Among practical and multifunctional wood materials, particle boards or simply chipboards occupy a special place. Their production can take place both in large wood processing plants and at home.

Purpose

Chipboard is an environmentally friendly, easy-to-process, functional material, and also a high-tech alternative solution to solid wood. It is used to sheathe walls, roofs, make wall panels, create carpet or linoleum flooring, flooring, various partitions, make a wide variety of furniture, packaging, construct enclosing arrays, and decorate interior spaces. What is the production technology for chipboard? How is it made at home? Let's look at these questions later in the article.

What is chipboard made of?

The basis for the production of particle boards is a process in which sawdust is mixed with a special adhesive mass and the resulting mixture is pressed under high pressure and high temperature. The great advantage of making chipboard is the use of sawmill waste.

Pressed slabs have good strength, created by mixing the sawdust mixture with glue (resin) hardened to the state of stone. To produce environmentally friendly types of material, an adhesive mass of minimal toxicity is used.

The production of chipboards can occur on a small scale. In general, only the size of the produced slabs is limited, which should be no more than 50 x 50 centimeters.

Making chipboard at home is the same process as on an industrial scale, but in miniature. All stages where automation should be involved are replaced by manual work.

How to make chipboard at home

Let's consider the sequence of chipboard manufacturing:

• first, the sawdust mass is mixed in a medium-sized container (from 10 to 15 l);
• then the adhesive solution is added, you need to make sure that the sawdust is completely saturated;
• shaped into tiles under high pressure;
• Then the workpieces are pressed using high temperature; this process requires special equipment;
• the manufactured slab is cooled in air, and its edges are trimmed.

Surface lamination is carried out in the same baking press that is used in the production of uncut blanks. You can purchase a ready-made special laminate for chipboard, which can be “baked” to the surface in a certain way using an iron. Such coatings have a beneficial effect on the appearance of wood boards, but are not considered a full-fledged laminate layer.

Equipment

Before making chipboard, you need to prepare the equipment. The technology for creating this material is based on the use of elementary and practical equipment, which is connected into a common system. The use of the most technologically advanced devices for the production of wood-based panels is not necessary, but setting up and maintaining the functionality of the entire production line is quite difficult.

List of equipment

The full list of equipment for chipboard production includes:

1. Mixers, which are needed in order to obtain a homogeneous mixture made from sawdust and an adhesive (usually a resin with special impurities to create a solid structure).
2. Forming devices are necessary to impart viscosity and shape to the mixture.
3. High temperature pressing equipment and machines.
4. Coolers are used to make hot chipboards cool faster.
5. Edge trimming devices that remove edges from slabs.
6. Grinding machines make the formed surface smooth.

The functionality of all equipment in large-scale production is ensured automatically. The quality of work is controlled by maintaining the mechanism settings at the required level.

All of the wood-based panel manufacturing equipment listed earlier is suitable for the job, assuming ready-made raw materials are available.

If you plan to use your own raw material in the manufacture of chipboards, then the equipment must be supplemented with auxiliary equipment, such as cutting machines, chopping mechanisms, mills and planing machines.

Among other things, additional equipment that will improve the manufacturability of wood-based panels includes conveyors, tables equipped with lifting mechanisms, ventilation systems necessary to remove sanding dust, drying chambers and conveyors. Let's look at how chipboard is made.

Manufacturing technology

The composition of wood boards includes wood chips, which are formed as waste from wood production. During a standard operating cycle, the non-functional mass is transformed into ready-to-use slabs.

Let's look at how to make chipboard with your own hands.

Manufacturing sequence

The manufacturing steps are as follows:

• first you need to find raw materials, sawdust and wood chips in the warehouse;
• then the raw materials are prepared for work by grinding;
• the materials are dried to obtain a suitable consistency for gluing;
• chips are sifted using automated sieves and sorted depending on size;
• larger and smaller chips are mixed with each other;
• a resin adhesive is added;
• the viscous mixture is sent to a molding machine, which forms wood boards;
• Chipboard is pressed under high pressure and high temperature;
• the plates are cooled;
• the edge is trimmed, and the resulting workpieces are sawn into pieces of the required size.

