The production of chipboard is usually considered to be one that uses waste from the wood processing industry. In addition, few entrepreneurs are interested in this simple production process like a business. This attitude is completely in vain. This building material is still in demand for commercial real estate and for domestic purposes among the population. Equipment for chipboard production– these are not only the main machines for pressing and forming products. The production line includes chipping and flaring units. They allow you to prepare raw materials yourself, from any wood products. Thanks to this, connection to industrial processing facilities is completely optional.

Another area of application for chipboard is furniture production. Not a single factory can do without it today. No matter how expensive the furniture is, its hidden elements are still made mainly from chipboard. Another type of particle board is laminated chipboard. This material is similar to conventional blanks, but its surface is well polished and covered with a film. The top layer is made of paper or resin of a special composition.

Chipboard production technology

Manufacturers of modern chipboards use technology that we will describe below. The raw material is shavings. Wood can be used inexpensively: deciduous and coniferous. A binder is also used as a material. Hydrophobizing additives in it increase the strength of the future product.

Processing of raw materials	At this stage, it is unloaded and large pieces are crushed. Next, the chips go through a sorting stage depending on the fractions. The raw materials must be cleaned of unnecessary impurities and contaminants.
Drying	Occurs up to a humidity level of no higher than 6%. For the inner layer, this parameter should not exceed 4%. The process temperature reaches 1000 degrees, and the output chips have a temperature of 120 degrees.
Resinization	As a result of this operation, each chip is coated with a binder. The durability and strength of the material depends on the quality of its execution.
Carpet formation	At this stage, the product itself is formed from the semi-liquid chip mixture. Previously, it was made in several stages, performing two or three layers. This technology made the material brittle and unstable to bending.
Pressing	It comes in two types: horizontal and extrusion. The production of modern chipboard and laminated chipboard usually chooses the first method, as it makes it possible to obtain a more durable product.
Trimming and cooling	Cutting into finished slabs occurs either hot or after the workpiece has completely cooled. The latter method minimizes the possibility of deformation when using the material.
Grinding	The last stage, at which the product is leveled, the edges and surfaces are processed until given parameters roughness.

What equipment is required for chipboard production?

All this technology can be implemented using such a set of machines and installations. Most often they are supplied in one production line. If you choose the right machines for productivity, then you can assemble them separately.

Hammer crusher DMR-600-10-55	Productivity of the model is 10-30 cubic meters. m. The cutting element consists of six discs mounted on a shaft. They are closed by the body. The crusher has a number of sieves for sifting raw materials.
Vibrating screens for sorting	Used additionally for better selection of sawdust.
Drying complex	Drum type dryer running on gas or fuel oil. The diameter of the working drum is 2.2 m, length is 10 m. Usually the platform has a slight slope towards the side from which the raw materials come.
Continuous mixer (for example DSM-7)	Resinization occurs in it. Raw materials and binders are supplied to the tank. It is added to the mixture through nozzles. The screw shaft with blades makes constant movements and mixes the mixture until smooth.
Presser	This equipment is capable of forming a workpiece in one pass required thickness and width. The uniform density and thickness of the product depends on the operation of this equipment.
Heat press	Here the workpiece is hot pressed at a temperature of 180 degrees. The pressure exerted on the plate is 2.5-3.5 MPa. I apply a press to 1 mm for at least 0.35 minutes. For the production of laminated chipboards, extrusion-type presses with internal channels are used. This equipment can be single or multi-storey. The latter allows pressing of up to 22 pieces of products simultaneously. The height of such equipment reaches 8 meters, so this must be taken into account when choosing a room.
Cooling chambers	They are a large rotating drum with special cells. In an hour, such equipment can cool about 200 workpieces to a temperature of 50 degrees.
Sawing machines	These include equipment for grinding ends and a cross saw.

How much money do you need to start a business?

