviation from the stringent in house specifications mat being rejected before it enters the Daylight Hot press system

13. 13. HOT PRESS Hot press is heated using thermal oil from the energy plant to elevate the resin coated Fiber to its reaction temperature and to ensure bonding of fibres the mat is compressed under accurately control high pressure for ensuring the precise surface core density and thickness Along and Across the mat.

14. 14. BOARD WHEEL COOLER Here we used * mark cooling wheel for conditioning of boards here there are 44 partition for board . 14. RAW BOARD STACKING We just conditioning and than taken to intermediate storage where they are stored to recover to natural atmospheric conditions for Min. 72 hours for sanding and finishing

15. 15. SANDING – Here the sander simultaneously sands the top and bottom surfaces of the boards to create a super fine surface finish 1 st & 2 nd Head – Rough sanding machine- Here we used 2 belts of 40 Greet for rough sanding at top and bottom 3 rd , 4 th ,5 th & 6 th Head -We used 4 belts of 80 Greet and 120 Greet for Fine Sanding at Top & Bottom 7 th & 8 th Head – Final sanding machine – We used 2 belts of 150 or 180 or 220 Greet for finishing and than printing be done as per pattern wise

16. GRADING:- MDF grade 100 % Material Grading Int o A grade , B grade & C Grade material divides separately and than send to WAREHOUSE AREA

17. 17. WAREHOUSE & DISPATCH The final panels are then greeted, stacked and stored to be dispatched to our customers ,After Grading the boards are stacked as per date and shift wise As per lot and than send to customer as per order wise.

18. QUALITY CONTROL CHECKING FOR PRODUCING BEST PRODUCT Incoming Timber - 100 % Consignment– 1. Separate Unwanted Logs 2. Moisture Content Incoming Wax- 100% Consignment 1. Check All Properties As per Specification. 2. Reject the Consignment in case of doesn't meet the quality standard Incoming Resin- 100% Consignment 1. Check All Properties As per Specification 2. Reject the Consignment in case of doesn't meet the quality standard RAW Material

19. Wood chips - Every 6 Hrs. 1. Separate Unwanted Logs 2. Moisture Content Raw Board - Every 3 Hrs. 1.Length , Width & Thickness 2. Density , Density Variation 3.Modulus of Rupture 4.Modulus Of Elasticity 5.Internal Bond 6.Water Absorption 7.Screw Holding 8.Moisture Content Fibre- Every 3 Hrs. 1. Moisture Content 2. Sieve Analysis 3. PH SFG Material Online Resin Test – Every 12 Hrs. 1. PH 2.Water Tolerance 3.Viscosity 4.Gel Time

20. Finish Board - Every 6 Hrs. 1.Length , Width & Thickness 2. Density , Density Variation 3.Modulus of Rupture 4.Modulus Of Elasticity 5.Internal Bond 6.Water Absorption 7.Screw Holding 8.Moisture Content 9.Thickness Swelling 10. Surface Swelling 11. AWR Internal Bond 13.Formaldehyde Emission 14.Online Sample Grading Check in Every 3 Hrs. FINISH GOOD Material Finish Board Grading 1. 100% Check 2. Physically Defects and Grade As per quality Norms. 3. Grading as per Quality In Multiple Grades