MUHAMMAD SAQIB

TRAINEE PROCESS ENGINEER

Medium density fiberwood line 1&2

DISCRIPTION:
Wood Storage:
➢ Mango 80%
➢ Sasbaniya 15%
➢ Sumbul 5 %

Chippers:
Two chippers are in operation, one with 2 blades and the other with 4 blades. The chips
produced have an outlet mesh size of 60mm.
Screening:
Vibratory screens are utilized to segregate the chips into different sizes. There are three
mesh sizes: 70 mesh (for chips returning to the crusher), 40 mesh (desired chips for the
vertical belt), and 20 mesh (for dust particles directed towards the boiler).
Pin Drum Shooter:
This equipment controls the flowrate of chips. It consists of two rods connected with
numerous teeth to grip the chips effectively.
Digester:
Chips, mixed with super-saturated steam, enter the digester operating at 230°C and 11 bar
pressure. The retention time is approximately 5 minutes. A prime mover motor and gear
reducer are installed to rotate the digester.
Defiberator:
The mixture from the digester is fed into the defiberator with the help of a plug screw.
Steam is used as the motive fluid. Urea formaldehyde is added to strengthen the mixture,
with around 5.5-6 kg of glue added to 80 kg of fiber.
Dryer:
An ID fan heats air with steam lines (10 lines), which is then used to remove moisture
from the fiber mixture. The target moisture level is 11-12.5%.
Cyclone:
Cyclones separate the desired fiber product from air, with the separated air vented out
through a stack.
Mat Forming:
Fiber is transferred from the bin to the mat formation process via an ID fan. Shave off
position is approximately 180mm. A sculpture fan is used to exhaust extra fiber into the
bin, and a mat trimmer shapes the cake.
Pre-Pressing:
A hydraulic press roller reduces the thickness of the cake to approximately 90mm. A
cross cutter operates with a length of 16 ft. and a width of 4.5 ft.
Hydraulic Press:
A wood-fired furnace heats oil, maintaining the temperature of hydraulic press plates at
190-200°C. A pressure of 180 bar is applied for 192 seconds to press the cake.
Cooling Wheel: A cooling wheel cools down the produced board from the heated
hydraulic press machine.
Trimming and Sanding:
The board is trimmed to 8 ft. by 4 ft. and then passed through a sanding train with
sanding paper of numbers P-40, P-60, and P-120

Process flow diagram:

WOOD STORAGE CHIPPER SCREENING BIN

GLUE BLENDING DEFIBERATOR DIGESTER PIN DRUM

SHOOTER

DRYER CYCLONE BIN MAT FORMING

TRIMMING AND COOLING WHEEL HYDRAULIC PRESS CROSS CUTTER

SANDING
OPERATING PARAMTER OF MDF
Parameter Description
Density Typically ranges from 600 kg/m³ to 800 kg/m³
Thickness Varies, but common thicknesses include 16mm, and 18mm
Size Standard sheet size is often 4 feet by 8 feet (1220mm x 2440mm)
Glue Type & fiber/glue ratio Urea-formaldehyde & 80 kg fiber/5.5kg UF
Moisture Content Target moisture content during manufacturing is typically around 5-7%
Digester configuration Allowable working pressure & temperature is 11 bar and 200 C
Digester inlet capacity 17800 L
MDF Receipt Mango 80%, Sasbaniya 15%, Sumbul 5 %
Hydraulics press configuration Allowable working pressure & temperature is 180 bar and 190-200 C

Observations and suggestions:

➢ Installation of flow meters for steam lines at DeFi depart

➢ Level sensor at glue storage tank
 CHIPBOARD LINE 4 AND 5

DISCRIPTION:
WOOD STORAGE:
➢ Mango 40%
➢ Eucalyptus 30 %
➢ Mix 30 %

CHIPPER:
2 chippers were in operation. Chipper 1 have 2 blades and the other one have 4 blades. The outlet mesh
size was 40mm

WOOD HAMMAER MILL:

There are four roads in wood hammer mill to fine the chips. Each rod consists of 225 blades. The mesh
size is 5mm

ROTARY DRAYER:
A wood fired furnace is placed to generate the flue gases. The flue gas temperature is about 550C. the
flue gas is directed to enter a 3-pass shell rotatory dryer at the 4-5 rpm to reduce the moisture of the fiber
up to 5%. An Induced Draft fan placed to direct the mixture of flue gases and fiber towards the cyclone.

CYCLONE:
Cyclone is used to separate the desired fiber product and flue gases. The separated flue gases vent out
through stack.

DRY HAMMER MILL:

4-8 rods consists of numerous blades to refine the fibers more. 2mm mesh is placed to screen out the
fiber.

SCREENING:
The screen mesh size is 8mm, 10mm and 12mm. 8mm fiber is used as fuel for furnace. 10mm used as
surface material. 12mm is used as a core material.
REFINER:
The oversize material of screening is feeded into the refiner to fine the fiber and use it as a surface
material.

GLUE BLENDING:
A feedback system is installed to add the urea formaldehyde glue as a binder in board. it vary with the
weight of the cake formed.

