br wood based panel plants e lq

www.dieffenbacher.com

Wood based pane l p lants

COMPANY LOCATIONS

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MÄRTIENS ROBOTEC GMBH Zum Haug 10 76646 BruchsalTel. +49 (0)7251-9573-0Fax +49 (0) 7251-9573-25E-mail: [email protected] www.maertiens.de

KARLE + JUNG GMBHWerkzeug- und MaschinenbauHeinrich-Hertz-Straße 376470 ÖtigheimTel. +49 (0) 7222 40655-0Fax +49 (0) 7222 40655-51E-mail: [email protected]

DIEFFENBACHER – CZ S.R.O.Hydraulické lisyRipská 15, 62700 Brno, TschechienTel. +420 5 4842 3111Fax +420 5 4821 7087E-mail: [email protected]

000 DIEFFENBACHER1. MPZ imeni KazakovaKutuzovsky Prospekt 36121170 Moscow, RusslandTel. +7 495 690 71 51Fax +7 495 690 71 52E-mail: [email protected]

DIEFFENBACHER PANELBOARD OYWipaktie 115560 Nastola, FinnlandTel. +358 10 572 9000Fax +358 10 572 9001E-mail: [email protected]

SUNDS MDF TECHNOLOGIES ABUniversitetsallén 3285171 Sundsvall, SchwedenTel. +46 60 524 200Fax +46 60 524 299E-mail: [email protected]

DIEFFENBACHER GMBH Maschinen- und AnlagenbauHeilbronner Straße 2075031 EppingenBesucheradresse Umformtechnik:Jakob-Dieffenbacher Straße 4Tel. +49 (0) 7262 65-0Fax Holzplattentechnik +49 (0) 7262 65-377Fax Umformtechnik +49 (0) 7262 65-297E-mail: [email protected]

Dieffenbacher GMBH + CO.KG Betriebsstätte Pfungstadt Werner von Siemens Straße 2 64319 PfungstadtTel. +49 (6157) 803-0 Fax +49 (6157) 803-109 E-mail: [email protected]

B.MAIER ZERKLEINERUNGSTECHNIK GMBHBrockhagener Straße 1633649 BielefeldTel. +49 (0) 521 4471-0Fax +49 (0) 521 4471-200E-mail: [email protected]

SCHENKMANN-PIEL-ENGINEERING GMBHBürgerbuschweg 151381 LeverkusenTel. +49 (0) 2171 3996-0Fax +49 (0) 2171 3996-99E-mail: [email protected]

DIEFFENBACHERMASCHINENFABRIK GMBH*Gewerbestraße 2975059 ZaisenhausenTel. +49 (0) 7258 609-0Fax +49 (0) 7258 8751E-mail: info@dieffenbacher-zaisenhausen.dewww.dieffenbacher-zaisenhausen.de

DIEFFENBACHERSYSTEM-AUTOMATION GMBHHeilbronner Straße 2075031 EppingenTel. +49 (0) 7262 6550-00Fax +49 (0) 7262 6550-11E-mail:[email protected]

DIEFFENBACHER NORTH AMERICA, INC.9495 Twin Oaks DriveWindsor, Ontario N8N 5B8, KanadaTel. +1 519 979 6937Fax +1 519 979 6803E-mail: [email protected]

DIEFFENBACHER, INC.3100 Cumberland Blvd.Cumberland Center II Suite 1470Atlanta, GA 30339, USATel. +1 770 226 6394Fax +1 770 226 6397E-mail: [email protected]

DIEFFENBACHER BRAZILAv. Benedito Castilho de Andrade, 609 – sala 107 CEP (zip code) 13.212-070, Jundiaí – São Paulo - Brasilienl Tel. +55 11 4523 1298Fax +55 11 4523 1298E-mail: [email protected]

DIEFFENBACHER INDIA PVT. LTD.Unit 105, First Floor, Prestige Towers99, Residency Road,Bangalore-560 025, IndienTel. +91 80 4151 0060Fax +91 80 4151 0062E-mail: [email protected]

