Wood Based Panels

Center for Wood Sciences
CASWoodͲBased Panels
Module1:Process Technology
Particle generation
Prof.Dr.JoergB.Ressel
September7Ͳ 12,2015– Biel,CH
www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html
Wood-Based Panels Content
Particle Generation
• Particle generation • Strand generation for OSB
• Long log ring flaker
• Particle generation – conversion paths
• Knife ring flaker
• Log debarking – drum and ring debarker
• Fibre generation for MDF
• Flake generation for PB • Defibration process steps
• Crusher – pre-breaker • Refiner and refiner plates
• Drum chipper • Refiner – additional equipment
• Impact hammer shredder
• Impact hammer mill
• Knife ring flaker
• Drum flaker
• Hammer mill
• Prallfiner – impact mill – sieve ring mill
• Waste wod processing
Wood-Based Panels Particle generation
Raw materials (summarised)

Logs – round wood Æ forests (industrial wood Æ timber harvest)
Forest residues Æ forest management actions (thinnings), small
diameter logs, large branches …
Residual wood Æ by-products from primary wood processing … Round Wood
Slabs, sidings, off-cuts
Chips (Æ chipper-canter lines), shavings
Sawdust
Peeler cores
Veneer residues
Sawmill Residues Industrial Wood
Reclaimed wood – waste wood Æwithout chemi-
cal pre-treatment, packaging materials, demolition
wood
Agricultural residues / annual plants … seaso-
nally harvested ! Æ cereal straw, bagasse, rice
husks … plantation residues Æ rubber wood, palms Straw Reclaimed Wood
Conversion of raw materials Æ Particle generation

Depending on the raw materials used particle generation is done step-
wise; often interrupted by screening and cleaning steps.
Screening Æ output fractions are:
Fines fine particles … dust Æ energy generation
Chips
Accepts convenient particles Æ panel production
Overs oversized particles Æ chopped up again
Impurities removed particles (metals, soil, sand, stones,
knots ...) to avoid any damage to processing
equipment and panel milling machinery
Strands (from logs) Flakes MRZ
Storage bunkers and bins ensure
continuous material supply. Mate-
rial transport occurs by suitable con-
veying and feeding systems
particle generation by … MRZ knife ring flaker
MSZ beating flaker
MPF prallfiner (mill type)
(Maier 03/2005) MPM impact mill Impurities (removed) Beaten flakes MSZ Fine flakes MPF/MPM
Conversion paths to achieve suitable particles for typical WBPs

Specific particles, e.g., for OSB, PB and MDF, and different raw materials require customized pro-
cess technologies to achieve an optimal result. The chart shows some alternative conversion paths
without intermediate screening, grading, storage and further disintegration of particle fractions.
Round wood, Round wood, Chips Slabs, off-cuts Reclaimed wood Round wood,
long logs short logs ... (Sawmill by-products) (Sawmill residues) Waste wood logs
Crusher Debar-
Debar- (Prebraker)
king king
Drum Drum
Cut to Drum chipper chipper
length chipper (OSB)
Wood
Preparation
Sawdust OSB
Direct fla- Drum Chips Chips
(Sawmill residues) chips
Raw mate- ker (KRF) flaker
rial - Input
Process Knife ring Strand

Impact mill Prallfiner Impact mill Refiner
technology flaker flaker
Product OSB- PB PB PB PB PB OSB- MDF

Output Strands flakes flakes flakes flakes flakes Strands Fibres

Specific particles (Æ flakes) for Particle Board
Round wood, Round wood, Chips Slabs, off-cuts Reclaimed wood

long logs short logs ... (Sawmill by-products) (Sawmill residues) Waste wood
Crusher
Debar- (Prebraker)
king
Cut to Drum
length chipper
Sawdust
Chips (Sawmill
Drum
Raw mate- residues)
flaker
rial - Input
Process Knife ring

Impact mill Prallfiner Impact mill
technology flaker
Product PB PB PB PB PB
Output flakes flakes flakes flakes flakes

Specific particles (Æ strands) for Oriented Strand Board
Round wood, Round wood, Slabs, off-cuts Reclaimed wood

long logs short logs ... (Sawmill residues) Waste wood
Debar-
king
Drum
Cut to chipper
length (OSB)
OSB
Direct fla- chips
Raw mate- ker (KRF)
rial - Input
Process Strand
technology flaker
Product OSB- OSB-

Output Strands Strands

Specific particles (Æ fibers) for Medium Density Fibreboard (MDF … HDF)
Chips Round wood,

