Laminated HDF Production line sections: The production line consists of the following sections: Impregnation lines (seven units). Continuous Press Lines (two lines). Bonding lines (Three Units). Milling Lines (two available). Factory Capacity: The impregnation lines can produce up till 230,000,000 m 2 of impregnation paper. The rest of line can produce up to 10,000,000 m 2 of laminated HDF. Factory requirements: Space required= 39,000 m 2 (24,000 + 15,000) Man Power required= 85 include management for 24 hours operation. Power Requirement (motors all 400 V, 50 Hz) Trelleborg 14.8 Gwh 3.2 Gwh Natural Gas 4.9 GWh Steam 26,800 ton/year Main Raw Material: Phenolic impregnation (formaldehyde + phenolic resin), Now both available on site through Chemical and other Chemical resin supplier on site. Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 1
Melamine impregnation (formaldehyde + melamine resin), now both available on site. Décor (in rolls), Kraft paper (in rolls), Overlay paper (in rolls) all paper mainly. HDF and Back paper. All are bought from outside. Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 2
Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 3
The production process Flow: Impregnation of paper (Kraft, Décor and overlay paper on impregnation lines) with resin. All impregnation papers pressed in press line (CPL) to produce laminate. The laminate consists of : o Layers of over lay paper, the more overlay layers the more hardness surface the final product are. o Décor printed paper that has all color and shapes. o Kraft paper at the bottom of laminate. Bonding line, where the laminate in glued over the HDF and back paper (for moisture protection) is glued in bottom of HDF then all pressed then dried in oven, then cooled in cooler. Milling line, where every HDF board cut to 12 pieces, then make joints in four directions then Quality control then packaging and labeling. Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 4
The production line consist of the following Sections: 1. Impregnation lines. 2. Continuous Press lines (two available) 3. Bonding line 4. Milling Line. (no milling Units available) Impregnation Lines In Impregnation process, the papers are saturated with chemical resin then dries in long path Oven. There are seven machines available, i. 2 Phenol impregnation: (for Kraft paper impregnation) o LA 13, German Vits (produce in rolls only) o LA 14, German Vits (produce in rolls or in sheets) ii. 5 Melamine impregnation: (overlay paper and Décor paper) o LA 12, German Vits o LA 16, German Vits o LA 17, German Vits o LA 13, German Vits o LA 13, German Vits Out of the five machines, three machines has middle section to add chemical, by example add ALO 2 to over lay paper impregnation to increase scratch surface resistance. Three of the five machines produce impregnated papers in sheet form or rolls form while other two just produce impregnated papers in rolls. Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 5
Cairo Rep. Office: ACE Group 3 Samir Moukhtar St., Ard Al Golf, Cairo Egypt Tel: +202 2690 3100/200, Fax: +202 2690 3500 E-mail: info@aceindustry.net Website: www.aceindustry.net 6
Impregnation line without middle section 6
Impregnation line with Middle Section for Additives (i.e. ALo2 to overlay paper to increase scratch resistivity) 7
Pictures of Impregnation Units: 8
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Continuous Press Section In the press section we form the laminate where the Impregnated over lay layers (the more layers the higher quality the final laminated HDF) are pressed with the impregnated décor paper with the impregnated Kraft paper to form laminate. The the laminate is sand papered from back for rough service then cut ends, then cut into final sheets with size 2.5 m x 1.35 m (LxW) The Laminate is formed off, from top to bottom of: Impregnated over lay (several layers). Impregnated décor paper. Impregnated Kraft paper. The Press Section consists of the following stages: Unwinder (Kraft/décor/overlay) as they delivered from Impregnation in rolls. Press ( all press together) 17
Up winder (option not in use) Cooling Sanding back laminate (to create rough service for Gluing) Cut edges ( as after press edges are not same) Up Winder (option not used) Cutting in Sheets (2.5x1.35) Stack sheets. Machine on site: Grecon (German) Other bigger machine Bison Pictures of press Section: 18
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Bonding Section In this section the laminate produced in the press section is Glued to the top of the HDF (high density fiberboard) while back paper (mixture of paper and plastic) is glued to the bottom of the HDF as mentioned earlier. The Sections in this Bonding stage are: Infeed Laminate In feed HDF Cleaning HDF Hardening HDF (using chemicals) Gluing HDF board (from top and Bottom) Press Laminate/HDF/back Cooling ( Stacking cooler) Stacking Machines on Site: Bonding Line 2, Wemhonern Anlage 29
Bonding Line 3,Wemhonern Anlage Bonding Line 5,Wemhonern Anlage r,.. 30
Pictures of Bonding Lines: 31
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Milling Section In the Milling section the HDF board get cut, every board (2.5 m x 1.35 m) cut into 12 pieces, Then profiler where is engraves connections in length side and width side too. Then quality inspection (online) then packaging, box making labeling, crating (7 pcs per box) then Shrink wrap it. Milling Section Consists of: In feed Cross Cut (2 pieces)-cross saw section Length Cut (6 Pieces)-length saw section Profiler (length joint) Profiler (width Joint) Quality Control Inspection Packaging (include side box making) Labeling Shrink wrap Out feed (final Product) 47
Machine On site:two Milling machine on site Pictures of Milling Process (for process preview not for machine inspection) 48
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Auxiliary Equipment for sale (part of offer) Graphite Mixer 61
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Air filter 62
Glue Tanks 63
Summary List of Production Machines on Sale Item Machine description Machine Manufacturer tag 1 Impregnation line La 14 Vits (phenol) 2 Impregnation line La 13 Vits (phenol) 3 Impregnation line La 12 Vits (Melamine) 4 Impregnation line La 15 Vits (Melamine) 5 Impregnation line La 16 Vits (Melamine) 6 Impregnation line La 17 Vits (Melamine) 7 Impregnation line La 18 Vits (Melamine) 8 Press Line (CPL) HPL G1 Grecon 9 Bonding Line Bonding 2 Wemhoner Anlage 10 Bonding Line Bonding 3 Wemhoner Anlage 11 Bonding Line Bonding 5 Wemhoner Anlage Automation: Feeding Impregnation line manually From Impregnation to Press manually From Press to bonding manually. From Bonding until final product is automatic. Advantages of production line: Line in general in Good conditions. 64