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How Super PB helps particleboard producers save costs

Photo Caption: DIEFFENBACHER Super PB plant at Guangxi Fenglin in Nanning, China.

In today’s increasingly competitive and profit-driven economy, reducing costs is a key factor for economic success. Another key factor is squeezing every percentage point of efficiency from the production process. This is true for both industry in general and particleboard producers in particular.

Two MAIER MSF Strand Flaker PB with FlowOptimizer for the production of slender, long core-layer flakes at Guangxi Fenglin in Nanning, China.

For the Indian particleboard market, so-called Supermechanical Strength Particleboard or Super PB has the potential to be a major force in increasing plant efficiency and realizing significant cost savings. By mixing standard core-layer flakes with slender, long core-layer flakes, it is possible to achieve a board density up to 30 kg/m³ lower than usual. This leads to substantial savings of wood, electrical and thermal energy, and resin without compromising board properties. The special two-stage production process for the slender, long core-layer flakes has another advantage: Raw materials other than logs can be used. Slabs and offcuts from sawn timber, for example, can easily be made into slender flakes. Far-less expensive extremely thin and curved logs can also be used.

By mixing standard core-layer flakes with slender, long core-layer flakes, it is possible to achieve a board density up to 30 kg/m³ lower than usual. This leads to substantial savings of wood, electrical and thermal energy, and resin without compromising board properties.

The existing production process, including wood preparation, flaking, screening, sifting, forming and pressing, can be technologically adapted to enable efficient production of Super PB. The chipper setting, screening process and design of the glue blender system can be modified to achieve minimum breakage of the slender, long core-layer flakes by preventing exposure to harsh mechanical treatment. The type of glue used remains unchanged, but due to the lower average board density, glue consumption can be reduced while keeping the board properties.

Slender, long core-layer flakes

Standard core-layer flakes

DIEFFENBACHER GmbH Maschinen- und Anlagenbau from Eppingen, Germany has a long tradition of working together with customers to develop new panel types. The company reconsidered the structure of standard particleboard, then developed Super PB, which can be produced at reduced manufacturing costs. The secret lies in the two-stage flake production process. In the first stage, a MAIER HRL Drum Chipper is used to produce high-quality macrochips from different wood assortments. In the second stage, the special MAIER MSF Strand Flaker PB with FlowOptimizer technology cuts the macrochips into the required slender, long core-layer flakes.

To date, DIEFFENBACHER has completed four new plant projects for Super PB lines and has adapted three existing particleboard plants to shift production to the lower density and cheaper Super PB.