(Sawmill by-products logs
Debar-
king
Drum
chipper
Sawdust
(Sawmill Chips
Raw mate- residues)
rial - Input
Process
Refiner
technology
Product MDF
Output Fibres
Conversion of raw materials

i.e. the raw material recipe
Production step preferably starts with …
A more or less constant blend of raw material sorts, particularly related to different
wood species to ensure uniform panel properties at the end of the overall process.
Debarking, only required for high quality, bright surface layers; for core layer particles
rough debarking during timber harvesting is sufficient; most bark particles will be remo-
ved later during various screening steps preferably after the particle drying.
Raw material cleaning (wet or dry log or chip cleaning, dust/sand/soil removal).
Metal detection and removal of contaminated pieces and contaminants.
Particle dimensions (… the required pre-product of this production step)

The first flaking process determines particle length and thickness; particle thickness - un-
like length and width of a particle - cannot be changed anymore in following process steps!
Î Particle slenderness: length to width ratio (Ɛ/w-ratio)
Î Particle size and shape (geometry) influence resin consumption, mat densification
behaviour, and panel properties, e.g., thickness swelling, MOE, MOR …
Log debarking
Round wood or logs are either debarked separately or as a bunch of individual stems.
Debarkingofabundleoflogs Debarkingofindividuallogs
Simultaneously,continuouslyor
batchwise
Drum debarker o Ring debarker

Rotary or cradle debarker o Flail debarker 1
o Rosserhead debarker 2
Mobile debarker 3
1 Debarking by means of rotating chains

2 Debarking by means of rotating cutter head
3 Debarking machinery installed on a mobile platform
1, 2 … without any importance for WBP industry
Rotary debarker Æ dry multiple stem debarking

Fixed tub (trough) assembly containing pairͲwise
openings in the bottom with rotors equipͲped with
debarking plates; rotating plates cause the logs to http://www.fujikogyo.co.jp/HP-English/king/barker/
spin and to hit each other crosssection20080327.jpg / 23.08.2011
Debarker is installed at a declined angle, enͲsuring

continuous log movement towards the discharge Rotor
end during debarking Debarking
plate
Slit
Fixed drum
Rotor
(http://www.fujikogyo.co.jp/HP-English/king/barker/crosssection20080327.jpg
/ 12.08.2015)
Movement of logs
Fuji Kogyo 2005
[ ] Rolling – rotating of each log on its own axis

[ ] Rocking – bouncing up and down of each log
[ ] Rotating – rotation of the entire batch of logs
Rotary debarker
SAVICO, QC/CAN
Debarking depends on
Wood specie + age,
Log shape,
Log dimensions,
Operating temperat.,
Bark retention,
Accept. fibre loss
three rotors !
(http://www.savico.com/en/debarker.html / 12.08.2015)
Prof.Dr.JoergB.Ressel 12
www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html 2015Ͳ08Ͳ05
Rotary debarker
FUJI Kingside
Outfeed Debarker
Æ cleaning belt Æ chipper
(http://iem.ca/images/forestry-projects/upm_blandin_project.jpg / http://www.fujikogyo.co.jp/HP-
12.08.2015) English/king/barker/kingbarker.html / 12.08.2015)
Debarking tools, shape depen-

ding on wood species / bark type;
mounted on the rotor
Drum debarker
Stationary plant with rotating drum, feeding devices and adjustable discharge gate
Drum dimensions: length 6…60 m, diameter 3…4.5 m;
(Æ recommended ratio log length / drum diameter is < 0.7)
Debarking capacity up to 350 m3 h-1 ÅÆ rotary debarker 5…30 m3 h-1
Continuous or batch-wise feed-in of logs
Processing either tumbling mode or parallel mode (log length > drum diameter)
Low wood losses (log breakage and “brooming” of log ends)
Achievable cleanliness 1 % remaining bark
Additional equipment:
o Particular infeed system, including optional de-icing station ahead (infeed conveyor)
o Bark separation section integrated in outfeed conveyor
Parallel mode
o Integrated process control
Tumbling mode
Metso panelboard 2005

Andritz 2002
Drum debarker
Bark removal slots

Drive unit
Debarking drum
Housing
Pallmann PDD
Technical data
Drum diameter 3–5 m
Drum length 12 – 32 mm
Log length 1–8 m
Capacity 40 – 350 m³ h-1
Discharge gate Bark remo-
Fulghum Drum Debarker [0:13 m] val conveyor
Pallmann 2011
Ring debarker
Debarking of single logs by passing
trough a rotating ring, equipped with
curved, scraping-tipped tools.
Tools are pressed against the fed logs
by particular devices (springs, rubber
bands, hydraulic, pneumatic pressure
elements).
Principles of ring debarking / debarking knife (Fronius 1989)
Special tools available for particular
debarking challenges, e.g., stringybark,
thick, fibrous bark Æ Eucalyptus ssp.
Rotation speed is 90…450 min-1,
feeding speed is 20…60 m min-1.
Ring debarkers are equipped with either
one single debarking ring or as tandem
debarker carrying two successive rings.
Debarking ring and pressure elements Æ variable pressure air seal,
bellow and air cell (Nicholson 2004)
Ring debarker
VK Air Seal Debarker

