panel production plants...• largest particleboard plant for recycled wood in the world – 2.000...
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P a n e l P r o d u c t i o n P l a n t s
for particleboard, OSB, OSL, MDF, THDF and LVL boards
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www.dieffenbacher.com
KARLE + JUNG GMBHWerkzeug- und MaschinenbauDieselstraße 7 D-76448 Durmersheim, GermanyTel. +49 (0) 7245 9308-0Fax +49 (0) 7245 9308-18E-mail: [email protected]
ASA GMBHANLAGEN- UND SYSTEMAUTOMATIONIm Grund 1-3 D-75045 Walzbachtal, GermanyTel. +49 (0) 7203 9150-0Fax +49 (0) 7203 9150-11E-mail: [email protected]
ASA GMBHANLAGEN- UND SYSTEMAUTOMATIONBetriebsstätte SeevetalAn der Reitbahn 13D-21218 Seevetal, GermanyTel. +49 (0) 4105 6676-0Fax +49 (0) 4105 6676-90E-mail: [email protected]
DIEFFENBACHER GMBH + CO.KGHeilbronner Straße 20 D-75031 Eppingen, GermanyTel. +49 (0) 7262 65-0Fax Panel Division +49 (0) 7262 65-377Fax Forming Division +49 (0) 7262 65-297E-mail: [email protected]
DIEFFENBACHER GMBH + CO.KGBetriebsstätte PfungstadtWerner-von-Siemens-Straße 2D-64319 Pfungstadt, GermanyTel. +49 (0) 6157 803-0Fax +49 (0) 6157 803-109E-mail: [email protected]
DILEB MASCHINENBAU GMBHDillinger Straße 130 D-66822 Lebach, GermanyTel. +49 (0) 6881 9207-0Fax +49 (0) 6881 9207-90E-mail: [email protected]
DIEFFENBACHER MASCHINENFABRIK GMBHGewerbestraße 29 D-75059 Zaisenhausen, GermanyTel. +49 (0) 7258 609-0Fax +49 (0) 7258 8751E-mail: info@dieffenbacher-zaisenhausen.dewww.dieffenbacher-zaisenhausen.de
SCHENKMANN-PIEL-ENGINEERING GMBHBürgerbuschweg 1 D-51381 Leverkusen, GermanyTel. +49 (0) 2171 3996-0Fax +49 (0) 2171 3996-99E-mail: [email protected]
COMPANY LOCATIONS
DIEFFENBACHER - CZ s.r.o.Hydraulické lisyRipská 15, 62700 Brünn, Czech RepublicTel. +420 5 4842 3111Fax +420 5 4821 7087E-mail: [email protected]
DIEFFENBACHER NORTH AMERICA, Inc.9495 Twin Oaks DriveWindsor, Ontario N8N 5B8, CanadaTel. +1 519 979 6937Fax +1 519 979 6803E-mail: [email protected]
DIEFFENBACHER, Inc.1800 Peachtree St., NW, Suite 425Atlanta, GA 30309, USATel. +1 404 609 9911Fax +1 404 609 9933E-mail: [email protected]
DIEFFENBACHER BRASILInserco BrasilAv. Dr. Pedro Soares de Camargo 543, sala 6213208-080 Anhangabaù, Jundiaí SP, BrazilTel. +55 11 4523-1298Fax +55 11 4523-1298E-mail: [email protected]
DIEFFENBACHER BEIJINGScitech Tower, Unit 130522, Jianguomen Wai Dajie 100004 Beijing, P.R.C.Tel. +86 (0) 10 6522 0935Fax +86 (0) 10 6522 0936E-mail: [email protected]
DIEFFENBACHER ASIA PACIFIC SDN. BHD.Unit #11-02 11th FloorMenara Multi-Purpose, Capital SquareNo. 8 Jalan Munshi Abdullah 50100 Kuala Lumpur, MalaysiaTel. +60 3 7490 0183Fax +60 3 7490 0184E-mail: [email protected]
DIEFFENBACHER MOSKAUKutuzovsky Prospekt 36MPZ imeni Kazakova, Building 7121170 Moscow, RussiaTel. +7 095 290 71 51Fax +7 095 290 71 52E-mail: [email protected]
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Competence and innovative power – The unbeatable combination
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Competence
Engineering
Performance range
Material preparation
Forming stations
Press systems
Finishing line
Lamination
Process automation
Panel products
Service
M I L E S T O N E S
1949 • Delivery of the first discontinuous particleboard production plant
1957 • First single-daylight press1964 • First short-cycle laminating system1967 • Delivery of the first particleboard plant with
screen (FLEXOPLAN)1969 • Delivery of the first complete system1976 • First plant with PLC1980 • Delivery of the first wafer board plant1987 • Largest single-daylight press of the world
• First MDF plant1988 • First plant with process management system1990 • First plant for gypsum fiberboard
• First continuous press type CPS1995 • Largest multi-daylight press of the world
• First 12-foot OSB plant1996 • First plant for bio-composite panels
• Largest continuous MDF press of the world – 900 m3/d
1997 • First continuous production line for LVL• First software platform for reduction of
production costs for all particleboard plants• Quickest short-cycle lamination plant of the world• First online service support system• First MDF plant using recycled wood only
1998 • Longest continuous press for particleboard made of recycled wood
• Longest continuous MDF press• Largest particleboard plant for recycled wood in
the world – 2.000 m3/d2000 • First continuous 12-ft OSB production line in the