So, we looked at how chipboard is made. Sanding this material is necessary as a final step in the manufacturing process. It is the level and quality of grinding that directly determines what grade the finished product will be classified as. First grade chipboards should not have scratches, stains, insufficient sanding, or waves on the surface.

The necessary parameters of wood boards are controlled both during production and after the chipboards are ready. The manufactured sheets are stored in blocks, which are laid on special wooden pallets - pallets.

Milling process

Creating shaped surfaces from the inside and processing corners from the outside is done during the milling process. A cutter is a cutter equipped with teeth; it usually has any regular shape (for example, a cone or trapezoid). Particle boards require processing along the entire thickness, which differs from processing harder materials. This is necessary to prevent accidental chips from appearing.

Before you start milling, you need to prepare. To do this, you need to cut out the contours of the planned figures in advance using a jigsaw or saw. They are usually processed manually or using a stationary milling cutter. In this way, cylindrical and oval-shaped holes of any size are obtained, which ensures an aesthetically pleasing appearance of the finished slab.

What is the process of chipboard lamination?

Considering how chipboard is made, let's take a closer look at the lamination process. Any furniture, including cabinets, kitchen units of any class, is made from wood boards, the surface of which has undergone a special stage of processing and has been laminated with special materials necessary to protect the product, as well as create a more aesthetic appearance. These products are called laminated chipboard or expanded laminated chipboard.

To laminate a product, it is necessary to apply a stable coating to its surface, which improves the appearance; no additional processing is required.

The main stages of the wood board lamination process are as follows:

1. First, the highest quality material is selected, the most durable and dense products that have low humidity.
2. The chipboard is coated with a primer to ensure the best adhesion of the laminate;
3. Now several layers of paper are applied (no more than three), which are impregnated with a resin mixture. With the help of paper, the product will be more durable, and painting the outer part creates an aesthetically attractive appearance of the slab. The process of creating layers is accompanied by compression at high temperatures.
4. Next, the product is quickly cooled, sometimes with the help of watering.

The surface of the particle board must be carefully polished before it is laminated. If even small roughness and uneven places remain, this can lead to deterioration of the laminate layer and, accordingly, the product will be rejected. The process of laminating with your own hands at home is very difficult to produce with high quality, so often already processed, industrially made laminated chipboards are purchased for subsequent use.

Chipboard- Chipboard - a sheet composite material produced by hot pressing of wood and woodworking waste, mainly shavings, sawdust, with a binder of non-mineral origin. If it is necessary to obtain special properties from Chipboard or due to the peculiarities of the technological process, special additives may be added to the composition in a volume of 6 - 8% by weight of the main filler (chips).

In English, the concept of chipboard sounds like this: particle board, which literally means - Board of Particles.

History of the creation of chipboard.

It is believed that the progenitor of chipboard was Ernst Hubbard, who proposed the idea of ​​​​creating a new, previously unknown to science, material from sawdust and casein glue. Back in 1887, Hubbard made his dreams come true and presented the first chipboard prototype to the public. The inventor's developments were to the taste of his colleagues, and already in 1918 another experimental model was created - a slab finished with veneer. Nowadays, laminated chipboard is available to everyone. But in the time of M. Beckman, who first covered particle board with veneer, such products could only be afforded by privileged people.

A landmark moment in the history of chipboard occurred in 1926. At this time, the German scientist Freudenberg derived the formula for the “ideal” particle board and calculated the optimal ratio between the binder and sawdust. According to his calculations, the wood chip “semi-finished product” should have contained from 3 to 10% of a viscous substance. Later, the scientist’s conclusions were slightly corrected, so today chipboards contain from 6 to 8% formaldehyde resins. By the way, resinous compounds began to be used in the production of chipboard only in 1933, 7 years after Freudenberg’s fundamental calculations.