(Valon Kone 2015 – 2:30 min) Formax™ replaceable
debar-ker tool arms
and tips
VK5000HD-Combi-2R
VK tool for stringybark logs
(http://www.valonkone.com/media/images/2R%20new.jpg / 12.08.2015)
Particle generation for different Wood-Based panels

Flake generation for particleboard – PB (ĺ Slide 19)
Waste wood processing – residual wood treatment (ĺ Slide 47)
Strand generation for oriented strand board - OSB (ĺ Slide 50)
Fibre generation for medium density fibreboard - MDF (ĺ Slide 54)
Flake
generation crusher
Flow chart example

for raw material pro-
cessing to generate
flakes for particle
board production Impact hammer mill
Stepwise processing
Different raw materials
Logs (long, short)
Slabs, offcuts, chips from
Waste wood \ sawmill
Screening Maier 03/2005
Overs / rejects breakdown

Fines / dust ĺ heat generation
Impurities / contaminants
Intermediate storage
Adapted conveying/feeding systems
Wood-Based Panels
Flake generation
Exemplary flow chart for raw ma-
terial processing to generate
flakes for particleboard production
Maier 03/2005
Crusher / Shredder / Pre-braker

Slowly rotating crushing rotor, equipped with particular
teeth to disintegrate wood residues, waste wood (Æ pal-
lets, packaging materials, etc.), generating coarse, pre-
broken raw material, requiring less volume and easier
handling and transport.
http://www.holzmatic.com/wp-
content/uploads/2008/12/shredd
After removal of contaminats (metals, plastics …) the pre- er.jpg
crushed material is further processed, e.g. in a beater mill.
Large feeding hopper for bulky materials
Hydraulic drive protection from overload
Discharge sizing grid for pre-crushed material
Horizontal grinder
Maier 08/2015
(http://media.westsalem.com/machines/titan-grinder-f1-img1.jpg / 12/08/2015)
Grinder – vertical / horizontal feed (WSM, West Salem Machinery, OR)
Horizontal feed Vertical

grinder feed grinder
(http://media.westsalem.com/landing/mulch-grinders-shredders-screens.v3.jpg / 12/08/2015)
(http://westsalem.com/wp- (http://media.westsalem.com/machin
content/uploads/2014/05/titan-grinder-ill.jpg / es/vertical-grinder-f1-img1.jpg /
12/08/2015) 12/08/2015)
Impact crusher – Impact shredder
2 or 4-rotor shredder for windscreens, wood, plastics ...

http://www.prall-tec.de/cms/upload/bildergalerie/PTG4.bmp / 26.08.2011
http://www.prall-tec.de/cms/upload/bilder/Schredder_zhne.jpg / 26.08.2011
Flake generation
Drum chipper Knife

Wedge clamping
… used to produce high quality chips from long and short Infeed rollers
logs, slabs, edgings, thinnings, veneer waste or board trims.
Chips are easy to handle, storage is without difficulties and
chips allow precise metering into fiberizers and flakers.
A belt or vibratory conveyor delivers the material to the
chipper. Draw-in rollers with coarse gripping serration assure
certain and continuous feeding. The fed material is chopped Stator knife
inside the case by means of a very robust rotor into quality Screen
chips and dis-charged via a heavy breaker screen. Pallmann 2015
High throughput capacity

Pallmann drum chipper - complete system (2013)
Applicable for very different feed materials
High chip quality
Robust, easy maintenance, trouble-free
continuous operation
Low operating costs
Fully hydraulic opening of the housing
cover, stator knife carrier, knife clamping,
Discharge example
lifting and damping of the swing
Drum chipper
Rotor brake and
turning device Feed rollers
special teeth (surface
Screen
hardened; high wear
Electro-hydraulic
resistance.
quick-change attach-
ment, heavy duty
screen basket for Hydraulic / pneumatic
accommodation of cylinders to regulate
the screen plates the pressure of the
(wear resistant upper feed rollers and
Hardox steel) to open the upper feed
rollers for maintenance
and easy cleaning
Chain drive of the

feed rollers
Counter knife / anvil (stator knife)

Electro-hydraulic assisted changing
of counter knife / anvil
http://www.fordaq.com/www/news/2007/Bruks_Kloeckner_Trommelhacker.jpg / 25.08.2011
Drum chipper
Vecoplan 2011 Flake generation
Wood-Based Panels
Disk chipper
…
Disk chipper
Used for chipping logs – high quality chips (Æ fiberboard, pulp)
Disc chipper consists in a heavy rotating disc (Diameter 1… 3 m) with 4
or more knives. Particle thickness is determined by the angle between
in-feed spout and chipping disc
Conventional horizontally fed disk chipper HHQTM disk chipper (Andritz 2010)
(Andritz 2010; Bruks 2011)
Disk chipper with chute

