MDF, OSB and particleboards from annual plants: The focus for Siempelkamp at Xylexpo 2018 in Milan is completely on new technologies for the production of superior-quality fiberboards. This is especially true in the field of alternative raw materials (e.g. rice straw) where the technol-ogy leader from Krefeld in Germany is unveiling its innovative new products. Rice straw is, in terms of quality, an equivalent alternative to wood as a raw material and available globally in large quantities as a waste product in rice cultivation. In addition, this raw material is 100 per-cent compostable. With the expansion of its fiberboard technology (which has proven its value for decades), Siempelkamp can now provide its customers with a “green” alternative to wood.
ContiRoll® Generation 9 and Generation 9 NEO
A core element of fiberboard production is Siempelkamp’s ContiRoll® which has been in use around the world for many decades. The latest Generation 9 and Generation 9 NEO enable fully automated and digitally controlled high-speed production of top-quality wood or rice straw fiber-boards. MDF boards can be produced in volumes of up to 0.9 million m3 per annum with a Con-tiRoll®. And, with a production speed of 2,500 mm per second, the ContiRoll ® sets technologi-cal standards on a global level. 320 systems installed in a variety of climate zones ranging from tropical to subarctic demonstrate the absolute reliability and unsurpassed product quality of ContiRoll®. During development, Siempelkamp engineers attached enormous importance to integration of the latest intelligent components for optimum control and monitoring of the produc-tion process. An innovative new press feed, state-of-the-art energy efficient drive and measuring technology and new methods for mat heating are further innovative developments of the Conti-Roll® Generation 9. The latest ContiRoll® generation impresses manufacturers all over the world through a productivity increase of 30 percent. Maximum system availability with minimum maintenance, high-precision production in continuous operation and considerable savings in material use and energy consumption make the ContiRoll® Generation 9 one of the most effi-cient production plants for fiberboards.
NEO Blender: Wear-resistant and maintenance-friendly resin blender for rice straw and annual plants
In contrast to normal MDF production, resinating of rice straw fibers only occurs after the dryer. Siempelkamp employs a process for the dry application of resin here using a newly developed continuous blending system. This blending system enables optimum adaptation of the glue sys-tem to production conditions. Glue consumption is lower than in the conventional gluing process as losses due to pre-curing are avoided.
The newly developed NEO Blender ensures uniform, continuous gluing of fibers, is extremely resistant to wear and, thanks to a screw-on mixing chamber cover, is easy to maintain. The material properties of rice straw in production were consciously taken into consideration during the process.
The main features of the NEO Blender are:
• a high peripheral speed of up to 100 m/s for optimum wetting and thorough blending
• optimized, wear-resistant mixing and transport tools
• an innovative housing design with double-walled cylinder jacket and wear-resistant inner cylinder jacket
• a maintenance-friendly overall concept
• integrated system monitoring through vibration measurement.
The EcoFormer SL is a further development of the traditional and proven CMC TEXPAN wind dispersion concept employed in mat forming systems for particleboard production.
A particleboard has a three-layered composition. The core of a board is made up of coarser particles to ensure excellent mechanical properties, while the outsides have a graduated struc-ture with very fine particles on the surface to enable further processing (e.g. melamine coating). The system was developed to improve the quality of face layer particle mats by optimizing sepa-ration of finer and coarser wood particles.
To accomplish this result, the airflow path within the wind dispersion chamber was analyzed through computational fluid dynamics (CFD) simulation to make it more efficient.
The core of the EcoFormer SL consists of a diffuser plate with perforations in a special pattern which absorbs the airflow blown by fans through a plenum chamber and ensures perfect chan-neling and distribution of the airflow between individual air nozzles.
These have the same overall dimensions as the previous wind dispersion chamber to facilitate their installation in existing systems.
The use of an EcoFormer SL system offers several advantages that achieve a higher level of quality at lower costs. These include perfect distribution of the airflow between the air nozzles for better cross weight distribution and material savings and a drastic reduction in pressure loss in the system, thereby requiring less fan pressure and saving energy. In addition, easier access for inspection and cleaning purposes makes the EcoFormer extremely maintenance-friendly and represents an optimum solution for the modernization of particleboard plants.
The EcoSifter from Siempelkamp is an innovative, reliable and energy-efficient fiber separator that can process all types of wood and alternative raw materials such as rice straw or rubber wood. The combination of a specially developed partition plate with innovative flow technology optimizes the circulating circuits within the EcoSifter. The airflow introduced at the base sepa-rates the light fibers from heavier contaminants which are then discharged rapidly and without residue from the EcoSifter via a rotary air lock. What is new is the separation of fiber flow and transport air so that the majority of the airflow is immediately returned to the EcoSifter. Special fans with enclosed impellers are employed for this purpose which achieve a high efficiency level and, in turn, significantly enhance the energy efficiency of the separator. In addition to a high degree of energy efficiency, flow resistance is minimized and simplified flow adjustment and high serviceability are achieved, thanks to Siempelkamp’s innovative flow technology.
