MELAMINE MDF PRODUCTION PROCESS
The MDF board is sourced out from reputed international manufacturers and undergoes a strict quality control inspection for consistency in thickness and density of material as well as its modulus of elasticity, tensile strength, bending strength and moisture content. An additional test for boiling water resistance is also conducted in case of the High Moisture Resistant grade MDF boards.
1. RESIN PREPARATION
Malamine in white crystalline form is dissolved in liquid formaldehyde in a stainless steel reactor and undergoes a chemical process called polymerization. This special resin is manufactured in house by Emilam using its own specially formulated recipe with rigid process control.
2. PAPER PREPARATION
Rolls of paper are readily available and a huge stock is maintained in the inventory. The paper is sourced from internationally reputed manufacturers and is available in a variety of shades and colours. Before being sent for “treatment” every batch undergoes various “quality tests” like wet strength, absorbency etc. and then taken to the Impregnation process.
The base paper is unwound from a paper roll and passed through a tray filled with the special Melamine resin patented . The paper gets impregnated with the resin in a process strictly controlled at every stage and undergoes an elaborate quality check before it is sent for curing.
4. CURING AND DRYING
The impregnated paper is cured and dried by passing the sheet through drying chambers under temperatures of up to 150°C using hot thermic fluid. The semi-dried and semi-cured paper is then stored in a controlled temperature and humidity chamber at 25 deg Centigrade and 48% Relative Humidity to protect their shelf life.
The plain MDF boards are sorted according to thicknesses ranging from 3mm to 30 mm and in the standard size of 2440 mm x 1220 mm and then laminated as per the customers requirement.
The plain MDF board is sandwiched between two resin treated papers which are “fused” to the board under heat and pressure in a hydraulic short cycle press in a time cycle of 30 – 45 seconds and the lamination process is completed.
6. STACKING AND STORAGE
The final product is trimmed on all the sides and then sent to the stacking assembly line where it is loaded onto forklifts and shifted to the stock yard.
The final product is a scratch resistant laminate which is also highly resistant to heat, chemical stains, moisture, termite attack etc. The entire specification sheet is as below and is the same in consistency for every batch.