(Bruks 2011)
Disk chipper
…
United States Patent 6976516

http://www.freepatentsonline.com/6848486-0-large.jpg / 8/25/2011
United States Patent 6976516

http://www.freepatentsonline.com/6976516-0-
large.jpg / 8/25/2011
Disk chipper
Gravity feed chipper
…
Metso Paper, Inc. 2010
Disk chipper
Horizontal feed chipper
…
Metso Paper, Inc. 2010
MDF fiber generation

Metso Paper, Inc. 2010 Flake generation
Impact hammer shredder

… converting pre-crushed waste wood particles into raw
material for reutilization in panel production or energy ge-
neration. Also contaminated materials can be fed into the
shredder. Foreign matter, travelling in the feed stock, is
separated and automatically discharged.
Material is vertically feed from above into the shredder.
Heavy rotating hammers hit in an upward action against
the feed material and throw it against the inside of the hou-
sing top above the rotor where it is pre-broken by impact.
The wood pieces are split along the grain, metal contami-
nants enclosed into the wood are set free in the special
feed chute because of their different ballistic curve. The
final preparation is effected by stationary breaker and
comb bars. The openings of the heavy grid defines the (http://www.pallmann.eu/language/upload/bilderleiste/PHP
finished product size. S3.JPG / 13.08.2015)
High throughput capacity at low specific energy consumption Impact Hammer Mill PHPS
Separation and removal of foreign matter (Pallmann 2015)
Insensitive against contaminants and feed fluctuations

Easy maintenance and access to the rotor Flake generation
Impact hammer mill

… particularly used for processing waste wood, e.g., pallets, cra-
tes, boxes, scrap wood, wood residues, bushes, branches, indus-
trial waste wood. The process outcome is valuable raw material
for the panel industry or for energy generation.
A vibro-feeder or an apron conveyor hauls the material towards
the machine mouth. Bulky feed material is hydraulically continuo-
usly guided towards the rotor, equipped with free-swinging tools,
i.e. hammers, steel strips, where it is shredded stepwise by itera-
ted impacts. Material discharge goes downwards through a heavy
screen-cage, determining the particle size. (http://www.pallmann.eu/language/uploa
d/bilderleiste/agrizzly.jpg / 13.08.2015)
Very high throughput capacity
Impact Hammer Mill
Insensitive against foreign matter
PHPH Grizzly
Homogeneous final product (Pallmann 2015)
Vibration free operation
Hammers easy to change
Low operating cost
Pallmann 2004
Low maintenance http://www.pallmann.eu/language/upload
Flake generation /bilderleiste/Grizzly1.jpg / 13.08.2015)
Knife ring flaker

… production of high quality flat flakes from chips, veneer
residues, purchased flakes and coarse material of any kind,
i.e., also low priced wood assortments can be processed
Chips
with the knife ring flaker.
A quick rotating impeller leads the chips to the knives of the
counter-rotating knife ring. This principle of counter-rotation
from the impeller and the knife ring guarantees a trouble-
and obstruction-free operation of the machine even with
very wet material, a uniform wear of exchangeable knives
and counter knives and therewith an excellent flake quality.
Excellent flake quality
High throughput rates
Quick, economic knife change
Economical prize for the performance
No clogging at high moisture content Pallmann 2011
Efficient wear protection

Maier / Dieffenbacher MRZ
(Maier 2011 – 6:06 min)
Flakes
Knife ring flaker

Vibro-feeder
Metal separator
Heavy particle sepa-
rator
Contaminant sepa-
rator
Controlled air-flow Maier 2011
Knife ring flaker

Cutting process
Pallmann 2011
(1) Wear plate (5) Wear segment

Additional information
(2) Beater plate (6) Impeller
Globus Knife Ring Flaker for particleboard production
(3) Wear shoe (7) Knife carrier ring
(4) Knife (8) Knife carrier https://www.youtube.com/watch?v=tEBaPiLrz5w [10:17 m] / 8/14/2015
Knife ring flaker

Ring assembly
50 knife konfiguration
increases production Holder assembly
capacity
Adjustable knife settings
for fine mircrometer knife
adjustments that can be
made in the ring assembly 3-bolt
spring
clamping
for quick
and easy
knife
release
and
clamping
4-bolt ring
attachment Dovetail locking assembly increases
allows for strength of system, decreasing the
Precise fit for con- quick and easy chance of parts releasing during
ventional knife ring base assembly operation
flakers removal
(http://www.keyknife.com/features/images/details/ringslicer_left2.jpg / 28.08.2011)
Knife ring flaker