DIEFFENBACHER ASIA PACIFIC SDN. BHD.Unit #11-02 11th FloorMenara Multi-Purpose, Capital SquareNo. 8 Jalan Munshi Abdullah50100 Kuala Lumpur, MalaysiaTel. +60 3 7490 0183Fax +60 3 7490 0184E-mail: [email protected]

DIEFFENBACHER MACHINERYSERVICES (BEIJING) CO., LTD.Scitech Tower, Unit 1305 13th Floor22, Jianguomen Wai Dajie100004 Beijing, P.R.CTel. +86 10 6522 0935Fax +86 10 6522 0936E-mail: [email protected]

DIEFFENBACHER MACHINERY(CHANGZHOU) CO., LTD.No 18 environmental protection 1st roadThe National Environment Industrial ParkXin Bei District, Changzhou,Jiangsu 213034, P.R.C.Tel. +86 519 586 6378Fax +86 519 586 6377E-mail: [email protected]

SHANGHAI WOOD-BASEDPANEL MACHINERY (SWPM) CO., LTD.No. 299 Hejing Road, Anting,Shanghai 201805, P.R.C.Tel. + 86 21 595 77480Fax + 86 21 595 72 568E-mail: [email protected]

DIEFFENBACHER AUSTRALASIA PTY LTD.9 Widford StreetHawthorn EastVictoria, 3123, AustralienTel. +61 3 9813 2916Fax +61 3 9813 1195E-mail: [email protected]

* Allianz

When it comes to designing and build-ing of turnkey production plants, both know-how and experience are required as much as financial strength and inno-vative technologies. This is the reason why customers all over the world place their trust in Dieffenbacher.

Our machines and plants are setting new standards for future-oriented, fle-xible and cost-effective solutions.

We realize your individual concept and have the right technology available no matter whether you want to produce particleboard, MDF, THDF, OSB, OSL or LVL boards or innovative products made of recycled wood. The efforts of about 1,600 experts all over the world are devoted to assist you in achieving your goals. We make use of synergistic effects from various corporate divisions and subsidiaries.

As a global player in board technolo-gy, our above-average expenditure in the field of research and development contributes to achieving these goals. The results are highly efficient processes and products. We also find solutions for raw materials that could not be used in the past, e.g. recycled wood and agricultural waste. These materials are low in price and available in certain areas of the world in sufficient quantities. New resin saving solutions help to reduce the production costs. Close cooperation with external insti-tutes, research laboratories and system users enables us to develop products which are close to our customers needs. Materials testing is performed as well as manufacture of sample boards. Having this knowledge enables us to offer maximum process safety. In our research center we use your raw materials to develop the optimum production method for innovative products help ing you to enter new markets.

1949 Delivery of the first discontinuous particleboard production plant

1957 First single-daylight press

1967 Delivery of the first particle-board plant with screen (FLEXOPLAN)

1969 Delivery of the first complete plant equipment

1980 Delivery of the first wafer board plant

1990 First continuous press type CPS

1995 First 12-foot OSB plant

1997 First continuous production line for LVL

First online service support system

2000 First continuous 12-ft OSB production line in the world, with a 56 m CPS press

2002 THDF-line produces at speeds above 1,300 mm/s

2004 New closed loop steam fiber dryer

2005 Steam preheating for production of OSB/OSL on a continuous press

2006 First 3,000 m3/d particleboard plant

2008 Woodfiber insulation board (rigid and flexible)

2008 Products to reduce the glue consumption in fiberboardplants

2009 Digital Printing of Wood surfaces

2009 Complete Biofuel- & Pelletplants

2009 Revolutionary plant visualization concept

Competence and innovative power –The unbeatable combination

MilestonesNew ideas create new markets

Competence

Engineering

Press systems

Performance range

Process automation

Panel products

Finishing line

Service

EVOjet™, PROjet

Material preparation, Energy generation

ClassiCleaner™, Forming stations

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More than 250 experienced engineers and technologists work together worldwide in developing optimum technical solutions to satisfy your demands. No matter whether you intend to build

a new plant or retrofit an existing one, our expert teams offer complete concepts from first consultancy up to overall planning and safe financing schemes – success included!