Our compatriots also worked, although not in their homeland. In 1935, in France, emigrant Alexei Samsonov made the first oriented particle boards (OSB) by laying long strips of veneer in a crisscross pattern. In the same year, an experimental plant for the production of boards using a phenolic binder by Ernst Lötscher began operating in the state of Iowa.

Much later, moisture-resistant chipboard was produced, which included paraffin compounds.

Currently, particle boards are the most popular material. The main advantages of chipboard are low cost and ease of processing.

Chipboard is made from pressed large wood chips with the addition of thermosetting synthetic resin as a binder.

A valuable raw material for chipboard is any low-value wood, both coniferous and deciduous. The use of round wood is being reduced through the use of materials such as wood chips, sawdust and reclaimed wood. Often all types of raw materials are used in the production of chipboards simultaneously, or in mixed forms. The presence of hydrophobic, antiseptic and other additives determines the strength and durability of the material.

Chipboard production, technological process.

(photo from website: elo.ru)

1. Processing of raw materials.

• receiving or unloading chips, grinding large raw materials.
• sorting chips into fractions.
• cleaning chips from impurities.

The output is chips. (photo from website: pkko.ru)

To prepare raw materials, industrial shredders or crushers are used, for example, like this one hammer crusher DMR-600-10-55 (link to manufacturer's website). This is a small crusher, larger ones are used in large industries, but the principle is the same. Video of the crusher in operation.

Various vibrating sieves are used for sorting.

The produced raw chips are stored in bunkers, where they are supplied by a pneumatic transport system or mechanical conveyors. From bins, raw chips are fed into dryers.

2. Drying of raw materials.

To dry the chips, drying complexes like this one are used.

(photo from website: www.equipnet.ru )

It is necessary to dry the chips to a moisture content of 4-6%, and for the inner layer - up to 2-4%. Therefore, chips of different layers are dried in separate dryers. In the production of chipboards, as a rule, convective drum dryers are used. Gas or fuel oil is burned in the dryer furnace, the temperature in it is 900 -1000 ° C. at the entrance to the drum. The temperature of the drying agent reaches 450-550° C, at the outlet it is from 90 to 120° C. The drum has a diameter of 2.2 m and a length of 10 m, it is installed with an inclination of 2 - 3° towards the entrance of the raw chips.

3. Resinization.

Resined chips are produced in continuous mixers, in which the binder is sprayed through a series of nozzles, each connected to a dosing pump. The tarred chips are moved by a screw shaft to another zone, where they are mixed by blades. Example: Mixer DSM-7. Manufacturer of the equipment shown: Vologda Machine Tool Plant ( www.vsz.ru).

This is the most complex and responsible, since the production technology requires coating each chip with a binder. Unresined chips do not stick together, and excess resin on the chips leads to excess binder consumption and poor quality slabs. The binder is supplied to the mixer in the form of solutions. Their concentration in the flow of the outer layer is 53-55%, the inner layer is slightly higher (60-61%).

4. Formation of the carpet.

The carpet is formed using forming machines. The machines place the tarred chips into the mold. In this case, the formation can be one-, two-, or three-layer. Three-layer carpet formation is typical for enterprises using old equipment. When using such equipment, the inner layer is made of large chips, and the outer ones are made of very small chips. Three-layer chipboard on the cut has clearly defined outer layers.

This is a continuous tape of a certain width and thickness. It is divided into packages, from which plates are subsequently formed during hot pressing. Naturally, the uniformity of the carpet filling directly affects the quality of the slabs (even density, equal thickness).

5. Pressing.

Pressing and gluing of particle boards is carried out in heat presses, which is carried out at 180°C and a specific pressure of 2.5-3.5 MPa. The duration of pressing is 0.3-0.35 minutes per 1 mm of slab thickness.

There are two types of pressing - flat and extrusion.

With flat pressing, the press force is directed perpendicular to the plate surface. In this case, the chips are located parallel to the surface, which somewhat increases the mechanical strength of the chipboard (although there are opposing opinions).