Flaker components: vibrating feeder, metal separator
Chips, sawdust
(removal of ferrous contaminants), wind selector ( re-
Magnetic
moval of heavy pollutants) and the flaker itself. drum
Vibrating
High capacities Æ KRFs arranged in series. feeder
Wind
High performance and excellent flake quality requires Ferrous selector
contaminants
quick knife ring exchange facilities and particular
sharpening and setting equipment
Heavy
Contami-
nants
Knife ring
flaker
Flakes
Pal 2005
Drum flaker
Pallmann 2011 Flake generation
Drum flaker
… designed for high production capacities of flat flakes from
round wood cut to length ( 2 m). Feed in logs are pushed
against the rotating drum by suitable clamping devices. Flake
length is determined by a particular knife design (Æ double
Double comb knife
comb knife); the flakes are crushed to width parallel to grain in
the knife pockets. Clamping strip Knife fixing plate
Two types of constructions are in use:

Drum flaker with stationary rotating drum; continuous
flaking of cut to length logs.
Wear plate
Drum flaker with rotating drum moving forth and back;
discontinuous flaking of random length round wood Knife
Knife fixing plate
Clamping strip
Drum body
Counter
knife Bridges
Flake
pockets
Deppe, Ernst 2000;

Figs. 3.1-22, 26, 29, 30
Drum flaker – Processing steps

1. Feeding the raw ma- Knife types
terial (logs, slabs …) Æ … determine flake length
into the processing 1. Scarifying knife 2. Comb knife
area 3. Slitting knife 4. Full knife
2. Vertical and horizon- c

tal adjustment of the
raw material by auto-
matic clamping
3. Drawing or scoring d
cut parallel to grain
e
4. Cutterblock and clam-

ping system move back f
to start position Æ dis-
Hombak 2011 continuous process
Drum flaker
Cross conveyor
Longitudinal conveyor
Hombak 2011 Flake generation
Maier MSZ 2015

Hammer mill – Beating Flaker
… used for production of core layer and surface layer material for par-
ticleboard from waste wood chips, core waste wood particles and annu-
al plants, dry or wet.
The material is feed in vertically from above. A gravity separator separa-
tes heavy contaminants from the infeed material. Flat steel beaters (steel
strips) rotating with high speed split the feed material mostly parallel to
the grain. The openings of the installed screens determines the particle
size. Stationary refining elements integrated into the mill assist the size
reduction. Particle discharge can be effected either pneumatically or
mechanically with an additional secondary suction.
High throughput capacity
Uniform material preparation at low specific energy
consumption
High versatility and easy adaptation to various feed materials
Maximum utilization of all wear parts
Dual operation direction increases economic efficiency
Robust and easy to maintain
High availability Pallmann PHMS 2011
Prallfiner – Impact mill – Sieve ring mill Maier MPM 2015
… are used for generating fine particles. Wood particles are

thrown against a grinding path by rotating impeller blades and
split up mainly along the fibre length. Subsequently particles
have to pass a stationary or counter-rotating screen ring; grin-
ding path patterns, screen perforations and shape determine
the final particle size of these versatile disintegrating machines.
Sieve Ring Mill MPS Impact Mill MPM Prallfiner MPF Maier MPF 2015
Prallfiner
1Vibrationconveyor
2Metalseparator(Magnet)
3Infeed(vibro chute)
[4]
4Rotor
5Grindingtrack [5]
6Distributiondisc
7Suctionpipe
8ByͲpass
[5]
[5]
Maier MPF 2015

Flake generation
Waste wood processing – residual wood

Two stage recycling plant – dry process
(1) Crushing – pre-braking

(2) Separation of ferrous material
(3) Sorting
(4) Second disintegrating stage
(6) Screening
(7) Separation of heavy contaminants
(8) Sifting of light particles
(9) Separation of non-ferrous material

Two stage recycling plant – dry process
(1) Crushing – pre-braking

(3) Sorting
(4) Second disintegrating stage
(6) Screening
(7) Separation of heavy contaminants
(8) Sifting of light particles
1. Stage waste wood recycling (9) Separation of non-ferrous material
crushing - cleaning - screening
2. Stage waste wood recycling

Urban waste wood beating - cleaning - screening
(PAL 2003 – 4:30 min)
Bunkers for separated

and cleaned residual
wood fractions
Containers for re-moved

materials (plastics, non-fer-
rous metals, …)
1. Infeed belt 12. Separation belt 80/150

2. Belt conveyor 13. Separation belt 150L
3. Drum screen 14. Collecting funnels
4. Transport belt 15. Transport belt 24/80
5. Flat screen 16. Transport belt 150L
6. Transport belt 0/24 17. Transport belt 80/150
7. Transport belt 0/24 18. Wind screen 80/150
8. Metal separator 19. Wind screen 24/80
9. Transport belt 0724 20. Control panel
10. Belt for fuel material 21. Transport belt
Deppe, Ernst 2000, Fig. 2-1.37
11. Separation belt 24/80
Decomposition of UF-bonded and laminated particleboard