world, with a 56 m CPS press and a screen imprint press
2002 • THDF-line produces at speeds above 1,300 mm/s2003 • New concept for thin fiber board lines2004 • New hot steam fiber drier
• Steam pre-heating used in a particleboard line for the first time
When it comes to designing and building of turnkey production plants, both know-how andexperience are required as much as financialstrength and innovative technologies. This is thereason why customers all over the world placetheir trust in Dieffenbacher.For more than 130 years, our machines and plantshave set new standards for future-oriented, flexible and cost-effective solutions. We realize your individual concept and have theright technology available no matter whether you want to produce conventional particleboard,
As a leader in board technology, our above-average expenditure in the field of research anddevelopment contributes to achieving this goal.The results are high-capacity systems, processesand products. We also find solutions for rawmaterials that could not be used in the past, e.g.recycled wood, soya, species of wood not usedbefore, bagasse, bamboo etc. These materials are low in price, available in unlimited quantityand their use helps to protect the environment.
Close cooperation with external institutes, research laboratories and system users enables us to define the benchmarks for further development. Materials testing is performed as well as manufacture of sample boards. Havingthis knowledge enables us to offer maximumsafety. In our technical and research center weuse your raw materials to develop the optimumproduction method for innovative products helping you to enter new markets.
New ideas create new markets
MDF, THDF, OSB, OSL or LVL boards or innovative products made of recycled wood. The efforts ofabout 900 experts all over the world are devotedto assist you in achieving your goals. We makeuse of synergistic effects from various corporatedivisions and subsidiaries.
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Accurate analysis of your individual projectsFeasibility calculations and financial schemesSupport with authorities and permit application proceduresElaboration of material flow diagramsSelection of individual technologies and production systemsEngineering including choice of location, supply of energy, raw and operating materialSite supervision and monitoring (optimization of building and start-up times) Cost transparency through intermediate reportsOn-time start-up through coordination of site work including management of services by subcontractors and subsuppliersModernization concepts under consideration of existing facilitiesControlling
We realize successes
More than 200 experienced engineers and techno-logists work together worldwide in developing optimum technical solutions to satisfy your demands.No matter whether you intend to build a newplant or retrofit an existing one, our expert teamsoffer complete concepts from first consultancy upto overall planning and safe financing schemes –success included!
From concept to start-up – expert advice in all aspects
Press installation
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Dependable services in every respect:
Panel production test in our technical and research center
Wood-based panel testing
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Everything from a single source
Suitable equipment for any case of application
We supply everything from a single source andmanufacture all process-relevant systems in ourown group. Many years of experience help us toselect supplementary components made by othermanufacturers and ensure their optimum inte-gration into the complete system.
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Service
MATERIAL PREPARATION
– DRYER
– SIFTER
Process visualization, control room
ENERGY PLANT
FORMING
STATION
CONTINUOUS
CPS PRESS
REFINER
GLUINGCONTINUOUS
PRE-PRESS
FINISHING LINE
WOODYARD
SANDING LINE
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P E R F O R M A N C E R A N G E
• Designing and building of complete production plants for particleboard, MDF, THDF, OSB, OSL and LVL boards
• Technique for process heat supply and waste heatrecovery (Intec)
• Dryers, air graders (Schenkmann-Piel)
• GRADO - Glue preparation system using weighingtechnology. Metering systems using weighing andflow rate measurement technology.