Multi-storey chipboard pressing line.

During extrusion pressing, the press pressure is directed towards the edge of the plate, and the chips are located perpendicular to the direction of the plate. The mechanical bending strength of the slab is lower in this case. Most vertical extrusion presses are classified as obsolete, although there are also modern vertical presses for the production of extruded chipboard with internal channels. This chipboard is laminated and used for furniture production and some carpentry (interior doors, etc.) Single-storey or multi-storey pressing lines are used. Single-deck low and medium capacity pressing lines for chipboards, with electronic thickness control and built-in general control system. Multi-storey lines for chipboards, medium and high capacity, with mechanical or electronic thickness control and integrated general control system.

Modern multi-deck presses have hot plate dimensions reaching 6x3 m, with up to 22 working spaces (22 particle boards are pressed at the same time). The height of the press reaches 8 m.

6. Cooling and cutting chipboards.

Pressed chipboard sheets are trimmed to fit a given commercial format. The sheet can be cut hot, immediately from the press or after it has cooled. In this way, hot and cold cutting are separated. Cold trimming is most often used in the production line.

The need to cool chipboards is due to the fact that after unloading from a heat press, they, firstly, have a very high temperature, and secondly, a fairly large difference in the same temperature and humidity. The humidity of the outer layers is about 2-4%, while the inner layers of chipboard contain about 10-13% moisture at this time. The difference in temperature can be about 80 degrees Celsius (105 outside and up to 180 inside). Such gradients are a source of internal stress. During further processing of the hot plate, these stresses can lead to its deformation. That is why the stove is allowed to cool in coolers.

Chipboard fan cooler. (photo from website: kitexport.ru)

To cool chipboards, fan coolers are used, which are an installation with a large rotating drum consisting of several dozen cells. When installing a new plate, the drum is rotated by one cell: while on the other side of the cooler, a plate that has already reached a temperature of about 50 degrees is removed. The coolers' productivity is about 200 sheets per hour: it takes about 12-15 minutes to cool one 19 mm thick plate to a temperature of 50 degrees. (quote from the site: fanera-bazar.ru)

Sheet cutting occurs on several special formatting machines .

Then the slabs are moved to an intermediate warehouse, stacked, where they are kept for at least 5 days.

6. Finishing chipboard, grinding the surface and ends.

Grinding machines for chipboard production are: four-head, six-head, eight-head. The advantage of having more heads is the quality of grinding. The more heads, the better the quality of grinding, but also the greater the consumption of electricity and sanding belt.

Appearance of grinding equipment for chipboards.

After this stage, the slab is ready and suitable for shipment to the consumer as sanded chipboard or sent to the next section for covering with various decorative coatings.

7. Packing chipboards on pallets.

In accordance with the requirements of the standard, the slabs are sorted and then either cut into blanks for furniture panels, or sent to consumers in full format.

Depending on the criteria for the appearance of the slab (cracks, chips, staining, stains, protrusions and depressions), chipboard slabs are divided into the following grades:

• laminated chipboard - 1st grade(defects other than minimal ones are not acceptable),
• laminated chipboard - 2nd grade(large surface defects are acceptable),
• no variety(cardinal surface defects, used in construction).

General, transportation, conveyor.

The conveyor moves the packages, which, after passing through the compaction press, become dense, transport-resistant briquettes. There are currently two fundamentally different types of main conveyors known in the particle board industry. They differ in that in one case the bags (and then briquettes) are moved on metal pallets, in the other type of main conveyor - on belt conveyors when the pressing is palletless. Each main conveyor scheme has advantages and disadvantages. The pallet method is simpler and more reliable, but the slabs are produced with greater thickness variations and the consumption of thermal energy is greater. The palletless method provides some energy savings and improved slab quality.

The technological process for the production of chipboards provides for strict control when using binder impregnations and therefore this the material can be considered environmentally friendly . All types of chipboard undergo mandatory testing for formaldehyde content.

How is formaldehyde content determined?

