Chipboard production technology. Press for the manufacture of chipboard. Chipboard manufacturing technology. Raw materials for chipboard

For the production of chipboard, wood raw materials, a binder and a hardener for it are used.

wood raw materials

As a raw material for the manufacture of chipboard, specially prepared chips, waste chips from the woodworking industry and sawdust can be used.

Specially made shavings (the so-called technological chips) are obtained from firewood, small-sized forest raw materials and some wood waste. For its manufacture, chippers are used, which grind wood with special knives. After planing, the chips are dried and divided into fractions. From such shavings the most durable plate with a relatively smooth surface is obtained.

Waste chips are obtained at sawmills, plywood and other woodworking industries. A board made from such chips is inferior to a board made from technological chips both in terms of mechanical strength and surface quality.

Sawdust board has a flat smooth surface, but low mechanical strength. Therefore, sawdust is not used in its pure form: usually only the outer layers of multilayer boards are made from them.

Binder

The binder is about 8...13% of the volume of the board, but the cost of the binder is up to 30% of the cost of chipboard: therefore, its price is very important.

An increased content of resins leads to an increase in formaldehyde emission, which is normalized by GOST, and a very high one also reduces the quality of products. A decrease in the amount of binder increases the yield of defective products and increases the pressing cycle time, which is also undesirable. Therefore, technologists are trying to choose the optimal amount of binder for each batch of wood raw materials.

As a binder can be used:

1. Urea-formaldehyde resins. They dissolve in water and therefore do not protect chipboard from moisture. A plate glued with urea-formaldehyde resins can withstand a single short-term soak in cold water, but with prolonged or repeated or contact with hot water, it quickly swells, loses strength and collapses. The advantages of urea-formaldehyde resins are relatively low price and the absence of phenol. This allows you to use chipboard in residential premises without restrictions. Those are the ones that are used the most.

2. Phenol-formaldehyde resins do not dissolve in water and quite effectively protect chipboard from premature swelling when wet. The downside is the high price and non-zero emission of toxic phenol. It is precisely because of the phenol emission that phenol-formaldehyde resins are used extremely rarely for the production of chipboard.

3. Melamine-formaldehyde and urea-melamine-formaldehyde resins contain melamine, a substance that replaces phenol. Such resins, like phenol-formaldehyde, are not washed out by water, but at the same time they do not contain phenol, which allows them to be used in residential premises. The only drawback of such resins is their high price. It is precisely because of the price that melamine-formaldehyde resins are not widely used and are rarely used in the production of MDF, chipboard and plywood.

The binder consists not only of resins: a certain amount of water is also added to it. The water content depends on the moisture content and the chip fraction. In different layers of multilayer boards, the water content in the binder can be different.

Hardener

The hardener reduces the duration of the pressing cycle and increases the mechanical strength of the chipboard. It can be added to the chips together with the binder or separately from it. When added together with resins, the hardener is more evenly distributed and improves board quality, but if the line is downtime, the hardener dries up and clogs the nozzles. Therefore, it is often added to the forms separately from the binder.

Production stages

Drying of wood raw materials

For the production of chipboard, chips with a moisture content of 2 ... 4% are used. Wood from the warehouse has a much higher moisture content: therefore, the chips are additionally dried in special convective dryers at a temperature of about 500ºС.

Resin

For high-quality pressing, the chips must be evenly covered with a thin layer of binder. Processing with a binder is called tarring. It is carried out in special mixers that spray the binder using nozzles. Modern equipment makes it possible to cover literally every wood particle with a thin layer of resin, and from all sides.

The resinous wood exits the mixer and is fed into the press.

Pressing

Pressing is carried out in special presses, which can have a different design. In any case, the chips mixed with binder hardener are pressed at a temperature of 220 ... 230ºС, then cooled and subjected to additional processing.

There are two types of pressing: flat and extrusion. With flat pressing, the press presses on the future plate perpendicular to its plane - usually from top to bottom. This method makes it possible to obtain multilayer boards, and the strength of chipboard, other things being equal, will be higher than that of extrusion-pressed chipboard. Therefore, at the moment, "flat" technology dominates the market.

During extrusion pressing, a mixture of chips with a binder is squeezed out into the space between the heated plates from the side, and the pressure vector is directed parallel to the plane of the plate. The strength of the slab is lower, but this method makes it possible to obtain ultralight multi-hollow slabs. Extrusion presses are rarely used today.

Press cycle

The duration of the pressing cycle in the production of chipboard is from 30 to 60 seconds and depends on the temperature of the press and the density of the board. The higher the density of chipboard, the longer it must be pressed; the higher the temperature, the shorter the cycle. At the same time, the optimum temperature and duration of pressing are also affected by humidity and chip size, type and amount of binder, quality requirements and characteristics of the press itself. As a rule, technologists empirically select the cycle parameters for each batch of raw materials.

Edge trimming and chipboard cooling

After pressing, the finished and still hot chipboard is cooled and cut to the required format. Pruning can be hot or cold. During hot cutting, a still hot plate enters the sizing machine. This technology improves performance, but during cutting, heated and still soft chipboard can be deformed. With cold cutting, the risk of deformation is minimal. The disadvantage of this trimming is the need to add a fan cooler to the production line, which is rather slow.

Conditioning

After trimming and cooling, chipboard is kept in an intermediate warehouse for 120...140 hours. At this time, the curing of the binder continues inside the slab, it gains hardness and strength. Upon completion of conditioning, the plate is subjected to additional processing.

Finishing chipboard

Finishing is the final stage in the production of chipboard. Most often used:

sanding on one or both sides;
lamination with paper-resin films;
veneering.

Package

Finished chipboard is labeled and packaged in packs. In this form, it is sent to the warehouse or immediately to the buyer.

The production of furniture products is a very profitable business, which ranks second after the construction industry. However, this segment is very busy at the moment, so it will take a lot of effort for a beginner to effectively enter the market.

If the question arises of how to start a business, it is worth saying that many entrepreneurs refuse to believe that it is much more profitable to produce raw materials for the furniture industry than finished products. At the moment, laminated chipboard (LDSP) is a very popular material that is actively used not only for the manufacture of furniture, but also for various interior finishing works.

Of course, chipboard is inferior to wood in a number of parameters, but ease of processing and low cost are its main advantages, so this material is in increasing demand every year.

If you decide to organize the production of laminated chipboard, you should be aware of another advantage of such a solution: at the moment you will have a small number of competitors on the market. The result of this can be called the drawing of a large sales market, since almost all furniture factories are ready to purchase materials for the production of their products.

Chipboard production is a competent business organization

Even a child understands that specialized equipment is required to make something. In this case, it is also needed. The production of laminated chipboard cannot be organized without the following tools:

Special dryer. It is used to make laminated paper.
Press. With its help, chipboard is pressed with such paper.
Calibrating and grinding machine (it affects the quality of the resulting surface).

So, not only the main equipment for chipboard lamination is necessary, but also the accompanying one. First of all, we can talk about a device designed to prepare an adhesive base, which is then poured into molds and pressed into slabs.

Chipboard base

Chipboard, or chipboard, is a fairly popular building material, as well as the basis of laminated chipboard used for furniture production. Chipboard is actively used in the following areas:

in the construction of floor coverings;
in the process of constructing various wall panels;
for the production of furniture, as already indicated;
as roofing material.

Such production can be called processing, since the main raw materials for the manufacture of such boards are waste from wood enterprises.

Production methods

Chipboard can be produced in one of two ways - batch and continuous. The periodic method involves the use of storey processes of periodic pressure, and the continuous method involves the use of extrusion processes.

Features of the manufacture of chipboard

The production process in this case can be divided into a number of main stages:

Preparatory. At this stage, the preparation of raw materials is carried out by crushing wood to obtain chips of the required size. If you immediately purchase ready-made raw materials, then this step can be skipped.

The second stage involves mixing the chips with a binder, which is traditionally used as glue. It is very important to adhere to strict proportions, since with an excess of glue, you can get a product that has deteriorated technical properties, and therefore such plates will be considered defective.

Next, the prepared mixture is placed in special molds, which are then pressed. The influence of factors such as pressure and a sufficiently high temperature allow the material to seize to form a single whole.

Next, the resulting blanks are placed in a special chamber for drying.

After that comes the stage of trimming the edges of the plates.

The final step is sanding the slab.

You can organize production in a warehouse, where you can install not only a chipboard production line, and subsequently laminated chipboard, but also stands where finished products will be stored.

Necessary equipment

If we consider the production option, when all operations are carried out at your enterprise, starting with the procurement of the raw materials themselves, then a number of instruments and machines will be required.

The preparation of raw materials implies the presence of such devices:

equipment processing logs into chips;
drying chambers for chips;
planer;
vibrating sieve.

The material production process involves the following equipment:

apparatus for mixing chips and binder;
forms where the plates will be harvested;
thermopress;
dryer or cooler for products ready for further processing.

To implement the final stage, you will need:

sawing machine, with which you will give the sheet some specific dimensions;
a machine that grinds the ends;
devices for coarse and fine grinding.

The manufacture of laminated chipboard will require the involvement of a press in the process, which applies two-sided lamination. You may need transport devices, such as belt or roller.

About lamination

Initially, the production and lamination of chipboard boards was a very labor-intensive process that required enormous energy costs. Nearly 30 years ago, completely new types of resins were developed, with the help of which it was possible to start using new processes for laminating boards.

During production, it is very important to distribute the load as evenly as possible, which can significantly improve the quality of the plate. A product made in this way can withstand a large number of deformations and loads, which is very important.

Options for how to properly laminate paper have been developed for many years, but now a solution has been found, and it is very effective. The paper is made in impregnating machines where it is processed with resin, which makes it possible to obtain a decorative film from it, which becomes plastic-like under pressure.

As you know, chipboard (chipboard) is widely used for the production of various structures. This material is inexpensive, durable enough, practical.

However, when it comes to use in a residential building, many people have a question: what materials are used to make such plates? And this is understandable: environmental friendliness and safety are an important point.

Now we will answer this question.

What is chipboard made from?

In fact, the manufacturing technology is quite simple. And few materials are used. Namely:

shavings, sawdust;
binder;
special additives.

Now let's take a closer look at what chipboard is made of.

sawdust, shavings

Sawdust is the main material used to make chipboard. Often this is a waste of woodworking, sawmilling enterprises.

Chips and chips can also be used, which are loaded into special crushers before making chipboard, where they are ground into small pieces. In fact, the same sawdust is obtained.

Particle sizes may vary. But basically their thickness does not exceed 1 mm. Of these, the largest go to the formation of the inner layer of the plate. And small particles form its upper layer (due to this, a relatively smooth surface is obtained).

Typically, such raw materials for the production of chipboard are obtained from low-value wood species (coniferous and hardwood).

Binder

In fact, it is a glue, due to which the particles bind (stick together) to each other, forming a solid body. Synthetic resin acts as such an adhesive. Often, glue is obtained by mixing resin, paraffin, chemical hardeners and water.

By the way, you have probably heard that chipboard emits such a harmful substance as formaldehyde. It really is. And… have you guessed where it comes from? Yes, that's right - it is binder resins that emit formaldehyde. These are substances of non-mineral origin.

We can say that the release of formaldehyde is the main disadvantage of chipboard. After all, everyone knows that this substance has a negative impact on human health.

Another thing is how much formaldehyde is contained in chipboard of various manufacturers. This is another question.

Special additives

Not always used. Their purpose is to add special properties to the plates. As a rule, the volume of such additives is approximately 6...10% by weight of wood particles.

Additives can be used that give chipboard fire resistance, moisture resistance, additional strength (flame retardants, water repellents, antiseptics).

Materials for chipboard cladding

Boards intended for the manufacture of furniture and other products can be veneered. Surely you have seen such chipboards many times. It looks very attractive, a variety of colors, shades, textures are available.

The plastic used for facing chipboard gives the boards good moisture resistance. Yes, and the appearance is very attractive. Often such plates are used for the manufacture of kitchen furniture.

In addition, paper, polymer films of various colors and shades can be used as facing materials. By the way, resins, varnishes and other substances are used to strengthen paper.

2016-09-06

It's no secret that chipboard is still the main material for furniture production. Which factories in Russia are engaged in its production, and what are the prospects for their development.

Russia has good prospects and prerequisites for the production of chipboard. This ensures low production costs and the availability of own raw materials. But, even in such conditions, manufacturers do not have absolute confidence in the future, because both domestic and foreign manufacturers are represented on the market. And, although now domestic producers have priority, but they are also forced to withstand fierce competition. To do this, they offer consumers more and more decors at an affordable cost.
According to statistics, the main consumer of chipboard is the furniture industry. In Russia, the largest share in the production of particle board falls on batch pressed chipboard, production occupies 44%. Further 33.8% is CPD. And chipboard with a finished surface occupies 19.7% of the total output. It should be noted that very little chipboard with special properties is produced - only 0.5%.

Where is the production of chipboard concentrated? The leadership in this indicator is held by the Central Federal District - 48.1% of the domestic production of chipboard is concentrated here. This is followed by the North-Western Federal District, where 24.5% of production is located. Siberian and Volga Federal Districts - 11.1% and 9.7%, respectively.

Central Federal District: OJSC Dyatkovo DOZ, CJSC Skhodnya-plitprom, OJSC MEZ DSP and D, CJSC Murom, OJSC MK Shatura, OJSC Fanplit, LLC Kronostar, CJSC Plitspichprom, ZAO Igorevsky DSP Plant, OAO MDOK, EGGER.
The following production facilities are located in the Northwestern Federal District: Pfleiderer Plant, Monzensky DOK LLC, Cherepovetsky FMK CJSC, Sheksninsky KDP LLC, Syktyvkarsky FZ LLC, Karelia DSP OJSC; - Intrast LLC, Zheshartsky FZ OJSC.
Siberian Federal District: Krasnoyarsk DOK CJSC, Ust-Ilimsky DZ OJSC, Tomsk EAF Plant OJSC.
Privolzhsky Federal District: CJSC Nizhegorodsky DOZ, OJSC Novovyatsky LK, OJSC Ufimsky FPC, LLC Uvadrev, CJSC Permsky FC.
Southern Federal District: ZAO Yug, OAO Tomsk DSP Plant, ZAO RNP Volgogradmebel.
Far Eastern Federal District: OAO Amursky MDK.
Ural Federal District: OJSC Tavdinsky FK, CJSC Fancom, OJSC DOK Krasny Oktyabr.

Speaking of wood-shaving materials, one cannot but mention import deliveries. According to statistics, imports still occupy a significant part of the market. Who supplies this material to the Russian market the most? Leading positions among suppliers are occupied by China and Poland - they supply about 49.1% of this production. Plates of German origin make up about 14.7%, followed by Italian manufacturers - 13.3% of all imports.
Does Russia export chipboard to other countries. Yes, but deliveries are made mainly to the CIS countries. Deliveries to non-CIS countries are very insignificant - their percentage is less than one.

The largest productions
There are quite a lot of chipboard production lines - more than 50, new production facilities are also being opened, and many of the existing ones are being modernized and automated, and new technologies are being introduced.

The group is leading the market EGGER, while it is one of those companies that makes large-scale investments in the modernization of Russian factories. In the near future, it is planned to launch the second phase of the EGGER plant in the city of Gagarin, Smolensk region. In the third quarter of this year, it is planned to launch a line for the production of floor coverings at the plant in the Gagarinsky district, and a new mini-CHP, which will run on biofuel, will also start operating.
Most of the foreign companies that have production in Russia are now freezing projects in anticipation of the end of the crisis, EGGER continues to invest. The company is implementing large-scale projects, while considering the Russian market to be promising.
So, at the beginning of 2016, the EGGER plant in Gagarin produced about 2 million cubic meters of chipboard and 100 million square meters. meters of chipboard.

Plant "Kronostar" is also a major manufacturer of wood-based panels, owned by the SWISS KRONO GROUP, which has nine factories in 7 European countries. The plant produces about 1,000,000 cubic meters annually. m of products, including chipboard, chipboard, MDF, LMDF, wall panels, laminated flooring design coverings. At the same time, the products are of high quality, and the plant maintains its status as an environmentally oriented company. In April of this year, the company celebrated its 14th anniversary, the largest investment project in the field of woodworking in Russia is Kronostar (Sharya, Kostroma region).
But not everything can be realized even by this giant. Earlier, the company announced the launch of a second plant for the production of OSB boards, but recently officially announced the suspension of the project in the Krasnokamsky district of the Perm Territory. This is due to the difficult economic situation, but the authorities of the city where the construction was planned still hope that the project will be resumed. There are objective reasons for this, because the investor does not intend to completely abandon his plans, and asked to keep the site, the land for it is the property of the company, and the project has already passed construction and environmental reviews. According to experts, about 300 million rubles have already been invested in site preparation.

OOO Syktyvkar Plywood Factory- the largest manufacturer of large format plywood and furniture boards. The production of the plant is equipped with the most modern equipment of such companies as Rauma Repola, Steinemann, Dieffenbaher. The company can boast of more than one modern equipment, it takes part in environmental protection, significant funds are allocated for the implementation of such projects. The plant produces more than 200 cubic meters of plywood. m per year and particle boards more than 300 thousand cubic meters. m. It has been operating on the market for more than 30 years.

CJSC "Cherepovets plywood and furniture plant" works not only on the domestic market, but also supplies its products to other countries of the world. For this, the company has repeatedly been awarded the "Best Russian Exporter" award. The range of the plant includes more than 40 types of products related to the technology of deep wood processing, from sawn timber to chipboard and laminated chipboard. So, the capacity is - 208 thousand cubic meters. m per year chipboard and laminated chipboard - 10.5 million square meters. m. per year.

Timber complex "Tomlesdrev" focuses on the complex processing of wood, that is, directly sawmilling and the production of chipboard and laminated chipboard. Produces about 15 million sq. m of chipboard and 14 million sq. m chipboard per year.

Plant "Karelia DSP" is focused on the production of laminated chipboard, the production of new products has recently been mastered - moisture-resistant chipboard with a thickness of 38 mm. Products meet high quality standards and fashion trends.

News posted Elena Vasilyeva, company Soyuzstroydetal

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 is a practical, relatively inexpensive, environmentally friendly material that has been a leader 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 the production of products of various types, properties and price categories.

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

single layer
three-layer,
multilayer.

According to the appearance and quality of the raw materials used, particle boards 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.

In order to offer customers a material suitable for different types of work, it is important to think over the formulations of boards 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. It is impossible to do without control over the production process, 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 reducing 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 products 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.