• Inline gluing systems
• CONFORM – Forming stations / spreader systems including feeders, metering bins and weighing equipment
• Forming lines including pre-presses
• Pre-heating systems
• Continuous presses type CPS
• Cycle presses in single- and multi-daylight design
• Finishing lines with board cooler, diagonal saws and stacking equipment
• Complete sanding lines with cut-to-size saws and stacking
• Automated transport systems for stacking devices
• Automatic highbay board storages
• Panel laminating systems (Dieffenbacher Zaisenhausen)
• PRODACON – Process control and automation systems
• Online support and maintenance systems
• Plant modernization
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Energy generation and material preparation
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Especially with energy generation and materialpreparation. For this reason our scope of suppliesalso includes single components and completesystems to generate the heat that is requiredduring the production process in panel plants.Energy is provided by different media such as hot gas, thermal oil, steam, warm/hot water.Production waste, sanding dust and bio mass are typical examples of fuel.
Dryers and sifters are decisive factors in obtaininga high board quality. Particles and fibers must beprepared to have a constant humidity level andbe sifted to remove unwanted particles such assand, metal pieces, glue knots etc. Different typesof dryers and sifters are used according to theindividual product and production capacity.
Upgoing line capacities and ever increasing environmental requirements ask for economically viable, precise and safe technologies...
Dryers for particles, strands and fibersThe dryers can be heated with different fuels, as well as with gas from a turbine or furnace, depending on the type of plant. Exhaust gas recirculation increases the efficiency. Indirect heating is possible by means of combined power generation/heating or thermal oil heating.Particle and fiber sifters for the removal of• Mineral matter• Metallic contaminants• Coarse particles• Glue knotsGlue preparation and gluing system for particleboard,OSB, OSL, MDF and THDF plants
The following alternatives are available to you:
Flexible, thanks to matured technologies available for all raw materialsSafe by compliance with valid safety regulations such as VDI 3673, spark detectors and deluge systems, plug detectors and automatic sprinkler systemEnvironmentally friendly through use of available residual energy and alternative sources of energyLow emission values
Benefits:
Particle sifter
Glue preparation systems
Energy plant
High-precision glue preparation and gluingsystems accurately meter the necessary quantitiesof glue and particles as defined in the recipe.They also are a decisive factor in securing con-stantly high outputs and economical production.
Drum dryer with wet fiber bin for strands
Fiber dryer
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Forming stations and spreading systems
Board properties are mainly determinedby the shape of particles / fibers and theirposition in the formed mat. For this reasonwe offer innovative spreading systems –tuned to
Raw materialsEnd productsPlant capacity
The forming belt, which connects the formingstation, prepress and main press is basicallyidentical for all three press types.Integrated mat scales for constant productweights, trimming, magnet systems and metaldetectors as well as a device for return of rejectmats are already included in the standard version.
Forming stations and spreading systems are decisive for high cost-effectiveness, quality and environment-friendliness
Combined particle spreading systems (wind / mechanical), variants depending on product, performance, surface, accuracy and raw materialMechanical spreading systems for particles, fibers, strands as well as recycled wood depending on product, performance and accuracy.
The following variants of spreading systems are available:
Core layer spreading system for
particles
OSB forming station
OSB forming line
High spreading accuracyContinuously high board qualityReduction of production costsSpreading of recycled wood materials without any problemStandardized componentsShort start-up timesLow maintenance requirement
Benefits:
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Particleboard forming station
These factors define the working principle andrequired number of spreading systems, whichaltogether combine to a forming station.The forming station includes conveyors,metering scales, spreader heads matchingcontrol and management systems.
