Woodforce | Natural Strength for Plastics

Making Woodforce

Woodforce can be manufactured in a world class Medium Density Fiberboard (MDF) plant by modifying the chemistry and adding a dicing equipment at the end of the process.

There are 6 major steps to the manufacturing

  1. Wood Chipping

    All the wood products used in the process are processed down to a square particle of approximately 25mm and 5 mm thick. We process chips, shavings, slabs and/or roundwood.

  2. Chip Washing

    After screening, wood chips are washed. This is a compulsory step in order to remove bark, soil, sand and abrasive contaminants. This is necessary to protect the refiner discs but it is also a guarantee of the quality of the product sold to our customers. Woodforce is a product free of any contaminants.

  3. Refining

    After being heated to 175-190 C with saturated steam, the refiner converts chips into individual fibre. Wood chips are fed into a gap between 2 discs. The surface of the discs have a series of raised bars. At the center of the disc, the breaker bar pattern is coarse and at the periphery, the bars are much finer. Consequently, as the wood is driven across the radius of the disc by centrifugal forces, it is gradually broken down into its constituent fibres.

  4. Blending with Chemicals

    The fibres are discharged from the refiner down to a pressurized blowline. Blending of the fibre in the blowline under high pressure facilitates a uniform dispersant distribution due to the steam expansion, which cause high turbulent flow, rapid accelerations (that separate fibres) to high velocity of up to 100 m/s.

  5. Mat Forming & Hot Processing

    The fibre is then dried and pneumatically conveyed to mat formers. The mat formers are designated to distribute an even layer of fibres onto a continuously moving belt. The hot pressing process applies a combination of heat and pressure to consolidate the mat and convert it to a panel. At this stage, the moisture in the product is constant between 5-8%.

  6. Cut to Size & Dicing

    After being cut-to-size for feeding into a pelletizer, the Woodforce panels are reduced to consistent sized cubes with minimal waste. This is similar to the plastics industry process to reduce plastic material to consistent sized pellets for feed hoppers.