Impact of Hot Pressing Pressure on Medium Density

Fiberboard (MDF) Performance

Waheed Gul, A Khan, A Shakoor

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Waheed Gul, A Khan, A Shakoor. Impact of Hot Pressing Pressure on Medium Density Fiberboard
(MDF) Performance. AAPPS Bulletin, Association of Asia Pacific Physical Societies, In press. <hal-
01612472>

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 Impact of Hot Pressing Pressure on Medium
Density Fiberboard (MDF) Performance
W. Gul 1*, A. Khan2, and A.Shakoor 2
1*
Department of Mechanical Technology,
University of Technology,Nowshera,Pakistan
2
Department of Mechanical Engineering,
University of Engineering and Technology, Peshawar, Pakistan
*Corresponding Author: waheed@uotnowshera.edu.pk

Abstract— This paper investigates the impact of hot pressing pressure onto the MDF Physical and Mechanical properties. It has
been observed that Physical and Mechanical properties of the products are improved but not too much when the maximum pressure
rises from 3.5 MPa to 5.5 MPa. It is indicated from the result that when the pressure is added after the hot pressing, it overcomes the
rebound force and the hot press plate contacts the thickness gauge, only the gauge is subjected to force and the raw board is not affected
too much. Therefore, under the aforementioned test conditions, a maximum pressure of 3.5 MPa can meet the requirement.

Keywords— Hot press Pressure, I.B, MDF, MOE, MOR, Water absorption rate,Thickness expansion rate

I. INTRODUCTION
Medium density fiberboard (MDF) is a type of wood sheet formed under optimum Pressure and temperature by using wood fiber
or other plant fiber as a raw material with the help of urea formaldehyde resin. The density of MDF in production is generally
controlled between 690 – 750 Kg/M3. The raw materials used for MDF are Firewood from nearby plantations and forest, Mango,
Ghaz wood (Tamarix aphylla), Poplar wood (Populus caspica), eucalypt, Wheat straws, Rice husk, Cotton stalks, Sesbania and
Sugarcane bagasse etc.
The performance index of MDF is divided into three categories, i.e. Physical performance, Mechanical performance and
Biological performance. The Physical performance mainly includes Density, Moisture content, thickness swelling etc. The
Mechanical performance mainly includes internal bonding, Modulus of Elasticity (MOE), Modulus of rupture (MOR), screw
holding force (face and side). The Biological performance mainly includes the release of formaldehyde. [1].
Figure.1 shows the whole manufacturing process associated with different work stations, i.e. Material Preparation, fiber
formation, fiber treatment, mat forming and hot pressing, board treatment and ware house. In material preparation section, the
wood is converted into chips through chipper machine. [7]. The chips are then screened to separate the required size. The
confirmed chips are then transported to chips washer through a belt conveyor with iron remover installed over it. These chips are
then washed to improve its quality. They are then transfer to fiber separation section. In fiber Separation Section, the chips are
cooked at a temperature (160 – 180 ºC) @ (6-8 bar) pressure for about 3-5 min to make it softer. About 1-2 (wt %) of paraffin
wax is added to the softened chips to make its swelling resistant. The softened chips are then delivered to grinding chamber.
Where, the materials are mechanically decomposed with the function of water and heat. Pulps are formed and passed in blow line
where urea formaldehyde resin is added into pulp. After this process, the pulp in the form of fiber enters into the dryer. [8]. In
Fiber treatment section, the moisture is vaporized in fiber and controlled it within the required range. The final moisture content

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in the fiber is controlled within 8 – 13 (wt %). In mat forming Section, the fiber is spread evenly into the matting conveyor belt.
Under the function of air blow, the mat of specified thickness is formed. The pre-press dispel the air out of mat and gives strength
to the mat.

Figure 1: MDF Manufacturing Process [wood Force plant]

In Board Trimming Section, the board is cooled and conveying to the longitudinal and transversal saw for cutting. The dust is
removed from sides of board. In Sanding Section, the board is polished to the required size by removing the extra surface. The
board is then inspected and transferred to ware house.

II. METHODOLOGY
Hot pressing is an important process to manufacture the MDF and plays a decisive role on the product quality and productivity.
Hot pressing refers to a process that the raw board under the combined function of temperature and pressure, is subjected to
moisture evaporation, increase of density, glue solidification and water proof agent redistribution. The compositions in the raw
materials are subjected to a series of physical and chemical change to form bonding force between the fibers and form the
products confirming to quality requirements. Plant fiber material is a micro-molecular organic substance complicated in chemical
compositions. Hot pressing process involves the change in geometric shape, chemical change and physical change. There are
some factors which affect this method,i.e. temperature of the process, type of raw materials, separation mass of fiber, moisture
content, resin type and performance, hot pressing method, and the temperature, pressure and time of hot pressing. A multi
opening Hot press is shown in figure 2. The number of hot platens depend upon the production capacity of the plant.

