The tests conducted confirm the validity of the project in terms of resin savings, reduction in electricity requirements and board properties.

Results:

The tests were conducted on three types of board [PB, MDF and OSB]. The PB panels were tested on the XILOPAN pilot line.

1. Performance testing including energy consumption.

Tests were conducted at various production facilities whereas in the case of the power requirements, we used the figures received from XILOPAN to determine the amount of electrical power saved as we did not have specific data for power requirements for the blending process.

1. Quality testing.

The tests conducted demonstrate that the panel produced, despite lowering the resin addition percentage, still have the same properties as the panel produced utilizing the former resination process.

1. Fine-tuning and optimization of all parameters and specifications for the process and the products.

The trials conducted at XILOPAN were run in an extremely thorough manner as from these, we obtained the information required for applying the technology to the MDF and OSB panel production processes. Interactive communication systems were used, connected via dedicated virtual networks, to avoid long hours travelling back and for to the site.

The work processes were fine-tuned with XILOPAN and COLOMER on the pilot line to obtain the same technical properties of the board, but with the addition of less resin.

1. