YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

PREPARED BY

JOCELYN G. CORPUZ
LEAD ENGINEER

GRAZEL MAE E. DIOLA

DESIGN ENGINEER 1

RENEE ROSE M. REGINIO

DESIGN ENGINEER 2

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

 CHAPTER 1

Introduction

Process Selection

There are two main processes used to classify the types of boards, the ‘wet’ process

used to manufacture SB and HB without glue and the ‘dry’ process used to manufacture

products such as MDF using adhesive resin.

Process Design 1: Production of Fiberboard Using Wet Process

The initial manufacturing step is breaking the wood down to fibers. Most products

today are made using a disc refining thermo-mechanical process. Defibration processes

generate fibers with lignin-rich surfaces. This is essential as the lignin has an important role to

play in bonding the fibers together in the finished product.

A lot of water is added to the fibers to create dilute mixtures. Other additives such as

glues, water repellents and various forming agents are also added. The mixture is then drained

on wire screens to form webs. Drainage alone does not reduce the moisture content sufficiently

and so the webs are then pressed between rollers to squeeze out more water.

If the factory is making low density (<400kg/m3) fiberboard, often known as softboard,

or insulation board, then the next step is to dry the webs in ovens. The softboard market has

been experiencing something of a revival in recent years thanks to the fashion for floating floors

which require an underlay; and to renewed interest in insulation materials from renewable

sources.

If, on the other hand, the factory is making high density (>880kg/m3) hardboard-type

products then the webs are pressed under high pressure and temperature. The webs have a high

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

moisture content of 65% or more and so hot pressing generates a lot of steam. To help both

liquid water and steam to escape, the webs are placed on screen meshes prior to pressing. This

explains why one face is smooth and the other has an impression of the mesh.

The press cycle of a panel is designed to maximize the removal of water in its liquid

form, as drying the panel requires a lot more energy. Therefore, a typical press cycle has three

stages: initial and rapid high pressure to squeeze out water as a liquid; a low pressure drying

stage; and finally a medium-to-high pressure consolidation phase which defines panel

thickness. The panels are then heat-treated by placing them in an oven for two to four hours at

around 165ºC to improve their water resistance. Unsaturated oil can be applied to panels prior

to heat treating to make tempered panels, which are even more resistant to moisture.

After such a long press cycle and subsequent heat treatment, the panels are extremely

dry and must be rehumidified before they are sent to the customer. Rehumidification is

achieved by passing the panels through a chamber containing a high humidity. The panels are

normally stood on their edge in order to expose both faces and maximize absorption. The final

manufacturing steps are trimming and packaging.

Process Design 2: Production of Fiberboard Using Dry Process

Dry process is usually used for MDF. The husks are crushed into chips, refined into

fiber, mixed with glue and wax and compressed under a high temperature hot press. This in

turn cures the glue which then binds the fiber together to become raw MDF. This raw MDF is

then conditioned, sanded, cut and packed before it is ready for sale.

At the Mat Former, the fiber will be laid out in the correct height and density before

passing through a Metal Detector and a Density Scanner before reaching the Hot Press for

pressing. If either the Metal Detector or the Density Scanner detect any problems within the

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

Pre-Press Mat, the conveyor belt will drop to purge and reject the problematic fiber mat and

prevent it from reaching the Hot Press. At the Hot Press, the fiber mat will be compressed while

undergoing a continuous press and the high temperature in the Hot Press will cure the resin,

activating it to bind the fiber together. This compressed and resin cured fiber will come out of

the out-feed as raw board.

The raw board will then be cut into master panel sizes before it is sent to the Star Cooler

for about an hour for the board to cool down naturally. The master panels will then been stacked

and further conditioning for an additional 3 to 5 days After conditioning, the master panel will

be sent for sanding where the surface is sanded to ensure a uniform smoothness while the

thickness of the board will be calibrated during this sanding process. The sanded board will

then be cut to size, packed and sent to the warehouse where it will be arranged for dispatch out

of the factory.

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

 Desgn 1 Design 2
Constraints Wt% Criteria Wt% Wet Dry
Process Process
a. Clent Specifications 12.07% 2 4
Choice of Process 18.11%
b. Design Team Choice 6.04% 3 4

a. Temperature Range 1.73% 2 5

Process Conditions 6.92% b. Pressure Rage 1.73% 3 3

c. Process Environment 3.46% 3 3

a. Availability 12.43% 3 4

b. By-products Generation 1.81% 3 4

Materials 29.65% c. Storage Requirements 2.85% 3 4

d. Materials Handling 4.74% 2 5

e. Renewable Sources 7.83% 3 4

a. Number of ersnnel 1.35% 3 4

Personnel 4.56% b. Level of Training Required 2.46% 2 5

c. Hazard for Personnel 0.74% 3 4

a. Time of Design & 4 4

5.29%
Construction
Time 11.11% b. Less Processing Time 2.91% 4 3

c. Less Down Time 2.91% 4 3

a. Safety 11.86% 4 4

Methods 29.65% b. Efficiency 11.86% 4 5

c. Versatility 5.93% 3 5

TOTAL 3.05 4.05

Criteria for Process Selection

Table 1. Criteria for Process Selection

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

 The two initially chosen design process underwent a thorough design process selection

using the criteria used in table 1. Table 1 shows that design 2 or the Dry Process was more

favourable process than that of the Wet Process when it comes to manufacturing Medium-

Density Fiberboards.

Process Flow Diagram of Pine Fiberboard

Fig 1. Process Flow Diagram of the Production of Medium Density Fiberboard Process.

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS

Equipment Overview

Screening is a mechanical process which stratifies (divides) particles according to size.

The media (screening surface) opening then accepts or rejects the particles. A screening

medium with predetermined openings used to classify (size) two fractions of a feed material.

The performance of a screen will revert back to five main parameters; motion, install angle of

the unit, screening media and available opening area, carrying capacity of the screen and

material characteristics (dry, damp, wet, sticky and etc.).

A Linear vibrating screen is widely used in mining, coal, refractories, metallurgy,

building materials and other industries. It is usually used for the screening and grading

materials in large, middle and small particles. Linear vibrating screen is designed with dual-

vibration motor drive, two synchronous motors are reversely placed so that the exciter generate

reverse excitation force, the exciting force generated by eccentric block cancel each other out

on the parallel direction of motor axis, and stack together with the perpendicular direction of

motor axis, so its trajectory is linear.

YOUR MODERN SOLUTION TO YOUR MODERN INDUSTRIAL NEEDS