MDF forming station
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Press systems
High surface quality adjustable to each case of applicationReduced thickness tolerances and, therefore,minimum sandingHigh capacities at constant qualityHigh flexibility through easy adjustment of thickness and widthUsable for very thin boards as wellExpansion possible without any problem, easy adaptation to modified capacity requirementsCompliance with all usual standards
Benefits:
and decades of experience in building hydraulicpresses to be highly flexible, simple to operate,maintenance-friendly and wear-resistant – pressesthat fulfil all demands put by usually rough production conditions …Our continuous presses are distinguished by highflexibility to cope with production-related changesin panel thickness or width. Very large presses upto 62 m long and 12 ft wide are our speciality. Wehave developed a specific infeed geometry, whichguarantees high reliability at very high productionspeeds, especially in the case of thin fiberboards.Single-daylight or multi-daylight presses are still indemand for small and medium plant capacities orfor OSB plants in North America. CPS press infeed
CPS press modules
Continuous CPS press systems are the result of consistent research and development…
Single-daylight pressMulti-daylight press
Dieffenbacher forming lines include continuouspre-presses for various products with varying individual pre-compressor lengths and pressuresection. Pre-presses guarantee a safe and smooth transferof the mats at any speed. Patented heating of OSB and LVL by microwave or steam injection for particleboard, MDF, THDF, OSB and OSLincrease the capacity and are an example forsuccessful innovation.
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Continuous CPS press system
Pre-pressPre-heating
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Finishing line
The Dieffenbacher plant spectrum is completedby transport of boards from the press to packingfor delivery of individual lots. Our finishing line offers optimum solutions foreconomic processing and efficient handling ofthe boards.We deliver systems for conveying, weighing,sawing, trimming, cooling, stacking, sanding, sorting, intermediate storage, packing and final storage – tailored to your specific needs.
Efficient handling for economic processing
Double diagonal saw
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High cutting speeds and the automatic formatchange option make the Dieffenbacher doublediagonal saw one of the most powerful systemsavailable in the market. Consistent reduction ofthe moved masses enables highly dynamic move-ment of the saw at maximum cutting precision.
Star cooler with subsequent stacking
Stacking conveyor system
Stacking boxes upstream the sanding line
High operation reliabilityStandardized elementsControlled board cooling and maturingSmooth panel transferAccurate board cutting
Benefits:
Stacking roller conveyor
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Lamination
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Decorative papers impregnated with melamine resinPrimer foilsFinished foilsPapers impregnated with phenolic resinReal wood veneers
A wide variety of materials can be used for lamination:
Fully automatic format change in all systems,including the adjustment of pressure and thickness in the pressAutomatic, laser-precision layup systemsShortest possible pressure timeHigh throughputModular, flexible structure
Benefits:
Lamination systems from Dieffenbacher Zaisen-hausen with short cycle times enable the produc-tion of marketable panels with a large variety ofdecorations.A fully automatic lamination plant with SynchronQuick NC press and discharge system offers opti-mum solutions for the manufacture of laminatedwood-based panels.Board supply is continuous, with automatic removalfrom the stack. Precise longitudinal and diagonalalignment, minimum film overlap und multiplefilm pack guarantee maximum economy. Short panel manipulation times and infiniteadjustment of the width enable operation of the press at maximum capacity.
High-quality products and decorative lamination boost the products‘ market success
Film layup area
Film drawing Laser-precision film positioning
Quality inspection and stacking
of the finished boards
Short-cycle press
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Reduction in production costs by saving energyand raw materialIncrease in board quality due to continuousinspection and optimizationEasy operation by means of clear color-graphicrepresentation of the informationAvoidance of operating errors through dialog and visualization in simple terms and multiple help functionsSupport of controlling and planning by documentation and evaluation of all production dataIncrease of plant availability thanks to clear fault diagnosis and online supportHigh flexibility through use of custom-tailoredhardware and softwareAutomatic produce changeover through flexible and comfortable production control with no need to stop operationFully automatic processing of production ordersOnline maintenance systems
Visualization and process automation
Dieffenbacher will be your best partner in achie-ving this goal.Our experts have all the knowledge about state-of-the-art production technologies as well as process management and automation. We combinehardware components and standard softwarecommercially available worldwide with individualsoftware into a highly powerful integrated system,custom-tailored to the desired plant configuration,the specific application, and compliant withnational standards to enable cost-effective andflexible production.The modular PROGUIDE - PRODACON manage-ment system enables control, monitoring, analysisand optimization of the entire production processand integration of a big variety of additionalsystems without any problem.Clear separation of the primary control and basic automation equipment makes our plantsindependent of the configuration of processmanagement. Start-up can, therefore, take placevery quickly.