The price of a line of such equipment is about 10 million rubles. About 1.5 million more rubles will need to be spent on additional and auxiliary mechanisms. There is domestically produced equipment on the market, and recently manufacturers have begun to import quite a lot of similar lines from China. Both equipment for the production of chipboards are successfully operating in production. Its price depends on performance, power and the set of functions performed.

Laminated chipboard (LDSP) is the main component for the production of cabinet furniture, which reliably imitates natural wood , But costs many times less.

Cheapness due to use wood waste- shavings.

The production of laminated chipboards has several basic technologies.

what is laminated chipboard;
how does the production of laminated chipboard differ from the production of chipboard;
what documents regulate the quality of laminated chipboards in Russia;
what equipment is used for lamination;
how edge tape is made;
How to laminate chipboard yourself.

laminated chipboard is regular particle board which we talked about, lined with decorative coating.

The coating can be either single-color and smooth, or multi-colored or imitating wood texture.

Main characteristics such as:

bending strength;
ability to hold a screw;
density;
moisture resistance classes;
formaldehyde emission class;
flammability

fully correspond to the same characteristics of the source material.

The thickness of the laminated material depends on its purpose. For the manufacture of cabinet furniture they most often take Chipboard thickness 16 mm, however, table tops are often made from thick slabs 25–38 mm.

Laminated chipboard for cladding walls, floors and ceilings is made from thick chipboard 8–12 mm.

The laminating layer with a three-dimensional pattern increases the thickness of the chipboard, because this the pattern is created by pressing the base layer, pressing the contours of the design on it.

Outdoor the film only follows the contours this drawing.

How are chipboards made?

For the manufacture of laminated chipboards, ordinary sanded particle boards are used, so they are produced at a chipboard production plant, connecting the lamination section.

Moreover, 3 technologies are used to cover the source material with a laminating film:

lamination;
laminating;
smooth lamination.

Lamination

When laminating 1–2 layers of specially prepared paper are glued onto the base, and the first layer - the base - is made as thick as possible so that the design can be pressed into it.

The thickness of the base, depending on the depth of the pattern, can reach 0.5–1 mm, the thickness of the second layer is tenths or even hundredths of a mm.

On top of these layers another layer is laid, made of transparent paper and a mixture of various resins, which when heated, they turn into a durable film, reliably protecting the decorative surface.

The base layer is laid on the prepared chipboard surface and pressed down with a hot stamp with a suitable pattern.

The die surface temperature is 150–220 degrees, due to which the resin that impregnates the base layer is mixed with the resin that glues the chips into the chipboard and, the paper becomes an inseparable part of the plate.

Then, in the same way, a decorative layer with a suitable pattern and an outer layer are glued, which protects the slab from damage.

At some enterprises, all layers of coating are first connected to each other, then dried and, only after that, attached to the chipboard.

With this technology, the coating is made in the form of a tape. The pattern on it is formed using a cylinder with an installed matrix, similar to the formation of a pattern during laminating.

Difference with laminating is that the tape is attached without glue, heating the resins that impregnate the paper until they melt and mix with the resin in the chipboard.

Laminating

When laminating, first prepare facing material, for which all layers are laid in order and a pattern is printed on them using a cold press.

At the same time, the uncured resin of the various layers is mixed, due to which the coating turns into a wide and long ribbon.

If you use it to print a picture cylindrical die, then the opportunity arises to do ribbons of any length.

Many small businesses producing 3D textured laminates prefer do not spend money on expensive equipment necessary for making the tape, and buy ready-made material.

The finished tape is sent to the dryer, then wound into rolls, which are delivered to the laminating area. There, the facing material is cut to size and placed on a slab coated with a special glue, then pressed with a press and heated until the glue is completely polymerized.

Thanks to this technology cladding goes faster, after all no need to heat each layer of coating separately, so the company can produce more products.

The disadvantage of this technology is that the glued cladding holds on much weaker than real lamination.

Smooth lamination

This technology similar to laminating, however, is a full-fledged lamination, because when heated, the resin of the coating and the boards are mixed, forming a single material. In addition, in the tape preparation area no press to create a pattern.