A sample of chipboard with a surface area of ​​1 sq. m is placed in a chamber with a volume of 1 cubic meter and after a certain time an air sample is taken from the chamber to determine formaldehyde in it. This sample is compared with standards and a hygienic conclusion is given on the applicability of chipboard for furniture production. This method is called “chamber”, it is considered the most effective and the State Sanitary and Epidemiological Supervision authorities issue their conclusions based on this test method.

Supporting Information.

• Lamination and lamination of chipboard. Chipboard technology Chinese characters, meaning .

Can be copied with an indication of the source and an active indexed hyperlink to the site

With this information, you will be able to organize large and small chipboard production, but not at home, because... the line is very cumbersome. Here you will learn about the equipment for making chipboards (line, machine), its price, as well as about the technology and video of the entire process.

Chipboard is an environmentally friendly, easy to process, practical material, a high-tech alternative to solid wood, successfully used for cladding walls and roofs, making wall panels, making flooring for carpets and linoleum coverings, flooring, various partitions, producing removable formwork, making shelves, furniture , packaging, construction of fencing and collapsible structures, decoration and finishing of premises.

Production technology

The essence of chipboard manufacturing technology is the use of direct hot pressing in combination with thermosetting adhesive resin and chip mixture. Chips, sawdust, veneer scraps and other small wood waste are used as raw materials for the production of chipboard. The shavings are mixed with a binder material, and the resulting mixture is placed in special molds. Under the influence of high pressure and temperature, the mixture sticks together and forms a single whole. The finished slab is removed from the mold and cooled, then it is cut and subjected to the grinding process.

This whole process and the line itself are shown in the video:

More useful:

As you can see, you are unlikely to be able to organize such a business at home, because... the line is very cumbersome.

Main equipment

So, you will need the following equipment for the production of chipboard:

• Mixers in which glue is mixed with wood shavings in strictly regulated proportions; glue is a heated resin with various additives and hardeners;
• Forming machines. In them, a carpet is formed - tarred shavings are laid in a special form;
• Thermal presses. Used for pressing slabs and gluing them;
• Fan coolers. Used for cooling hot workpieces;
• Vertical and horizontal side trimmers. Used for cutting edges;
• Grinding machine. It is used for grinding the ends and surfaces of the finished product.

The above-described line for the production of chipboards is suitable for a cycle that requires the availability of ready-made raw materials.

If you plan to use your own raw materials in the production of chipboards, the kit must be supplemented with auxiliary equipment such as cutting machines, chippers, planers and mills.

In addition, additional equipment that increases the manufacturability of chipboard production includes conveyors, tables with lifting mechanisms, vibrating screens, ventilation systems for removing grinding dust, stackers, loaders, and drying chambers.

The price of a fully equipped mini-line producing sanded chipboard and having a capacity of 100 sheets per day is approx. 190,000 euros. A line with high productivity (1000 sheets per day) costs 550-650 thousand euros (if you go by the prices of the SMS private enterprise, Ukraine, subject to pickup). It will be cheaper to buy Chinese equipment from the Harbin Luniwei plant - approximately 280,000 euros, with a capacity of 10,000 cubic meters. per year.

When purchasing a line with a capacity of 10,000 cubic meters, the following capital costs are required:

• The price of a line for the production of chipboards (machine) is 8-10 million rubles;
• The price of auxiliary equipment is RUB 1,500,000;
• Delivery of the line and its installation – 500-600 thousand rubles;
• Repair and preparation of premises for the production of chipboards and placement of the machine (area 450 sq. m) - 450,000 rubles;
• Creation of inventory for a month - 4,200,000 rubles;
• Ave. expenses – 450,000 rubles.

In total, to organize the chipboard production process, an investment of approximately 17-18 million rubles is needed.

With an average selling price of 1 cubic meter of chipboard of 7,800 rubles, monthly revenue is 6,500,000 rubles. The average statistical profitability of large and small production ranges from 18 to 30%, the payback time for investments ranges from one to one and a half years.

