Stage 1: Bamboo Preparation  

1. Splitting: Automated bamboo splitter → 25mm strips  

2. Steaming: 160℃ saturated steam × 90 mins (lignin removal ≥92%)  

3. Fiber Refining:  

   Defibrator: 0.85MPa steam, 0.1mm disc gap  

   Fiber yield: 88.3% (screen analysis: >20 mesh ≤5%, <100 mesh ≤12%)  

Stage 2: Moisture Modification  

4. Resin Formulation:  

   Melamine-modified UF resin (MF:UF=1:4)  

   Nano paraffin emulsion (particle size ≤100nm, dosage 1.2-1.5%)  

5. Blending:

   High-pressure glue blender (atomization pressure 2.8MPa)  

   Resin distribution uniformity ≥95%  

Stage 3: Pressing & Curing

6. Mat Formation:  

Layer	Fiber Fineness	Density	Function
Surface	120-150 mesh	780kg/m³	Moisture barrier
Core	60-80 mesh	720kg/m³	Stress absorption

7. Hot Pressing:  

   8' continuous press line  

   Temperature profile: 180℃ (pre-press) → 220℃ (main) → 150℃ (cooling)  

   Pressure gradient: 8MPa (0-5s) → 30MPa (5-15s) → 18MPa (15-25s)  

Stage 4: Finishing  

8. Cooling: Roller cooler (160℃ → 45℃)  

9. Calibration:

   BINZEL 3-stage sander (60→120→240 grit)  

  Thickness tolerance: ±0.08mm on 1220×2440mm panels  

10. Edge Sealing: PU waterproof coating (8-10g/m application)  

1. Raw Material Preprocessing  

11. Multi-stage Bamboo Shredding Unit  

  Working Principle: Three-stage progressive shredding with high-speed blades  

   Key Components:  

     Primary shredder: Hydraulic hammer rotor (Φ1200mm)  

     Secondary cutter: Twin-screw shearing discs (HRC58-62)  

     Screening module: Vibrating sieves (10/25/50mm apertures)  

1.2 Steam Softening Tunnel  

   Working Principle: Saturated steam dissolves lignin in bamboo chips  

   Key Components:  

     Pressure vessel (0.8-1.2MPa working pressure)  

     Chain conveyor (0.5-3m/min adjustable speed)  

     Condensate recovery system  

2. Fiber Preparation System  

2.1 Thermo-mechanical Refining Unit  

   Working Principle: High-pressure steam fiberization  

   Key Components:  

     Preheating silo (150℃±5℃)  

     Refining chamber (0.1-0.3mm adjustable disc gap)  

     Fiber analyzer (real-time 200-300 mesh monitoring)  

2.2 Fiber Drying Tower  

   Working Principle: Instant dehydration by cyclone airflow  

   Key Components:  

     Three-stage cyclones (≤1.5% output moisture)  

     Gas-fired hot air generator (±2℃ precision)  

     Explosion relief valves  

3. Forming System  

3.1 Moisture-proof Resin Blender  

   Working Principle: High-pressure atomization of resin and additives  

   Key Components:  

     Dual-fluid nozzle array (30-80μm droplet size)  

     Online viscosity controller  

     Nano water-repellent dosing pump  

3.2. Gradient Forming Machine  

   Working Principle: Airflow stratification for density gradient  

   Key Components:  

     Dual forming heads (independent surface/core control)  

     Ultrasonic density scanner  

     Fiber recycling loop  

4. Pressing System  

Continuous Hot Press Line  

   Working Principle: Resin curing under heat and pressure  

   Key Components:  

     Segmented heating platens (8 independent zones)  

     Hydraulic servo system (±0.5MPa pressure control)  

     Steel belt tensioning device (200-300kN)  

5. Finishing System  

5.1 Multi-stage Calibrating Sander  

   Working Principle: Progressive grinding for thickness accuracy  

   Key Components:  

     Three sanding stations (coarse/medium/fine)  

     Laser thickness feedback  

     Dust collection system  

5.2 Automated Cutting & Stacking Line  

   Working Principle: Vision-guided sorting  

   Key Components:  

     Flying cross-cut saw (±0.15mm precision)  

     6-axis robotic palletizer  

     Defect inspection CCD cameras  

Equipment synchronization: Central DCS control system  

Speed matching: Refiner (12t/h) → Former (60m/min) → Press (0.6m/s)  

Continuous operation: Fully automated from input to output (72h non-stop)