Kronospan Egorievsk (PB plant in Russia)

Engineering team Lab pressWood-based panel testingPress installation

Accurate analysis of your individual projects

Feasibility calculations and financial schemes

Support with authorities and permit application procedures

Elaboration of material flow diagrams

Selection of individual technologies and production systems

Engineering including choice of location, supply of energy, raw and operating material

Site supervision and monitoring (optimization of building and start-up times)

Cost transparency through interme-diate reports

On-time start-up through coordina-tion of site work including manage-ment of services by subcontractors and subsuppliers

Modernization concepts under consideration of existing facilities

Controlling

Dependable services in every respect:

We stand for success

From concept to start-up – expert advice in all aspects

Competence

Engineering

Press systems

Performance range

Process automation

Panel products

Finishing line

Service

EVOjet™, PROjet



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The new woodfiber insulationboards combine excellent insulation proper-ties, superior sound insulation and heat capacity with a very low carbon footprint.

The product is available in a more rigid style for roof and floor insulation and a flexible type for the traditional appli-cation of insulation boards. Both types can be produced on the same produc-tion line.

Thin boards with a thickness of 1,5 – 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, furni-ture and rear panels, drawer bottoms as well as moulded or even door faces.

High quality and universal applicability – these are only a few of the advan-tages that have made the particle-board a classic of wood-based panels.Dieffenbacher plants have significantly contributed to the success of this high-quality panel.

High uptime and cost-efficiency of our plants are proverbial.

LVL is made of glued veneer, has excel-lent physical properties and continu-ous manufacture is the standard in the plants we deliver. High strength makes the LVL board a popular product used for engineered wood applications.

OSB is the economic alternative to common plywood. The big variety of appli cations has continuously increased acceptance of these boards in the market. Dieffenbacher have set this trend. The first plant was started up in 1980 already.

New products open up new markets

Woodyard

Woodfiber Insulationboard – the ecological alternative

Present trends – MDF/THDF board Well-tried, highly topical – the particleboard

Extremely loadable layer-by-layer – the LVL board

Alternative and economic – OSB

Competence

Engineering

Press systems

Performance range

Process automation

Panel products

Finishing line

Service

EVOjet™, PROjet



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Everything from a single source

Performance range

We supply everything from a single source and manufacture all process-relevant systems in our own group. Many years of experience help us to select supple-mentary components made by other manufacturers and ensure their optimum integration into the complete system.

Supply of complete production plants for particleboard, MDF, THDF, OSB, OSL, LVL boards as well as for Wood fiber insulation boards and of Biofuel & Pelletplants

MDF Frontendsystems incl. the EVOjet™ and PROjet fiber blending systems

Moulded Doorskin lines Equipment for process heat supply

and waste heat recovery ClassiScreenTM and ClassiCleanerTM

systems for flake preparation Dryers, air graders GRADO – Glue preparation and

metering systems Gluing systems ClassiFormerTM Forming stations Forming lines including pre-presses

Steam and microwave pre-heating systems

Continuous presses systems Cycle presses in single- and multi-

daylight design Finishing lines with diagonal saws,

board cooler and stacking equipment Complete sanding lines with

cut-to-size saws and stacking Automated transport and LukkiTM

storage systems Panel laminating systems

(Dieffenbacher Zaisenhausen) PRODACON – Process control and

automation systems Online support and maintenance

systems Plant modernization Digital printing line for wood

surfaces

Competence 2

Control room

Suitable equipment for any case of application

Engineering

Press systems

Performance range

Process automation

Panel products

Finishing line

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MDF production line


Drum dryer for strands Energy plant

These alternatives are available to you: Benefits:

Strong team of engineers with long experience from energy plant de-sign for wood based panel industry

Well proven concept with heavy duty design

Energy plant and dryer control system from one hand seamlessly integrated in the plant control

Engineering responsibility in one hand; minimizes interfaces

Upgoing line capacities and ever in-creasing environmental requirements ask for economically viable, precise and safe technologies …

especially with energy generation and material preparation. For this reason our scope of supplies also includes sin-gle components and complete systems to generate the heat that is required during the production process in panel plants. Energy is provided by differ-ent 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 obtaining a high board quality. Particles and fibers must be prepared to have a constant moisture level and be sifted to remove unwanted particles such as sand, metal pieces, glue knots etc. Different types of dryers and sifters are used according to the individual product and prod - uction capacity.

