MDF production line is fully automated and controlled by Siemens Step7 controllers. The operator only sets technological parameters and controls them with the help of visualization systems. The Plant is fully equipped with all necessary systems of automation, power supply and drivers: 9000M group for groups 1100-2300, and 9000S group for groups 2400-7000.
1 – debarking, chipping
2 – chips storage
3 – chip washing
4 – fiber preparation
5 – drier
6 – sifter
7 – glue kitchen
8 – forming line and press
9 – mechanical and pneumatic conveyors
10 – cooling and stacking
11 – stacking station
12 – surface handling line
13 – packing line
14 – pneumatic transportation
15 – energy plant
16 – auxiliary equipment (spark detection and explosion protection)
17 – quality control system (laboratory equipment)
18 – saw blade and knife machines
19 – technical means of automation, drivers and control
MDF production stages:
1 Stage – Chipping of round wood logs
Chipping of round wood logs 80-300 mm in diameter, 1.5 – 4.0 m long, into chips 25х15х10 mm. At this stage the wood is transported from the wood yard to the feed chute of the debarking drum by hydraulic crane. The wood goes to the debarking drum, where the bark is separated from the logs. From the drum wood logs are transported first by belt conveyor, then by roller conveyor to the wood chipper. Bark is separated from the logs on the roller conveyor. Then it is fed to the energy plant for combustion. Chips are transported to chip silos (2 silos, capacity of 1 silo – 4300 m3).
2 Stage – Fiber production
Chips are transported on the roller conveyor from the silos through magnetic separator into the sifter, where they are devided in three fractions: large fraction (bigger than 25x25x10 mm) goes into production; conditioned fraction is also used for production; fine fraction (smaller than 25x25x10 mm) is burnt. Next, chips are washed and steamed. After removal of excess moisture chips are fed to refiner for fiber production.
3 Stage – Fiber drying
Fibers with glue are dried in the drier to 10% of moisture content. The drier is heated by flue gases of the energy plant. Then fibers are transported through pneumatic separator to the forming bunker.
4 Stage – Mat forming and pressing
From the bunker fibers are fed on to the mat former. The mat is formed depending on the finished board thickness. The mat goes through pre-press (cold compression), then into hot press, temperature – 280°C. After the press, continuous board is cut to size 2790×5600 mm. Then boards are cooled and stacked. Stack height is 4 m.
5 Stage – Stack storing
Three days are required for the final glue curing of MDF board.
6 Stage – Sanding of finished boards
After press boards have rough surface and are not ready for lamination. To avoid this they are sanded, cut to size (1830×2790 mm, 1830×2440 mm, 2135×2790 mm, 2135×2440 mm) and stacked. Stack height is 800 mm.
7 Stage – Packing
Finished board stacks are strapped with packing tape for transportation.