To create smooth surface it is enough to lay 2 layers, the bottom of which will be made made of paper, and the top one is made of a special film, which, when heated, forms durable and transparent coating.

Due to the fact that large chipboard manufacturers are constantly looking for ways to increase production manufacturability and reduce costs, they are constantly introducing various changes, the essence of which is kept secret by manufacturers. After all, any improvement in the quality of the laminating coating, as well as a reduction in costs, makes their products more competitive.

Documents regulating quality

The main document regulating the quality and characteristics of laminated chipboards in Russia is GOST R 52078-2003 which you can find at this link.

There is also international standard EN 14322:2004, which is in many ways similar to the Russian one. You can find it.

These standards differ from those adopted for chipboard only in the requirements for the laminating coating. In everything else they completely identical.

Besides, there are various specifications (technical specifications), which are developed by both manufacturers of laminated particle boards and furniture manufacturers. The technical specifications prescribe those requirements that are not included in generally accepted standards or for some reason fall outside them.

For example, the technical specifications may specify non-standard sizes products, and also indicated detailed composition of glue, different from what the company uses in the production of conventional chipboard.

Equipment: plant and its components

In most cases, a multifunctional device is used for laminating chipboard, which is called laminator. Its basis is powerful press with steam or oil heating of the plate, as well as with the possibility of installing matrices with the required pattern.

The laminator can be large, capable of processing sheets maximum size, as well as medium or small. If a large press is installed, then after cooling the laminated sheet goes to a cutting machine, completely similar to that used in the production of chipboards.

In addition, the laminator can be one- or two-sided, that is, stick the film only on the front side or simultaneously process the front and back planes.

Medium-sized presses are designed for laminating already cut slabs, the size of which complies with the requirements of GOST R 52078-2003 and EN 14322:2004.

The small press is designed for laminating finished parts, for example, input and interior doors or furniture elements. Therefore, the enterprise you should choose a laminator based on the range products.

In addition, together with a large or medium laminator, a tape laying line is often used, which also performs several functions:

determines the quality of chipboard surface preparation for further processing;
lays the tape on the slab and orients it correctly;
trims off excess tape.

In enterprises where small laminators are installed, this operation is usually performed by a specially trained highly qualified worker, laying and cutting the tape by hand. Most often this is done on furniture factories when you have to make parts that for some reason cannot be cut from a whole sheet.

They do the same in large woodworking shops or factories that produce not only furniture, but also various carpentry products.

The laminator can be used not only for lamination, but also for regular gluing, so there is no point in spending money on a special line.

Often, after cooling, medium and small slabs are fed to a cutting machine, which cuts off 1–2 mm of slabs, forming an even edge. This machine is equipped with circular saws large diameter with carbide or diamond-coated tips.

The slabs are moved along the entire line using belt conveyors and vacuum lifters, and all operations occur automatically.

The cost of equipment depends on many factors, so most enterprises that produce such lines and individual machines announce the price only after the customer has provided specific requirements in terms of configuration and performance.

On Aliexpress and other sites you can find individual devices and entire lines indicating the approximate cost excluding delivery and installation.

Medium single-sided laminator for slabs measuring 1220*2440 mm can be purchased for 100–200 thousand US dollars, and a laminating tape supply line 60–120 cm wide will cost 18–25 thousand US dollars.

Edge tape

When manufacturing laminated chipboards, only the front and back surfaces are laminated, and edges remain uncoated. Therefore, enterprises producing laminated chipboards also supply edge tape, which is used for self-lamination of ends.

The color of the tape completely matches the color of the slab, so after sticking the tape, the entire slab becomes one color.

The tape for edging, that is, gluing the edges, is made noticeably thinner than that used for lining chipboards in production. Indeed, in the conditions of a furniture workshop it is impossible to create such high pressure and most craftsmen make do with a regular iron, warming up the tape laid on the edge with it.

How to laminate chipboard yourself?

Not always Laminated chipboard, which can be purchased in stores, matches the color or pattern, so you can veneer the slab yourself.