The EcoScan NEO enables inspection of uniform material distribution and detection of foreign bodies in a fiber mat. To achieve this, the EcoScan (a scanner based on the latest X-ray tech-nology) performs a high-resolution basis weight measurement over the entire cross section di-rectly after the pre-press. A system of probes traverses the full width of the mat in a sinusoidal scanning mode below the product, while self-adjusting probes above the fiber mat detect resid-ual radiation. A special algorithm detects even the smallest foreign particles, even if these are not metal. As a consequence, the smallest scattering errors and impurities are reliably detected and surface weight fluctuations limited or mats with foreign bodies removed. The EcoScan NEO measuring system is connected to the intelligent Prod-IQ® process control system, thus ena-bling online evaluations through visualizations on different HDI surfaces. As a result, manufac-turers of wood-based panels can reduce their waste, save material and enhance the cost-effectiveness of their plant.
During production of superior-quality MDF, OSB and particleboards, resinated mats are heated in the press line and the resin contained in the mats begins to harden. Moistening and preheat-ing of the mat before the pressing process facilitates speedier heating of the mat in the press and, consequently, accelerates board production. The innovative ContiBooster is the optimum and cost-effective solution for this purpose. The treated mats are heated before being fed to the press line, whereby climatic changes at production locations can also be compensated for. Up to 30 percent more output for wood-based panel plants is possible with the ContiBooster from Siempelkamp.
The EcoPulser from Siempelkamp employs a completely new, non-cutting and virtually wear-free process for reshredding wood chips and particles. Impact waves act on the bulk material, breaking up the material structure. Even highly abrasive chip material can be processed with excellent results, thanks to the non-contact process involved, as the chips are broken up in the air. The EcoPulser crushing process is based on two impellers rotating in opposite directions that produce extreme air vibrations and negative pressure due to their rapid rotation. This air stream sucks the wood chips or chip material through the rotor combination, causing the wood cells filled with air, water or ice to crack through the action of abrupt negative pressure and sev-er along their fibers. The wood fibers are largely retained in their length, ensuring greater strength in particleboards. This innovative comminution method ensures that the EcoPulser has excellent energy efficiency, as only about 10 percent of frictional energy is lost as heat. The energy saving potential is enormous. Comminution for core layer material can save approxi-mately 10 kWh/t of produced material, and this rises to about 40 kWh/t for the production of face layer chip material. Since no cutting edges are used for comminution, no re-sharpening or re-placement of cutting blades is necessary. The EcoPulser is even insensitive to impurities such as stones or metal parts, as no material contact occurs with the impellers. It can therefore be used without difficulties for alternative materials.
The 6-fold diagonal saw
At up to 2,500 mm/s, the production speeds of the ContiRoll® also require efficient finishing. Cutting of the shortest boards must be ensured, and the replacement of a saw blade should not affect ongoing production. Siempelkamp’s 6-fold diagonal saw has been developed for maxi-mum production capacity in continuous operation, while also reducing the dust emission rate. The modular design minimizes the fitting effort for the Siempelkamp 6-fold saw, and the startup time is kept extremely short through the latest IBN simulation. Thanks to pre-simulation, se-quential product changes or board format modifications are also realized during the ongoing production process, and all necessary functions are optimally integrated in the control concept. A mechatronic approach means that the production parameters required for this are recorded conductively on the machine frame and processed by the process control system. This means that laboratory cuts and saw blade changes can also be realized during operation at full produc-tion speed. The Siempelkamp 6-fold saw executes its ultra-fast cuts during operation while matching these perfectly to the respective product. Extraction hoods of all Siempelkamp saws have been optimized for high-speed production and suction efficiency has been increased by 40 to 50 percent. This new development involves a considerable energy saving potential, as less suction power is needed.
Patented by the Siempelkamp subsidiary Strothmann Machines & Handling GmbH, Round-Track® technology is an innovation designed for in-house transportation of loads (e.g. plant components). The system is ideally suitable for use in manufacturing and assembly plants, large warehouses and outdoor areas. Due to low rolling resistance, it is possible for a single person to move loads weighing up to 5 metric tons manually without any major effort using special trolleys on the RoundTrack® system embedded in the floor. The system has extremely low rolling re-sistance (coefficient of friction of 0.01). Even the overlying running wheels of the carriages (which are designed for loads of up to 200 metric tons) have only two points of contact on the RoundTrack® protruding a few millimeters out of the floor. The system thus proves to be the most economical type of material handling equipment, due to the very low energy consumption involved. Quadro turnstiles embedded in the floor which can be passively or pneumatically ac-tuated ensure a high degree of maneuverability at fixed approach points. In addition, built-in crossings even allow right-angled slewing of dollies. The risk of an accident is practically zero, due to the flush mounting of the RoundTrack® systems. Trolleys and carriages can be equipped with lifting or rotating devices and also external starting aids (e.g. MoviMax from Strohtmann).