Semy-dry two stage chemo-thermo-mechanical batch process,
annual capacity of one decomposition unit Reaction bin (insulated)
including quick closing
up to 20.000 t/a of particles in three shifts lid and discharge device
Vacuum
Recycled furniture, pump
production residues, rejects Heat
Crusher
infeed
Pre-crusher (breaking up)
Discharge
Impregnation condensate
and surplus
Pre-impregnation (possibly liquid (caustic Slowly rotating Impregna-
t = 1…10 min soda solution, pre-braker tion liquid
after vacuum treatment)
urea, water)
Coarse wood
particles, metal
parts, plastic and
t § 20 min Heat-treatment coating materials
Moving floor
T = 110 ºC (chemical-hydrolytic process) Stoker discharge
Water,
urea and
additives
Bin for Particles (to dryer
Screening preparation and screen)
and storage Drum screen
of the impreg-
nation liquid
Coating and edge Wood particles
banding materials Pilot plant for processing urea bonded particleboard –
used furniture and production residues (WKI 1996)
Particleboard Refiner
Particle recovery process from urea bonded particleboard
MDF (according to Michanickl and Boehme, WKI 1996)
Strand generation for OSB –

Long log (knife) ring flaker
… particular knife ring flaker for producing precise strands
with specific length, width and thickness from either fixed
length logs or random length logs. The long log ring flaker is
mostly used for flake generation for Oriented Strand Board.
Pallmann 2011
The logs are batchwise fed into the flaking

chamber with an integrated water injection
system. Particular vertical swords hold down
the logs during the cutting stroke. A closing
gate hydraulically clamps the log bundle at
the flaking chamber and closes the flaking
chamber during the final cutting stroke. The
wood is cut parallel to grain; this cutting action
results in rectangular flakes with smooth
surfaces and a minimum of fines.
OSB strand generation Pallmann 2011
(Siempelkamp 2013 – 1:45 min)
Strand generation for OSB – Long log (knife) ring flaker
Pallmann 2008
Pallmann 2008
Strand generation for OSB – Disc strander

… cuts tree length or batch fed logs into strands for OSB production.
The clamping system secures the logs in place while the strander,
which is carriage mounted, extends into the cutting chamber. Disc-
mounted knives strand the wood within the cutting chamber and the
carriage returns automatically to repeat the sequence. The knives on
the strander extend to the outer edge of the precision ground disc,
allowing the disc to advance through the batch of logs during stran-
ding while maintaining consistent strand thickness..
Disc Strander Kadant

(Kadant Carmanah 2015 – 0:20 min) Carmanah 2015
Disc Strander for long logs … for short logs – Block Strander
Strand generation for OSB – Knife ring flaker

Two-step process for strand generation developed by Maier (2002)
Raw Green wood (logs, thinnings, tree tops), sawmill residues
materials (slabs, offcuts) and residual wood
Step 1 Drum chipper HRL/OSB ĺ chipping raw material into
OSB chips; chip dimensions have to meet the require-
ments for desired strand length. 1 Drum chipper
HRL/ OSB
Step 2 Knife ring flaker MSF ĺ converting OSB chips into (Maier 2011)
strands.
Quantity of surface and core layer strands and the content of

fine material obtained hardly differ from the respective quan-
tities obtained from conventional strand production.
The two-step process supports inexpensive plant concepts
with an increased flake capacity of existing plants, to install
medium-size plants at lower investment expenditure, or to
2
produce novel board types from recycling wood. Fines are
usable for particle board production or as fuel. Knife ring flaker
MSF (Maier 2011)
Wood-Based Panels Fibre generation
Fibre generation for MDF

… based on a two step process. Initially cleaned wood (washing, debarking of logs) is converted
into chips or are purchased, e.g., as sawmill by-product. In the second wet process step the chips
are converted into fibres by means of a refiner; also sawdust can be processed in the refiner (re-
quires particular grinding plates).
Chipping
and storage
Chip preparation
and fibre production
Chip generation
Chips purchased either as raw material from sawmills
(Æ particular quality requirements) or directly made from
green wood (logs, sawmill residues) by means of a drum
chipper or a disc chipper (the latter is the most common
chipper in pulp mills).
Cleanliness of chips, uniformity of chip size and clear cut
surfaces are very important for even conversion into
fibres in the following pressurized defibration process.
Disc chipper types (Andritz 2002)
Chip storage
• Open air storage or storage in suitable metal/concrete bins/silos
• Material losses due to thermal degradation and/or fungi attack
Defibration process
Steam flow
Material flow Chip bin (pre-
heating)
8…19 bar abs.
Digester
Refiner
H. Roll (2008)
(grinding chamber)
Defibration process
Energy consumption – reference values
Steam – Refining Process
Nominalvalues ChipBin 35%…
500– 850kg/tfibre (target ੥chips at љwith discharge limitations Æ steam digester,
outfeed 60°C) Æ energy consumption fibre dryer ј
јif chips are frozen (inpractice +50…60%;
Practical values designvalue approx. +100%)
250– 450kg/tfibre Digester 60%
Grinding Chamber 4%(depend.onȴpDig.ͲRef.,Blow valve opening
Others 1%(max.200…250kg/h)
Mechanical Energy (Elektricity)– Refining Proces

