1. Core Performance Metrics:
Line Speed: Typically expressed in meters per minute (m/min). This is the actual running speed at which the mat enters the press and the finished board exits the press.
Annual Capacity: Typically expressed in cubic meters per year (m³/year) or square meters per year (m²/year). This is a broader, more commonly used commercial metric that considers line speed, board thickness, board width, operating time (working days per year, operating hours per day), and equipment utilization rate.
2. Key Factors Influencing Production Speed:
2.1 Product Thickness: This is the most critical factor affecting speed.
Thin Boards: Production speed is fast. Thin boards have high heat transfer efficiency, allowing the core layer temperature to reach the curing temperature required by the adhesive resin more quickly, resulting in a shorter required hot-pressing time (dwell time of the mat inside the press). For example, producing 3mm or 5mm thin boards can achieve line speeds of 60 m/min or even higher.
Thick Boards: Production speed is slow. Thick boards have slower core layer heating and require a longer hot-pressing time to ensure complete resin curing. When producing 25mm, 30mm, or even thicker boards, line speeds may be only 5-15 m/min.
2.2 Product Density: Higher density boards typically require longer hot-pressing times (or higher pressure/temperature) to achieve the desired physical and mechanical properties, resulting in slightly lower speeds compared to lower density boards of the same thickness.
2.3 Process Formulation: The type of adhesive used (urea-formaldehyde, phenol-formaldehyde, MDI, etc.) and its curing characteristics (curing temperature, curing time) directly affect the required hot-pressing time. Faster-curing resins allow higher production speeds.
2.4 Press Specifications:
Press Length: A longer press means the mat stays under high temperature and pressure for a longer time (at the same line speed). To produce thick boards or use slower-curing resins, a longer press is needed to provide sufficient hot-pressing time. A long press enables the production of thick boards at lower line speeds or thin boards at higher line speeds.
Press Opening Height: Determines the maximum board thickness that can be produced. Producing thick boards requires more space for the steel belt travel path.
Drive Power & Control System: Powerful drive systems and precise synchronization control are fundamental for achieving high-speed, stable operation.
2.5 Thermal Energy Supply Capacity: The heating platens must provide sufficient heat to rapidly heat the mat. The power and efficiency of the thermal oil or steam system affect the heating rate, indirectly influencing speed.
2.6 Raw Material Characteristics: Particle geometry, moisture content, resin distribution uniformity, etc., also affect heat transfer efficiency and pressing results.
2.7 Target Product Quality Requirements: Higher requirements for board density profile, internal bond strength, surface quality, thickness tolerance, etc., may necessitate more precise control and/or slightly longer hot-pressing times, potentially limiting the maximum achievable speed.
3. Typical Speed Range (Line Speed - m/min):
Ultra-Thin Boards: e.g., <3mm, speeds can reach > 60 m/min (very high speed).
Thin Boards: e.g., 3-8mm, speed range typically 20 - 60 m/min.
Medium/Thick Boards: e.g., 8-19mm, speed range typically 10 - 30 m/min.
Thick Boards: e.g., 19-40mm, speed range typically 5 - 15 m/min.
Ultra-Thick Boards: e.g., >40mm, speeds may be < 5 m/min.
4. Typical Capacity Range (Annual Capacity - m³/year):
Modern large-scale continuous press lines (press width >2.5m, length >30m) typically have annual capacities in the range of 200,000 - 500,000 m³/year or even higher.
Per Minute Example: A line with 300,000 m³/year capacity has an average production rate of approximately 1.14 m³/minute (300,000 / (365 days 24 hours 60 minutes) considering utilization rate). However, this is an average; the actual per-minute production varies significantly with board thickness (much lower when producing thick boards, much higher when producing thin boards).
