Ⅰ.Particleboard Production Line Process
1. Raw Material Processing
Wood materials (logs, branches, recycled wood) are chipped by a drum chipper, then refined through a hammer mill to form uniform particles sized 0.2–2mm. Wood utilization rate ≥95%.
2. Drying
Wet particles enter a triple-pass rotary dryer using direct natural gas heating. Moisture content is rapidly reduced from 40–60% to 3–5% (±0.5% accuracy) at 180–220°C, with a drying capacity of 18 tons water/hour.
3. Screening and Classification
Dried particles are graded via multi-deck screens:
- Surface layer: <0.5mm fines (for high-density surfaces)
- Core layer: 0.5–2mm coarse particles (ensuring core strength)
- Oversized particles: Returned to recycling system
4. Resin Application System
Classified particles enter a high-speed ring blender:
- Surface fines: Coated with 12–14% melamine-modified urea-formaldehyde (MUF) resin
- Core particles: Coated with 8–10% MDI resin
- Resin application accuracy: ±5g/m², processing speed: 12 tons/minute
5. Mat Forming
Mechanical-pneumatic blending forming system:
- Bottom layer: 0.3mm fines (density ≥750kg/m³)
- Core layer: 1.5mm coarse particles (density 650kg/m³)
- Surface layer: 0.2mm super-fines (density ≥780kg/m³)
Creates three-layer graded-density structure at 120 meters/minute.
6. Pre-pressing
Mat passes through a double-roller pre-press:
- 1.5MPa pressure, compressed to 70% target thickness
- Eliminates fluffiness and prevents mat disruption
7. Continuous Flat Pressing (Core Stage)
Mat enters dual-steel-belt continuous press:
- Hot Pressing: Belt temperature 220–250°C, 40 pressure zones (entry: 4.0MPa → exit: 1.5MPa)
- Precise Dwell Control: Automatic speed adjustment by thickness (6mm: 60m/min; 25mm: 9m/min)
- Real-time Thickness Control: Laser measurement + hydraulic pads ensure ±0.1mm tolerance
8. Cooling
Hot boards enter roller-type cooling station:
- Forced-air cooling reduces temperature from 180°C to 45°C in 10 minutes
- Eliminates internal stresses and prevents warping
9. Sawing
High-speed cross-cut and trim saws:
- Cut to standard dimensions (2440×1220mm)
- Edge trims recycled to raw material system
10. Stacking and Curing
Automated stacking followed by 24–48hr ambient conditioning:
- Ensures complete resin curing and stress release
11. Sanding
Four-head double-side calibrating sander:
- CCD thickness detection + adaptive grinding
- Final tolerance ±0.1mm, surface roughness Ra≤5μm
12. Grading and Packaging
Automated inspection by quality grade:
- Grade A: Flawless, direct film wrapping
- Grade B/C: Marked for secondary processing
- Finished goods stored for shipment
II. Core Production Components
Component | High-Capacity Specification | Feature Highlights | Function |
Chipper System | Drum chipper + Hammer mill | Wood utilization rate ≥95%, particle size of crushed materials 0.2-2mm controllable | 120 BDt/h output |
Dryer | Triple-pass rotary (gas-fired) | Gas direct heating, outlet moisture content error ±0.5% | 18 t/h H₂O removal |
Resin Blender | High-speed ring type | Atomized glue spraying + dynamic weighing, glue application accuracy ±5g/m² | 12 t/min @ ±5g/m² |
Forming Station | Mechanical-airflow composite paving head | Forming a gradient density structure, fine material on the surface/coarse material in the core | 3-layer graded density；Paving speed: 120m/min |
Continuous Press | Dual-steel-belt system (see below) |
| Production core |
Cooling Conveyor | Forced-air spiral type |
| 10-min cooling cycle |
Sanding Line | 4-head double-side sander | CCD thickness detection + adaptive sanding, tolerance ±0.1mm | 150 m/min throughput |
Chipper
Dryer
Resin Blender
Forming machine
Continuous Press
Sanding machine
III. Continuous Flat Press: Technology & Capacity
Core Technical Features
1. Dual Steel Belts
- Material: Hastelloy® with nano-ceramic coating
- Thickness: 1.8mm
- Service life: ≥5 years
2. Heating System
- 40-zone thermal oil circulation
- Temperature control: ±0.3°C (200–250°C range)
3. Hydraulic Pressure
- 500bar servo-controlled system
- Response time: ≤50ms
4. Thickness Control
- Laser measurement + hydraulic adjustment
- Thickness changeover: 90 sec (18→6mm)
Ⅳ.Continuous Press Core Capacity Data (2.5m width line example)
Actual output capacity under different thicknesses
Thickness | Line Speed | Output per Minute | Annual Capacity (10k m³) |
6mm | 60 m/min | 0.9 m³ | 38.9 |
12mm | 30 m/min | 0.9 m³ | 38.9 |
18mm | 18 m/min | 0.81 m³ | 35 |
25mm | 9 m/min | 0.56 m³ | 24.3 |
Ⅴ. Key technological breakthroughs for high production capacity
1. Press inlet acceleration technology
- Paving-hot pressing synchronous control system, slab gap shortened to 15cm (traditional ≥50cm)
- Effectively improve time utilization by 12%
2. Near infrared online moisture content monitoring
- Real-time control of wood shavings moisture content after sizing (target value 9.5±0.3%)
- Reduce hot press steam release time by 15%
3. Intelligent operation and maintenance system for presses
- Ultrasonic monitoring of steel belt stress, reducing the unexpected downtime rate to <2%
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