Material preparation and drying

Particleboard air grader Energy plant

Dryers for particles and strands.The dryers can be heated with different fuels, as well as with gas from a tur-bine or furnace, depending on the type of plant. Exhaust gas recircula-tion increases the efficiency. Indirect heating is possible by means of com-bined power generation/heating or thermal oil heating.

Particle sifters for the removal of• Mineral matter

• Metallic contaminants • Coarse particles • Glue lumps

Benefits:

Environmentally friendly through use of available residual energy and alternative sources of energy

Low emission figures

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Competence 2

Energy generation

Engineering

Press systems

Performance range

Process automation

Panel products

Finishing line

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Extinguishingnozzle

Explosion vent

Infeed material

Vent duct

Pressure sensor

Dry powder tank

Air grader

Coarse materialdischarge

Sand discharge

HURRICLONE

Fine materialdischarge

Spark detectionSpark extinguishing

Main fan To filter

By-pass flap

Fresh air flap

ATEX protection for insideinsallation

ATEX protection for outside insallation

Manual extinguishing

Spark detection and extinguishing


Standard installation

EVOjet™ and PROjet –

Frontends for fiber plants

Efficient dry fiber sifter

The Z-Sifter has an unique zig-zag plate design which efficiently removes light and heavy contaminants, such as wood residues, fiber deposits, minerals and metals.

Furthermore, it protects the machinery downstream particularly when produc-ing thin boards.

The optional fiber heating and mois-turizing system offers a higher press production capacity.

Fiber dryer. Flue gas heated two-stage dryer with RAS, integrated with energy plant PROjetZ-SifterEVOjetTM

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PROjet – optimized blowline blending

The optimized blowline blending achieves resin savings of 4 – 12% by

Optimized blowline dimensions Automatic control loop for process

parameter Special self cleaning nozzles with

steam automization

The PROjet is an economical and quick solution with limited resin savings but very fast payback.

EVOjet™ dry resin blending system

The new EVOjet™ system secures a perfect resination with a combination of a large surface area of fibers in the conveying air and an effective resin distribution.

The system provides all the benefits of traditional blow line blending but none of its drawbacks. The EVOjet™ system is simple and reliable and requires a minimum of maintenance, thus reducing the operating costs further. Reduced emissions from the dryer is another valuable benefit of the system.

EVOjet™ in brief:

Mechanical fluidization and homog-enization of fiber flow

Effective distribution of the resin on the fiber

No build-ups of resinated fiber No resin spots on the panel surfaces Major savings in resin costs between

30 and 50%

Sunds MDF Technologies, the MDF-competence center, provides the Know-How and the equipment for complete MDF Frontends. The fiber-dryer, the resin blending systems and the fiber sifter are the key prod-ucts provided.

Dryer concepts

Single-stage dryer integrated with fiber cleaning:

Simple process control Low capital cost Rapid process changes

Two-stage dryer with RAS integrated with fiber cleaning and pneumatic transport systems:

Excellent moisture tolerance: +/-0.5%

Gentle drying High energy efficiency 30% dust emission reduction

compared to a single-stage dryer 30% lower exhaust air flow than

in a single-stage dryer

Two-stage dryer with RAS-C integrated with energy plant:

High energy efficiency Low emissions 50% exhaust air flow reduction

compared to a single-stage dryer

Competence 2

Engineering

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Forming stations and spreading systems are decisive for high cost-effectiveness as well as quality and environment-friendliness

The following variants of spreading systems are available:

Competence 2

ClassiCleaner™ Roller bed Core layer spreading system OSB forming station

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Combined particle spreading sys-tems (wind/mechanical), variants depending on product, perfor-mance, surface, accuracy and raw material

Mechanical spreading systems for particles, fibers, strands as well as recycled wood depending on product, performance and accuracy.