Particle board, or chipboard, is a composite sheet material. It is produced from wood waste and non-mineral binders using the hot pressing method. The composition of chipboard may vary depending on the nuances of technological processes or the desired properties. But in general, chipboard is compressed wood waste, which is clearly expressed in English translation - “particle board”, that is, “particle board”.

Currently, chipboard is one of the most popular materials for furniture production, interior design, and construction of structures that do not require increased strength. The irrefutable advantages of this material are its cost-effectiveness and ease of processing.

The chipboard production technology of different manufacturers is practically the same. The difference lies only in the quality of the materials used and the cost of the raw materials.

Technological stages of chipboard production

At any enterprise, chipboard production consists of several successive stages.

Stage I - preparation of the necessary raw materials

The process of mixing various wood materials takes place based on the desired quality characteristics of the finished product. Wood shavings, chips and sawdust are used.

Stage II – grinding of wood components

To obtain the required density of the finished material, the raw materials must have maximum homogeneity. Therefore, wood waste is crushed and further shredded to the required size.

Stage III – drying of raw materials

To increase the effectiveness of the glue, the prepared wood components must be removed from excess moisture. To do this, the crushed raw materials are dried.

Stage IV - mixing components

Prepared, crushed and dried, the raw materials are thoroughly mixed with adhesive ingredients. The result is a mass ready for the formation of chipboards.

Stage V – formation of chipboards

The adhesive mass is poured into a special moving belt with a predetermined width. Next, the mass is pressed to the required thickness. At the same time, a high temperature regime is maintained throughout the entire pressing process.

Stage VI – cutting the finished chipboard sheet

The pressed chipboard sheet is cut into sheets of a given size, and the resulting products undergo additional drying.

Stage VII – surface treatment of chipboards

At the final stage, the surface of the manufactured chipboard sheets is processed: the products are laminated or a thin layer of veneer is applied on top of the sheet and a veneered chipboard is obtained. To laminate finished boards, a special film is used, which covers the sheets. Can be used for additional processing of chipboard and paper or plastic. The cost of additionally processed chipboard sheets is low, but in the end their price far exceeds the cost of chipboard with a simply sanded surface.

The main raw material for the manufacture of chipboards: wood

The direct raw materials for the production of chipboard, technological chips and shavings, are obtained in the process of processing deciduous and coniferous wood, various wooden waste from sawmills, woodworking, match and plywood industries.

Technological chips are produced by crushing the feedstock in chippers. At the same time, depending on the desired condition of the finished chips, different types of chipping equipment are used.

The shavings have higher quality characteristics. It is used to form the outer layer of three-layer chipboards. Such chips are produced on special flaring machines, after which the produced thin chips with a long-fiber structure are transported to a crusher to create the required width.

At the next stage of production, chips and shavings undergo mandatory sorting. If necessary, the components are crushed and further sorted.

All sorted chips and shavings are sifted by electromagnetic separators, which allows you to remove metal particles, if any. Next, the technological raw materials are finally cleaned, that is, washed with water to remove possible dirt and sand impurities, as well as to increase the humidity level to the required level. Excess moisture from conditioned raw materials is removed by drying it in rotary, drum, pneumatic or belt dryers.

Dry shavings and industrial chips, sorted, cleaned of various impurities and dried, are sent by a conveyor system to special storage facilities - bunkers. The volume of the bunkers is designed to ensure continuous production for at least three working shifts.

Chemical components in the production of chipboards

In addition to wood raw materials, chemical materials are also necessary in the chipboard manufacturing process. Their purpose is to bind and glue prepared wood particles under high temperatures and pressure. The binding materials used are urea and phenol-formaldehyde resins, which vary in color, level of toxic fumes and moisture resistance.

Phenol-formaldehyde resins have a dark brown color, which affects the final color of the finished product, are highly toxic and have a pungent odor. When using them, pressing times require longer periods. The advantage of using such resins is their increased resistance to moisture; water has virtually no effect on such adhesive joints.

