MDF Manufacturing Process
The Company has set up a fully integrated state-of-the-art computerized plant to produce in the State of Haryana. Our manufacturing facilities have types of machinery from the widely acclaimed makers of hardware for this industry. The plant has a complete setup for making the MDF board right from the initial step to guaranteeing that the quality is not bargained at any stride.
Debarking and chipping
The first step in the manufacturing of MDF board is Debarking. The bark of the soft wood of eucalyptus can be used as it is but to get the better quality of the final product the bark from the log is removed. This decreases grit and organic waste. It also allows faster drainage of the water and helps in finer surface finish.
Once the bark is removed the log is then stripped. The chipper drum reduces the logs into evenly shaped chips. The resulting chips, if they are too large, may be re-chipped and the undersized chips are used for another purpose.
The chips are then washed to check for the defects. The process also removes bits of bark, dirt, dust and so on.
Before the defibration process, the chips are coated with molten paraffin wax. This glues the chips together. The glued chips are then dried by transporting through hot air dryer. This takes out the defective fibers.
The chips are then fed into the defibrator for few minutes under high temperature while they are ground to form a pulp. From the defibrator, the pulp enters a blowline, where it is mixed with resin, The wax improves moisture resistance and the resin initially helps reduce clumping, but ultimately is the primary binding agent. It is then passed through dryer where it dries out quickly.
The dry fibers are then conveyed to the mat forming system. Here they are dropped on the belt which is converted into an even mat with the help of the distribution arms.
The mat is rolled through a series of heavy roller which give them the desired thickness. The edge trimming saws trim the edges of the mat to give the desired length to the board. The chipped fiber from the edges is vacuumed and recycled.
The mat is then passed through the hot press to make the strong bonding of the fiber mats. The hot press allows up to 10 mats to be pressed at a time to the specified thicknesses.
The boards are weighed on a weighing platform, cooled to room temperature in a star cooler, and then stacked on a platform. They are then trimmed with the help of the saws to the required size
The trimmed MDF boards are then stacked in the warehouse from where they are loaded into the trucks as per the required quantity.