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 Figure 2: Multi opening Hot Press

The press cycle and parameters are shown in the following table 1and figure 3. In table 1, for 16mm board thickness the whole
press cycle time is 280 sec plus position time, i.e. (s1 + 30).

Table 1: Hot Press Parameters for different thickness of board

Th(mm) P1 P2 P3 P4 P5 P6 P7 P8 P9 t0 t1 t2 t3 t4 t5 t6 S2 T(˚c)

8 170 30 40 90 80 20 12 11 10 55 35 15 15 10 15 S1+25 170

11 170 35 45 90 80 19 12 11 10 80 50 15 15 12 15 S1+30 170

16 190 30 40 160 140 19 12 11 10 100 100 15 20 20 20 S1+30 190

18 190 35 45 170 150 16 12 11 10 120 100 15 20 20 25 S1+30 190

S1 is the press closing time normally 10 second. So the total cycle of the hot press for 16mm is calculates as 320 second. The
adjustment is based on the gel time of Urea formaldehyde (UF) resin. Similarly, for different thickness and curing of resin,
different parameters are adjusted. The main function of the pressure during hot pressing is to encounter the rebound force of the
raw fiberboard, further discharges the air out of the raw board, enhances the contact and weaving between fibers and meet the
requirements for thickness and density. The Pressure of the hot press during various stages of board varies from P1 to P7. At P7,
the pressure value in the press cycle becomes constant till the pressure reached to P9.

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 Figure 3: Hot press cycle Graph

The graph shown in figure 3 is formed from the hot press parameters mentioned in table 1.
The main experiment was carried out on 16mm board. Four samples of 16mm MDF were manufactured with initial parameters as
shown in table 2.
Table 2. Initial fixed process parameters for hot pressing

S. No Parameters Value

1 Moisture in fiber 11 %
2 UF resin 10 %
3 Hot press plates temperature 190 ⁰ C
4 Thickness of board to be produces 16 mm
5 Press closing time 40 sec
6 Total press cycle time 320 sec

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 III. RESULTS AND DISCUSSION
Final manufactured MDF properties are concisely summarized in Table 3. The comparative analysis of the well-defined MDF
properties, such as Water Absorption rate (Wt), Thickness Expansion rate (Ts), Modulus of Rupture (MOR) and Internal Bond
(I.B) and density can be accomplished on the basis of Pressure variation under fixed process conditions. Wt ,Ts and density are
physical properties of MDF while MOR and I.B are Mechanical properties of the formed MDF.

Table 3. The final MDF properties at various pressures

P (MPa) I.B (MPa) Wt (%) Density (gm/cm³) MOR (MPa) Ts (%)

3.5 0.67 21.4 0.74 28.7 8.6

4.5 0.7 20.1 0.73 29.4 8.2
5.5 0.74 19.2 0.74 31.3 8.5

Three samples of MDF are produced at Pressure 3.5 MPa, 4.5 MPa, and 5.5 MPa. While during manufacturing the initial
parameters, i.e. preheating time, UF resin, Wax, Press timing and board size were kept constant.
The physical property, Thickness Expansion rate (Ts) of MDF is consummate with Pressure variation ranging from 3.5 MPa – 5.5
MPa. At Pressure 3.5 MPa, 4.5 MPa, and 5.5 MPa, the Ts values were recorded as 8.6 %, 8.2 % and 8.2 % and 8.5 % respectively
as shown in figure 4.

Figure 4: Relationship between Hot Press Pressure and Thickness Expansion rate

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As the Pressure increases from 3.5 MPa to 4.5 MPa, the value of Ts decreases from 8.6 % to 8.2 %, but when we increase the
Pressure from 4.5 MPa to5.5 MPa, the Ts value is slightly increases from 8.2 % to 8.5 %. It means that if we further increase the
Pressure, the Ts value will move in ascending order and the strength of MDF will be reduced. Calculated Ts values also depend
upon the nature of curing of resin used as binder and hot press time and temperature. High Pressure is strictly prohibited for MDF
in normal case of resin curing. While the Ts value according to standard (EN-317) is <12 %.