Urea-formaldehyde resins are considered less environmentally harmful, but they have less strength and the adhesive layer is destroyed at a temperature of 60 ° C. Chipboards containing this type of resin are used in conditions of slight differences in humidity levels.

In addition to adhesive components, strengthening and water-repellent (hydrophobic) additives are used in the production of chipboard. Their use helps maintain the shape of finished products during changes in humidity, since without additional processing the porous structure of wood materials absorbs moisture from the air or when immersed in water.

Hydrophobic viscous substances in molten form are able to close the surface pores of the material, which becomes an obstacle to the penetration of moisture inside. Such substances are ceresin, paraffin, distillate slack. They are introduced into wood pulp as alkaline emulsions diluted with hot water. The deposition of hydrophobic substances on wood fibers is carried out using aqueous solutions of aluminum sulfate or sulfuric acid.

Phenol-formaldehyde resin is used as a reinforcing additive, which is also used for gluing. Its presence in the composition increases the strength of chipboard when the composition of the boards contains more than 30% hardwood or when the content of fibers is shorter than required.

Equipment for the production of chipboards

At any stage of chipboard production, equipment is required that corresponds to the process being performed, among which there are basic and additional ones.

Main equipment

The main equipment for the production of chipboards includes technological equipment installed in the main workshops of the enterprise for the production of chipboards: the preparatory workshop, the main workshop and the grinding workshop.

The pre-production workshop is equipped with a crushing plant and a flake machine. To equip the main workshop, thermal presses, fan-type coolers, as well as machines for automatically cutting the edges of the product to a given length and width are required. The grinding shop is equipped with grinding machines.

All necessary indicators of width and processing power are determined separately for each batch of products; the final grade of manufactured chipboard sheets depends on the selected indicators.

Additional equipment

Equipment of secondary importance are vibrating screens and conveyors - roller, chain, belt or spiral. When stacking finished sheets into bundles, lifting tables are used. All production workshops are equipped with ventilation systems to get rid of process dust, collect and remove it.

The use of modern technologies, high-quality equipment and necessary additives in the production of chipboards allows the manufacturer to produce chipboards with increased fire resistance, moisture resistance and high strength. The result is a material whose cost is much lower than other analogues, which makes chipboard so popular among a wide range of buyers.

Among the universal wood-based composite materials, it stands out. The production of particle boards is carried out on production lines of large wood processing plants and small enterprises.

The essence of the process of obtaining the material is mixing sawdust with an adhesive agent and pressing this mixture at high pressure and temperature. A significant advantage in the production of wood-based panels is the use of sawmill waste.

Pressed sheets have high mechanical strength due to the combination of sawdust and resin (sticky mass) hardened to stone. To produce environmentally friendly varieties of material, low-toxic adhesive compositions are used.

Equipment

The technological production cycle is based on the use of simple and effective equipment combined into an integral system. The use of high-tech lines to produce slabs is not required, although setting up and maintaining the functionality of all units is a complex and non-trivial task.

The chipboard production line includes:

• mixers - necessary to obtain a homogeneous mixture of sawdust and glue (resinous substances with technological additives and hardeners);
• molding devices - give the viscous mixture shape;
• hot pressing devices and machines - necessary for complex thermal and mechanical effects on the formed workpiece;
• coolers – used to speed up the cooling of hot plates;
• devices for cutting sidewalls - remove edges from sheets;
• grinding machines - give the formed surface smoothness.

All devices operate automatically. Ongoing quality control is carried out in parallel with maintaining system settings at a given level.

In the video - how chipboard is made at the factory:

Manufacturing technology

The raw materials for producing chipboard are wood chips and waste. The working cycle allows you to transform substandard viscous mass into finished sheets of material.