MAT FORMING:
Surface-core-surface Mat forming system is placed to form the cake.

PRE-PRESSING:
A hydraulic press Roller is placed to reduce the thickness up to 60mm of cake.

HYDRAULIC PRESS:
A wood fired furnace is placed to heat up the oil which is used to maintain the temperature of Hydraulic
press plates at 190-200C. A stroke of 180 bar is applied for 172 seconds to press the cake.

COOLING WHEEL:
A cooling wheel is placed to cool down the produced board from the heated hydraulic press machine.

TRIMMING AND SANDING:

The board is then trimmed to 8 ft. by 4 ft. After trimming it is placed on a sanding train where it is passed
through the sanding paper of numbers P-40, P-60 and P-120.

PROCESS FLOW DIAGRAM:

WOOD STORAGE CHIPPER WOOD HAMMER ROTARY DRYER

MILL

REFINER SCREENING DRY HAMMER MILL CYCLONE

CORE AND SURFACE GLUE BLENDING MAT FORMING PRE PRESSING

CYCLONES

TRIMMING AND COOLING WHEEL HYDRAULIC PRESS CROSS CUTTER

SANDING
OPERATING PARAMTER OF MDF
Parameter Description
Density Typically ranges from 600 kg/m³ to 800 kg/m³
Thickness Varies, but common thicknesses include 16mm, and 18mm
Size Standard sheet size is often 4 feet by 8 feet (1220mm x 2440mm)
Glue Type & fiber/glue ratio Urea-formaldehyde & 80 kg fiber/5.5kg UF
Moisture Content Target moisture content during manufacturing is typically around 5-7%
Rotary dryer configuration Allowable working pressure & temperature is 1 atm and 530 C
Rotary dryer rpm 3-4 rpm
MDF Receipt Mango 40%, Eucalyptus 30 % ,mix 30 %
Hydraulics press configuration Allowable working pressure & temperature is 180 bar and 190-200 C

Observations and suggestions:

➢ Suction of ID fan at sanding machine 1 is too low and pollute the environment of sanding depart
➢ Installment of ID fan at Trimming area

AVERAGE COMSUMPTION AND PRODUCTION OF MDF LINE 01 &

CHIPBAORD LINE 05

PRODUCT NO SHEET GLUE THICKNESS WOOD STEAM

TYPE OF PRODUCED CONSUMMED CONSUMPTION CONSUMPTION
PRESS
MDF 250- 3000 16500 KG 16mm 240000 KG -
300
CHIPBOARD 270- 2320 15080 KG 16mm 185600KG -
290
 PROCESS OF IMPREGNATION PAPER
The industrial impregnation of Kraft papers is a manufacturing process where Kraft paper is
treated with urea-formaldehyde with KSN or melamine-formaldehyde with KSN-01 to enhance
its properties. This impregnation process is commonly used to make materials like laminates.

STEP OF IMPREGNATION:

1. Preparation:
Roll of Kraft paper are unwound and prepared for impregnation.

2. Impregnation:
The Kraft paper is passed through a bath or coating process where it is impregnated with
urea formaldehyde with hardener. These substances can include resins urea or melamine,
which are often used to improve strength, durability, and resistance to moisture and heat.

3. Drying:
After impregnation, the paper goes through a drying process to remove excess moisture
and to cure the impregnating chemicals.

4. Cutting and Packaging:

Once the impregnated Kraft paper is dry and cured, it is cut into sheets or rolls of the
dimensions of 8.2"and 4.2" the packaged for distribution or further processing.
 Operating parameter Value
Line speed 17.5 (m/min)
Paper produce per minute 8
Curing time 5 min
Urea formaldehyde & Melamine 60% & 40%
stiffness 6-6.5%

No. of dryers Temperature (C)

Dryer 1 175
Dryer 2 180
Dryer 3 200
Dryer 4 225
Dryer 5 230

LAMINATION
Parameter value
Temperature 190-200C
pressure 20 Mpa
Stroke time 10-15 sec

PVC COATING
PROCESS:

ROLLER CONVEYOR BOARD GLUE

CURING PRESSING SHEET

TEMPERATURE
PROCESS DISCRIPTION:

➢ Single side laminated board is placed on the conveyor roller which is then cleaned with
pressure fan.
➢ Glue splits on the laminated board
➢ Paper imported from China is pasted on the laminated board
➢ Board is passed through the electric heater for curing

UV COATING
CHEMICALS CODE CHEMICAL USED PER SHEET
571 50g to 60g
5404 50g to 60g
230 30g
5416 450g to 500g

FOR THE 1st CHEMICAL PROCESS

APPLY 571-B
CLEANING DRYER
CHEMICAL

FOR THE 2nd CHEMICAL PROCESS

APPLY 5404
CLEANING CHEMICAL BY DRYER
DOUBEL LAYER

FOR THE 3rd CHEMICAL PROCESS

APPLY 230 & 5416 COATED WITH

POLISHING CLEANING GLOSS SHEET
CHEMICAL