In record of the manufactured MDF samples, the experimental values of Mechanical adhesive property i.e. Internal Bond (I.B) is
ranging from 0.67 Mpa to 0.74 Mpa for a Pressure range from 3.5 MPa to 5.5 MPa as shown in figure 5.

Figure 5: Relationship between Hot Press Pressure and Internal Bond (I.B)

The I.B value at low Pressure (3.5 MPa) is 0.0.67 Mpa, while for a 16mm MDF the I.B value is standardize (EN-319) as 0.6
Mpa. Hence at 3.5 MPa, the MDF will have a very good strength. But when the Pressure exceeding from 3.5 MPa to 4.5 MPa, the
I.B value is reached to 0.70 Mpa. So at 4.5 MPa, the MDF exceeding from the standard value and strength. If we further increase
the Pressure from 4.5 MPa to 5.5 MPa, a direct relation is setup between Pressure and I.B and the I.B value is continuously
increases.

The samples of MDF are also tested for a very important Mechanical property, i.e. Modulus of Rupture (MOR). The experimental
values of MOR are calculated as 28.7 Mpa, 29.4 Mpa and 31.3Mpa for a pressure range from 3.5 MPa to 5.5 MPa as shown in
figure 6.

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 Figure 6: Relationship between Hot Press Pressure and Modulus of Rupture (MOR)

At low Pressure (3.5 MPa), the MOR value is 28.7 MPa which is below the standard (EN-310) value (≥ 30 MPa). At 4.5 MPa, the
MOR value is close to the standard value, i.e 29.4 MPa. However, at 5.5 MPa, the MOR value is at its peak (31.3 Mpa).
Figure 7 demonstrates the effect of Pressure over the density.

Figure 7: Relationship between Hot Press Pressure and density of MDF

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The physical property, density of MDF is consummate with Pressure variation ranging from 3.5 MPA – 5.5 MPa. At 3.5 MPa, 4.5
MPa and 5.5 MPa, The values of density were recorded as 0.74 g/cm3 ,0.73 g/cm3 and 0.74 g/cm3 .At low Pressure, the density
value is maximum,i.e. (0.74 g/cm3 ). If we increase the Pressure from 3.5 MPa to 4.5 MPa, the density value dropped from 0.74
g/cm3 to 0.73 g/cm3. If we further increase the temperature from 4.5 MPa to 5.5 MPa, the value of density increases from 0.73
gm/cm3 to 0.74 g/cm3.
For systematic judgment of the MDF property, the hot press Pressure values are drawn against Water absorption rate. The water
absorption rate at Pressure 3.5 MPa is 21.4 % as shown in figure 8.

Figure 8: Relationship between Hot Press Pressure and Water Absorption rate of MDF

However when the Pressure increases from 3.5 MPa to 4.5 MPa, the water absorption rate value decreases from 21.4 % to 20.1 %.
At 5.5 MPa, the water absorption rate value is ideal, i.e 19.2 % among all the three values and the strength of MDF is at its peak.

IV. CONCLUSIONS
In this research, the impact of high pressure onto board property under fixed process conditions was described. It was observed
that that Physical and Mechanical properties of the products are improved but not too much when the maximum pressure rises
from 3.5 MPa to 5.5 MPa. It is indicated from the result that when the pressure is added after the hot pressing, it overcomes the
rebound force and the hot press plate contacts the thickness gauge, only the gauge is subjected to force and the raw board is not
affected too much. Therefore, the pressure shall be such as the hot press plate is in contact with the thickness gauge, otherwise too
high pressure will cause the damage to Hot Press plate, deformed the thickness gauge or even affect the thickness and density of
the products. It may also increase the design tonnage and price of the press. Therefore, under the aforementioned test conditions, a
maximum pressure of 3.5 MPa can meet the requirement. In addition, too high pressure in hot pressing process may also affect
the distribution of the board sectional density. Generally, the surface density is high and the density of the core is low, forming a

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density gradient. The main reason causing density gradient is the surface of raw board is in direct contact with the hot press plate,
so that it will be quickly heated, the moisture will be quickly dried, the glue will be solidifies in advance and loses elasticity for
shrinkage. However the core layer of raw board remains its elasticity for insufficient heating and continuous to generate
compression resistance, resulting in reduced compression and decrease density. The layers with different distance to the center
differ in heating, which causes the density gradient. The higher the pressure, the faster the compression and the more obvious the
density difference between each layer. Therefore, to reduce the uniformity of the board density, it is better not to use too high
pressure during hot pressing process. Also too high pressure may cause the steam difficult to vaporize and thus the hot pressing
cycle shall be extended.

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