The main stages of production include:

• collection of raw materials (chips and sawdust) at the chip exchange (warehouse);
• preparation of material (grinding) in the chipping shop;
• drying until an optimal condition for gluing is obtained;
• sifting of wood chips on automatic sieves and calibration by size (size);
• mixing large and small fractions of wood chips with each other;
• adding a binder (resin);
• directing the viscous mass into the molding machine, which determines the shape of the chipboard;
• pressing under pressure of 20-40 kgf/cm2 at a temperature of 180-220 ºС;
• cooling the plate;
• trimming edges and sawing to specified sizes.

It is produced both during the manufacturing process and after receiving the finished product. Sheets of material are stored in blocks placed on pallets - wooden pallets.

Certificate of Conformity

Certification of wood-based products is carried out in three areas:

• general requirements of regulatory documentation (GOST, TU);
• fire safety standards;
• sanitary standards.

The certificate of normative and technical compliance is issued by the state certification body. For questions regarding checking the parameters of wood products in accordance with sanitary standards and fire regulations, please contact the relevant territorial authorities.

Features of chipboard lamination

The lamination process involves applying a durable melamine film to the surface of the board, which improves aesthetics and does not require additional processing.

The production of laminated boards is as follows:

• selection of the most dense and durable slabs with low humidity as the starting material;
• coating with a primer to ensure better adhesion of the laminate;
• applying several (no more than three) layers of paper impregnated with melamine resin filler. The paper gives the film mechanical strength, and the coloring of the outer layer shapes the appearance of the material. The procedure for applying layers is accompanied by pressing at elevated temperatures;
• sudden cooling of the surface, sometimes accompanied by pouring water.

The surface of the chipboard sheet must be thoroughly polished before lamination. The slightest residual irregularities will lead to damage to the laminating layer and defective products.

Laminating solid sheets of chipboard at home is quite difficult to do efficiently, so most often, ready-made industrial chipboards are purchased for further use.

The video will tell you about the features of making laminated furniture chipboard:

Milling

The production of internal shaped surfaces and external processing of corners is carried out using milling. The cutter is a toothed cutter having an arbitrary regular shape (cone, trapezoid, truncated figures, etc.). Unlike working with harder materials, chipboard is processed throughout its entire thickness to avoid chipping.

Preparation is carried out, which consists of preliminary cutting out the contours of the planned figures with a circular saw or jigsaw. Processing is carried out using a manual or stationary milling cutter. In this way, cylindrical and oval holes of any size are obtained, ensuring the aesthetics of the finished product.

Making chipboard at home

The production of wood-based panels can be carried out on a small production or farm scale. The main limitation is the size of the resulting slabs - no more than 50 × 50 cm.

The manufacturing technology is a miniaturized industrial process in which automatic steps are replaced by manual labor:

• mixing sawdust in a small container (10-15 l);
• adding a binder and ensuring complete impregnation of the sawdust mass;
• shaping with light pressure;
• hot pressing of the workpiece, which requires special equipment;
• cooling the resulting chipboard fragment in air and trimming the edges.

The laminate is glued in the same baking press that is used to produce rough, uncut material. There are ready-made coatings for wood boards that can be “fried” to the surface with an iron. They improve the appearance of chipboard, but are not fully a laminating layer.

The main layers in the manufacture of slabs

Manufacturers and factories in Russia

The slab manufacturing business is very profitable because... However, it involves the need to purchase expensive equipment and hire qualified personnel. There are small enterprises that produce small batches of chipboard.

The largest and most famous associations (factories) include:

• “Russian Laminate” - located in the Moscow region and has been operating since the early 90s;
• "Cherepovets FMK" - produces plywood and chipboard;
• "Flyderer" is a Novgorod enterprise, which is a subsidiary of a Polish company;
• Plitspichprom is a Kaluga-based manufacturer of a wide range of wood products, including chipboard;
• "Krasnoyarsk DOK" - offers a large selection of wood materials, using a chipboard production line to increase waste-free production.

The production of particle boards is a technologically advanced and cost-effective production line. Increased competitiveness of products occurs due to improved environmental performance and fire safety. Timely product control allows timely recording of deviations from the requirements of technological regulations and minimizing the amount of defects.