Benefits:

High spreading accuracy Continuously high board quality Reduction of production costs Spreading of recycled wood

materials without any problem Standardized components Short start-up times Low maintenance requirement

Engineering

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ClassiCleaner™ – screening and cleaning in single unit

ClassiCleanerTM is developed specifically for the particleboard and MDF indus-tries for processing of chips, flakes, mixtures of sawdust and chips or chips made of recycled material. The machine separates heavy impurities and light foils efficiently and classifies the clean-ed raw material into desired fractions. The compact design makes it ideal for rebuilds and modernizations.

ClassiCleanerTM Benefits:

Raw material cleaning and screening in single unit

Efficient mineral separation – maxi-mum yield

No waste water treatment No plugging – maximum availability Stable performance – self-cleaning

high-wear-resistant rollers Minimum energy consumption, low

emissions Minimum dynamic loads, light

foundations Modular design – fast installation

and start-up

ClassiScreen™ –screening reduces production costs

The ClassiScreenTM is incorporated into the cleaner system and it carries out the screening of flakes. Flakes are screened on a DiamondRoll roller bed. The gap between the rollers, their rotation speed and the shape and depth of the roller surface pattern control how the flakes are screened.

ClassiScreenTM Benefits:

High capacity Efficent thickness screening,

improved wood material quality Reduced resin consumption Best screening accuracy with high-

precision Diamond Rolls Low maintenance, no plugging Low energy consumption Low dust emissions and noise level Fast installation, compact and

modular design Minimum dynamic loads, light

foundations Options for separating impurities

Forming stations and spreading

systems

ClassiCleanerTM and ClassiScreen™ –

Using alternate raw materials saves costs

Flax with capsules ClassiFormerTM

Particleboard forming station

and decades of experience in building hydraulic presses to be highly flexible, simple to operate, maintenance-friend-ly and wear-resistant – presses that fulfil all demands put by usually rough production conditions.

Our continuous presses are distin-guished by high flexibility to cope with production-related changes in panel

thickness or width. Very large presses more than 60 m long and 12 ft wide and very fast presses are our special-ity. We have developed a specific infeed geometry, which guarantees high reliability at very high production speeds, especially in the case of thin fiberboards. Single-daylight or multi-daylight presses are still in demand for small and medium plant capacities.

CPS press infeed Pre-pressPre-heating Multi-daylight press Single-daylight press

Press systems

Continuous CPS press system

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Continuous CPS press systems are the result of constant research and development …

Forming lines:

Dieffenbacher forming lines include continuous pre-presses for various products with varying individual pre-compressor length and pressure sec-tion. Pre-presses guarantee a safe and smooth transfer of the mats at any speed. Pat ented pre-heating of mats and billets by microwave or steam injection for particleboard, MDF, THDF, OSB, LVL and OSL increase the capaci-ty and areand example for successful innovation.

Benefits:

High surface quality adjustable to each case of application

Reduced thickness tolerances and, therefore, minimum sanding

High capacities at constant quality High flexibility through easy adjust-ment of thickness and width

Usable for very thin boards as well Expansion possible without any problem, easy adaptation to modi-fied capacity requirements

Compliance with all usual standards

Competence 2

Engineering

Press systems

Performance range

Process automation

Panel products

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CPS press modules

The Dieffenbacher plant spectrum is completed by transport of boards from the press to packing for delivery of individual lots.

Our finishing line offers optimum solutions for economic processing and efficient handling of the boards.We deliver systems for conveying, weighing, sawing, trimming, cooling, stacking, sanding, sorting, intermedi-ate storage, packing and final storage – tailored to your specific needs.

High cutting speeds and the automat-ic format change option make the Dieffenbacher diagonal saw one of the most powerful systems available in the market. Consistent reduction of the moved masses enables highly dynamic movement of the saw at maximum cut-ting precision.

LUKKI™ Stacking boxes upstream the sanding line

Finishing line

Diagonal saw

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Efficient handling for economic processing Benefits:

High operation reliability Standardized elements Controlled board cooling and

maturing Smooth panel transfer Accurate board cutting

Competence 2

Automated intermediate storage systems with the LUKKITM or carrier systems:

One of the key elements in efficient panel handling is a flexible interme-diate storage system through which the panels flow smoothly without disturbing board production. LUkkI™ intermediate storage system was de- signed in order to meet the demands of board producers worldwide.