Quick and flexible answers to changing market requirements are decisiveadvantages in the long run
Superior process management with decisive advantages:
Visualization of continuous pressingprocess
Visualization, spreading station
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Visualization, finishing line
Visualization, sanding line / storage
Customer’s ERP andQuality Control System
P R O D A C O N
P R O C H A N G E
P R O G U I D E
AutomaticProduct Change
Process- &Production Data
Management
Operating and Monitoring
Equipment &Process Control
DataPrinter
Process Bus
F ie ld Bus
Automation-System
Automation-System
Automation-System
Automation-System
Automation-System
Automation-System
Green End
MaterialPreparation
Gluing/Blending
FormingStation
Forming Line Press Raw Board
HandlingRaw Board
StorageSanding
Line
Basic-Automation
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New products open up new markets
Opening up new market potentials secures success in the long run
SCORING POINTS IN DESIGN –
THE MDF BOARD
Excellent machining and application
properties make the MDF board an
economic and future-oriented
substitute of solid lumber. Many
products, especially in the design-
oriented furniture industry would
be unthinkable without using this
high-quality board.
ALTERNATIVE AND ECONOMIC –
OSB
OSB is the economic alternative to
common plywood. Their big variety
of applications has continuously
increased acceptance of these boards
in the market. Dieffenbacher have set
this trend. The first plant was started
up in 1980 already. Nowadays, the
majority of OSB is manufactured in
plants delivered by us.
PRESENT TRENDS –
MDF/THDF THIN BOARD
Thin boards with a thickness
of 2 – 8 mm open up new
applications and markets.
They are given preference in
the manufacture of interior
trims for railroad cars, recreation
vehicles (RV), picture frames,
packing material, furniture and
rear panels, drawer bottoms
as well as shaped or even door
faces.
WELL-TRIED, HIGHLY TOPICAL –
THE PARTICLEBOARD
High quality and universal applicabi-
lity - these are only a few of the
advantages that have made the par-
ticleboard a classic of wood-based
panels.
Dieffenbacher plants have signifi-
cantly contributed to the success
of this high-quality panel.
High uptime and cost-efficiency of
our plants are proverbial.
EXTREMELY LOADABLE LAYER-
BYLAYER – THE LVL BOARD
LVL is made of glued veneer, has
excellent physical properties and
continuous manufacture is the stan-
dard in the plants we deliver. High
strength makes the LVL board a
popular product used for engineered
wood applications.
Success is only possible by early recognition oftrends and quick reaction to changing marketrequirements enabled by flexible technology andinnovative products.For decades, Dieffenbacher has advanced development in panel production by setting new standards.
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ECONOMIC SUBSTITUTE OF SOLID
LUMBER – THE OSL BOARD
The OSL-Product (Oriented Strand
Lumber) has a very high bending
strength and can substitute tradi-
tional lumber in many applica-
tions. OSL can now be produced
on a Dieffenbacher CPS-press in
connection with a steam pre-
heater. This very efficient method
of producing OSL reduces the cost
of the product and enables a
wider range of applications.
CUSTOM-MADE DECORATION –
LAMINATION ENHANCEMENT
Cost-effective lamination of
particleboard, MDF, wood-
based materials or plywood
boards is a prerequisite for the
production of low-cost furni-
ture and laminate flooring with
a wide variety of decorations.
Flexible lamination systems
help to satisfy customer
demands quickly and reliably.
Woodyard of a processing plant for recycled wood
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Service
increased cost-effectiveness through innovative,cost-saving production technologiesmaximum production flexibility through matured concepts enabling simple and quick changeover to new productsmore safety and high availability through manufacture according to international quality standards, integrated quality assurance systems and online serviceecological production through solutions savingboth energy and resourcesincreased competitiveness and opening up of new markets through development of new production methods using raw materials that could not be used in the past
PERFECT MASTERY OF THE EQUIPMENT
For this reason we not only put on ope-
rator-friendliness of our plants and
systems but also attach utmost attenti-
on to perfect training of your person-
nel.
Take advantage of our experience and know-how to achieve
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Our plants, systems and processes for economic production of marketable products and our comprehensive service are the key to our customers‘ success
To date, we have delivered more than 1,000 plantsand press systems for a wide variety of raw ma-terials. A major part of the global output ofpanels is produced in plants supplied by Dieffen-bacher – a sign of our leadership in technologyand the success of our customers.Our worldwide sales and service network guaranteesdirect contact with experts for competent consul-tancy and immediate help when service is re-quired. On request, also online – 24 hours a day,365 days a year.
Service center
Training
Service