Softwood (Spruce) 80– 170kWh/tfiber o.d.
Hardwood (Beech) 90– 150kWh/tfiber o.d.
Sawdust 100% 250– 400kWh/tfiber o.d. H. Roll (2008)
Defibration Process steps

1. Screening of chips (uniform chip size and shape, removal of over-sized chips and
contaminants)
2. Chip conditioning by means of a moistening screw
3. Double mixing screw to feed chips into the pre-steaming bin. Pre-steaming
reduces the temperature difference to the affiliated cook-ing process. The forming
condensate in the pre-steaming bin can easily squeezed out in the plug screw
feeder and chips have to be only heated up in the digester from pre-steaming to
cooking tem-perature. Condensate reduction in the chips also significantly saves
energy in the fibre drying process.
4. To prevent from steam blow-out from the digester (temperature and pressure drop)
a blow back valve is located opposite the plug screw feeder to close the digester
infeed opening if necessary.
5. The digester is used to heat up and cook the chips. Retention time – an important
parameter to fibre quality - is determined by flow rate and digester level indicated by
a radioactive level mea-suring device. Digester discharge is accomplished by
particular discharge unit underneath the digester on customers indications on wood
species, bulk density and chip moisture content.
www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html cont. Æ
2015Ͳ08Ͳ05
Defibration process steps (cont.)

Before chips enter the refiner they have to pass a ribbon feeder, which operates at
constant speed and feeds the material continuously into the refiner. At the same time
it allows steam, generated in the refiner to flow back into the digester trough the
steam equalization line.
6. Typically the refiner is designed as single disc pressurized refiner with a rotating
and a sta-tionary plate holder. The rotor is adjustable in horizontal direction to the
stator which is mounted stationary onto the door. While at lower throughputs the plate
gap will be electromechanically adjusted the large refiners use a most precise and
reliable hydraulic plate gap adjustment. By adjusting the rotor against the stator the
power consumption of the refiner main drive motor can be increased or decreased,
which allows adjusting the specific energy to the refining process, considering
different raw materials and the required end products. To increase the refiner speed,
e.g., for processing sawdust, an additional high speed gear is built in.
(Andritz 2005)
Chip washing process

Chips
Chip washing is essential for
producing board with low mineral
content.
Increasing use of purchased chips,

e.g. from sawmills, results in an ever-
increasing need for chip washing.
Existing impurities, as metal parts,
stones and sand, must be removed Closed
water
before the chips enter the process.
circuit
(Æ CleanMax System)
Metso 2010
Waste
water pro-
cessing
Chip treatment and refining
Blow back
valve
Metso
Metso2010
2010
FeedMax
Æ screw feeder
upgrade provides
uniform feeding,
optimized dewa-
tering and redu-
ced energy con-
sumption
Metso 2010 Metso 2010
Refiner unit
Top view
Side view
Metso 2011
Refiner unit
Pallmann 2015 Æ http://www.pfalz-express.de/wp-content/uploads/2013/02/Pallmann-Refiner.jpg / 17/08/2015
Refiner unit
Single-Disc refiner Andritz 2011
EVO-series Defibrator™ Metso 2011

Energy saving EVO Traditional radial
helical discharge. discharge.
Metso 2006
VALMET Evolution Defibrator Series

(former METSO - EVO-series Defibrator™)
Development objectives Æ reduced energy consumption and better
fibre quality by improved furnish flow into and through the refiner by
particular high-speed screw feeder,
efficient dewatering ĺ reduced mc in pre-heater, less steam
demand, less mc at dryer inlet
new infeed geometry in coarse breaker bar section of the seg- Metso panelboard 2006
ment area and improved centre plate design,
low-energy unidirectional refiner segments, Metso 2010
helical discharge – instead former radial discharge - combined

with blow valve.
Specific energy saving approx. 25 …
50 kWh/ton softwood fibres, i.e.,
approx. 10 % for all fibre qualities
compared with the M54 Defibrator.
Additional reduction of specific steam
consumption by 25…45 %
Refiner and refiner plates