Benefits:

Efficient flow of materials through the plant

Rapid response to customer orders Consequently, more profitable

board production

Engineering

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Star cooler with subsequent stacking

Dieffenbacher will be your best part-ner in achieving this goal.

Our experts have all the knowledge about state-of-the-art production tech-nologies as well as process manage-ment and automation. We combine hardware components and standard software commercially available world-wide with individual software into a highly powerful integrated system. These systems are custom-tailored to the desired plant configuration, the specific application, and compliant with national standards to enable

cost-effective and flexible production. The modular PROGUIDE-PRODACON management system enables control, monitoring, analysis and optimization of the entire production process and integration of a big variety of addition-al systems without any problem.

Clear separation of the primary con-trol and basic automation equipment makes our plants independent of the configuration of process manage-ment. Start-up can, therefore, take place very quickly.

Visualization, finishing line

Visualization and process automation

Process visualization, control room

Quick and flexible answers to changing market requirements are decisive advantages in the long run

Green end Materialpreparation

Gluing/blending

Forming station Forming line Press Raw board

handlingRaw board

storageSanding

line

Customer’s ERP and quality control system

Data-printer

Process bus

Field bus

Automation-System

Automation-System

Automation-System

Automation-System

Automation-System

Automation-System

Competence 2

Reduction in production costs by saving energy and raw material

Increase in board quality due to con-tinuous inspection and optimization

Easy operation by means of clear color-graphic representation of the information

Avoidance of operating errors through dialog and visualization in simple terms and multiple help functions

Support of controlling and planning by documentation and evaluation of all production data

Increase of plant availability thanks to clear fault diagnosis and online support

High flexibility through use of custom-tailored hardware and software

Automatic produce changeover through flexible and comfortable production control with no need to stop operation

Fully automatic processing of produc-tion orders

Online maintenance systems

Superior process management with decisive advantages:

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Customer’s ERP and quality

control system

Process- & production

data management

Automatic product change

Process data

Production data

Operating and monitoring

Basic automation

Equipment & process

control

Production line

Control pyramid

Engineering

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Performance range

Process automation

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Visualization, spreading station Visualization of continuous pressing process

Service

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Modernization Technical online service

We are well aware that delivering the machine is not the end of the job. For this reason, we have put together an attractive package of services for you in order to ensure excellent machine serviceability. We want you to be happy with all aspects of our work! If you need our assistance, we are ready to help you with a well trained and expert service team in Europe, North America, Asia and are planning the formation of additional service centers in the near future.

Service throughout the entire operating period

Dieffenbachers service begins with the support of panel manufacturers to increase the performance for their processes like quality, productivityand profitability.

To get the best results from existing machines we invest in tools like:

TEO tele-engineering online service Contracts for regular inspections Checking processes and conditions Analyses of machine performance

values Modernization, conversion and

relocation Training Technical research & development

center Spare parts and consumables

Plant modernization and optimization

Pre-studies, plant analyses and surveys can be offered for all wood based panel plants to deliver customized and cost-effective modernization con-cepts. The Dieffenbacher Group proposes profitable solutions for:

Increasing plant performance Improving product quality Reducing consumption Relocating existing equipment Implementation of new

technologies

Training – competitive edge due to qualified teams

We offer practically oriented instruc-tion courses directly on your machines or in our training centre. Other training courses serve to provide information about the typical modules in the machine. In addition, we offer targeted product or machine training courses right through to the communi-cation of process expertise. The training proposal is provided appropriately for specific customer requirements and with regard to the following points:

Fundamental and detailed know-ledge of mechanical, hydraulic and electrical systems

Technological knowledge Preventative maintenance for opti-

mum serviceability of the machine and reducing production costs

Diagnostic assessment for rapidly locating the causes of problems

TEO – technical online support and elimination of faults

With our online service, we can offer you local-independent and, above all, rapid assistance at any time when it comes to questions about process parameters and eliminating faults:

24/7 service Online diagnosis and trouble-

shooting Technical and technological support

Benefits:

Reduction of unscheduled down-time

Increased productivity Reduced service costs

TEO: Internet support

Competence 2

Engineering

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Dieffenbacher worldwide

br wood based panel plants e lq

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