Various types of decorative films that are sold in hardware stores are well suited for this.

Films There are self-adhesive and regular.

To apply a self-adhesive film, remove a thin layer from it. protective coating and lay it on a chipboard sheet cleaned of dirt and dust, then roll it with a roller, removing air bubbles.

To apply a regular film, use a special glue recommended by the film manufacturer, then wait 2–5 minutes and carefully apply the film without allowing wrinkles to appear.

Such methods allow you to stick on the chipboard only those designs that are in the store, so you can use method that was used during the USSR, when laminated chipboard was in huge shortage.

Apply to a chipboard surface free of dust and dirt. thin layer primers (PVA diluted with water in a ratio of 5:1). Then the desired drawing was made on sheets of landscape paper and reverse side primed with PVA.

After 2–4 days, when the glue had completely hardened, the sheets with the pattern were laid out on the surface of the chipboard so as to assemble the pattern together. Then each sheet was heated with an iron.

If all the sheets were correctly laid and heated, then after cooling they formed a continuous pattern that completely covered the entire surface of the slab.

However shifting any of the sheets led to a violation of the pattern and spoiled the whole picture, so for greater reliability they tried to get not landscape paper, but printing paper, which was larger than the slab in size.

The finished drawing was covered with furniture or parquet varnish in 2–3 layers and a homemade laminate was obtained with low coating strength, but with the necessary pattern.

Video on the topic

In this video you can see the work of a chipboard production plant:

Conclusion

The production of laminated chipboards is a complex process that includes many operations, therefore, to convert ordinary chipboards into laminated ones it is necessary site with good equipment.

After reading the article, you learned how the lamination process occurs and whether you can do it yourself.

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 material is mixing sawdust mass 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 efficient equipment, integrated into a complete 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.

Produced both during the manufacturing process and after receipt finished products. 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);
norms fire safety;
sanitary standards.

A certificate of normative and technical compliance is issued government agency on certification. 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 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 forms appearance 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.

About the features of manufacturing laminated furniture chipboard will tell the video:

Milling

The production of internal shaped surfaces and external processing of corners is carried out using milling. The cutter is a toothed cutter with an arbitrary correct form(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 circular saw or a 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" - Kaluga manufacturer wide range wood products, including chipboard;
"Krasnoyarsk DOK" - offers large selection wood material using a chipboard production line to improve 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.

Particle board, or chipboard, is a composite sheet material. It is produced from wood waste and non-mineral binders using the hot pressing method. Composition of chipboard may vary depending on the details technological processes or 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 the production of furniture, for interior decoration, and in the 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 chipboard production

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

Stage I - preparation of the necessary raw materials

There is a process of mixing different wood materials 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, crushing is carried out wood waste and further grinding them to the desired 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 chipboards, technological chips and shavings, are obtained in the process of processing deciduous and coniferous species, various wooden waste from sawmill, 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.

Taller quality characteristics disposes the chips. 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 screened by electromagnetic separators, which allows metal particles to be removed, 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 under the influence of high temperatures and pressure of prepared wood particles. 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 shape finished products when there are changes in humidity, since without additional treatment 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 hot water. The deposition of hydrophobic substances on wood fibers is carried out by aqueous solutions 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 a 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.

In pursuit of super-profitable and often excessively technological complex industries, novice businessmen often simply do not pay attention to the most simple materials, which for various reasons seem outdated, unused and unattractive for investment.

Such materials include, for example, chipboard or chipboard. Many people generally consider this material to be just an attempt to recycle wood waste and are surprised to learn that chipboard factories often use special chippers and flakes that produce so-called wood from non-commercial wood. technological chips – i.e. main component of chipboard.

But chipboard is used very widely: furniture manufacturers use laminated boards in the manufacture of doors, sides, facades, and polished boards for various hidden elements; builders and finishers also widely use wood board– mainly for creating various floorings; In addition, chipboard manufacturers trucks and carriages they make partitions and bulkheads. Although, of course, the main consumer of this material is furniture production.