Refiner … main machine for chip conversion
into fibres. Softened chips are feed in the cen-
tral area of the pressurized defibration zone
between particularly designed refiner plates
mounted on the stator and rotor respectively.
Refiner plates consist of replaceable segments
with a special bar and groove pattern. Pattern
design (mostly depending on wood species)
Refiner plate details (Durametal Corp. / Andritz 2004)

and adjustable distance between the two discs
determine for refiner energy consumption and
fibre quality. Additional refiner characteristics
are:
Mechanical sealing
Hydrodynamic axial bearing
Radial roller bearing
Electromechanical disc adjustment
Disc diameter: 44”, 50”, 56”, 64”, 70”, 74”
Throughput: 10…65 to.d./h
Power supply main drive: § 5…20 MW
Refiner plates
… design reduced energy consumption + increases fibre quality
58°
Inconsistant
cutting angle
30°
Constant cutting
angle of 30°
(http://www.andritz.com/service-pp-
refinerplatesandfillings-mdf-spiral-en.pdf /
17.08.2015)
Refiner – additional equipment

Blow valve - directly attached to the Three way fibre diverter valve is Start-up cyclone guarantees a safely
discharge opening of the refiner and used when different raw materials start-up of the system. After checking
actuated by means of a pneumatic (chips, sawdust …) are processed in the fibre quality at the starting cyclone
actuator and electro-pneumatic positi- the refiner to meet the required velo- and rechecking if all characteristic va-
oner as well as a manual remote sta- cities for the glue injection by using lues have levelled off and remain con-
tion. The purpose is to gradually ad- different piping diameters. stant the valve is switched to produc-
just the opening to the blow line to The fibre diverter valve is a rotating tion.
allow the actual fibre steam mixture diverter driven by two pneumatic
being safely discharged from the cylinders attached to a base frame.
refiner.
Andritz 2004 Andritz 2004 Andritz 2004
Wood-Based Panels
Overview / Intro

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Center for Wood Sciences

September7Ͳ 12,2015– Biel,CH

Raw materials (summarised)

Conversion of raw materials Æ Particle generation

Conversion paths to achieve suitable particles for typical WBPs

Process Knife ring Strand

Product OSB- PB PB PB PB PB OSB- MDF

Conversion paths to achieve suitable particles for typical WBPs

Round wood, Round wood, Chips Slabs, off-cuts Reclaimed wood

Process Knife ring

Conversion paths to achieve suitable particles for typical WBPs

Round wood, Round wood, Slabs, off-cuts Reclaimed wood

Product OSB- OSB-

Conversion paths to achieve suitable particles for typical WBPs

Chips Round wood,

Conversion of raw materials

Particle dimensions (… the required pre-product of this production step)

 Drum debarker o Ring debarker

1 Debarking by means of rotating chains

Rotary debarker Æ dry multiple stem debarking

 Debarker is installed at a declined angle, enͲsuring

[ ] Rolling – rotating of each log on its own axis

Debarking tools, shape depen-

Metso panelboard 2005

Bark removal slots

VK Air Seal Debarker

Particle generation for different Wood-Based panels

 Waste wood processing – residual wood treatment (ĺ Slide 47)

 Strand generation for oriented strand board - OSB (ĺ Slide 50)

 Fibre generation for medium density fibreboard - MDF (ĺ Slide 54)

Flow chart example

 Overs / rejects breakdown

Crusher / Shredder / Pre-braker

Grinder – vertical / horizontal feed (WSM, West Salem Machinery, OR)

Horizontal feed Vertical

Impact crusher – Impact shredder

2 or 4-rotor shredder for windscreens, wood, plastics ...

Drum chipper Knife

 High throughput capacity

Chain drive of the

Counter knife / anvil (stator knife)

Vecoplan 2011 Flake generation

Disk chipper with chute

United States Patent 6976516

United States Patent 6976516

Metso Paper, Inc. 2010

Metso Paper, Inc. 2010

MDF fiber generation

Impact hammer shredder

 Insensitive against contaminants and feed fluctuations

Impact hammer mill

Knife ring flaker

 Efficient wear protection

Knife ring flaker

Knife ring flaker

(1) Wear plate (5) Wear segment

Knife ring flaker

Knife ring flaker

Two types of constructions are in use:

Deppe, Ernst 2000;

Drum flaker – Processing steps

2. Vertical and horizon- c

4. Cutterblock and clam-

Maier MSZ 2015

Drum debarker o Ring debarker

Debarker is installed at a declined angle, enͲsuring

Waste wood processing – residual wood treatment (ĺ Slide 47)

Strand generation for oriented strand board - OSB (ĺ Slide 50)

Fibre generation for medium density fibreboard - MDF (ĺ Slide 54)

Overs / rejects breakdown

High throughput capacity

Insensitive against contaminants and feed fluctuations

Efficient wear protection

helical discharge – instead former radial discharge - combined