But why not produce some more technologically advanced material - the same laminated chipboard or even blanks for modular furniture? The answer is simple - the production of the starting material is much cheaper and technologically (and therefore in investment plan) is inexpensive. The production of chipboard requires a lot less equipment, and the cost of materials than for the manufacture of its derivatives - for example, chipboard.

It is obvious that the opening of chipboard production can be very profitable business, especially if there is access to cheap raw materials - sawmill waste. The sales market is practically limitless, so there will be no problems with this.

Technology and equipment for chipboard production

Chipboard is produced by hot pressing a mixture of chips and thermosetting resin. IN general view the technology is as follows - the chips are mixed with a binder material and placed in molds, where they are exposed to high pressure and temperature are glued together into a single whole. The finished slab is then removed, cooled, cut and sanded.

The chipboard production process itself can be divided into several stages: preparing raw materials, obtaining chips, mixing chips with glue, forming a carpet, pressing and gluing boards, cooling and trimming edges, grinding ends and faces.

By and large, the first two stages are optional if you use imported material. If not, then you will have to purchase a crusher or chipping machine (160-460 thousand rubles, depending on the type, power, etc. characteristics), as well as a flake machine (approximately 1280 thousand rubles).

As you can see, some additional costs, although small, will still be required, so it makes sense to think about the feasibility of working on ready-made or requiring preparation raw materials.

However, this question, due to its financial insignificance, is quickly resolved by studying suppliers: are there appropriate manufacturers of process chips in your city?

Mixing of shavings with glue is carried out in special mixers (235 thousand yuan per unit), into which shavings and heated resin with hardeners and other additives are supplied. It must be remembered that the weight fractions of chips and resin are strictly regulated and if their ratio is violated in any direction, a deterioration in the physical and mechanical properties of the product may occur.

The formation of the carpet is carried out using molding machines; they place tarred shavings into a mold. Pressing and gluing of particle boards is carried out in special thermal presses. The total price of a paired forming machine and an 8-deck press is only 1536 thousand yuan per set. After the blank sheet is produced, it is cut to the specified dimensions using an automatic sheet cutting machine (88 thousand yuan per unit) and submitted for grinding.

Grinding of chipboard is the final stage of mechanical processing in the production process, and the grade depends on the quality of surface grinding: according to GOST 10632-89, first-grade boards should not have depressions (protrusions) or scratches, paraffin, dust or resin stains, chipped edges, chipped corners , under-polishing, surface waviness.

Second-grade slabs may not be sanded at all, but they are used only in construction - for furniture production Sanded boards are required, although chipboard manufacturers often purchase second-grade boards and sand them themselves.

Used for sanding chipboard sheets grinding machines, the selection of which takes into account parameters such as processing width, number of grinding heads (usually 2, 4 or 6 grinding heads) and power. According to these parameters, prices vary - from 440 to 995 thousand rubles.

The above equipment for the production of chipboards is the main one. Additional options include vibrating screens; various types roller, belt, spiral and chain conveyors connecting different units; roller lifting table for stacking sheets of finished chipboard; ventilation system for removing dust during grinding and some other specific devices (loader trucks, stackers, etc.).

As you can see, the list of equipment for chipboard production is quite small. However, in addition to equipment, production space is also required.

To launch a full-fledged chipboard production, about 1800 square meters are required. m actually production area plus at least 600 sq. m of warehouse space - and this is not counting utility rooms, offices, sanitary facilities and others.

Business prospects for chipboard production

The prospects for chipboard production are determined by the very specifics of this production. As you may have noticed, sanding, coating and other forms of finishing significantly increase the selling price of slabs.

Ideally, it is better not to sell first grade slabs at all, but to laminate or veneer them yourself. This, of course, will require small expenses, however, the sale of such slabs occurs at prices that are an order of magnitude higher than usual.

In addition, on the basis of chipboard production, it is also possible to organize the production of related materials: MDF, fiberboard, etc., not to mention furniture production.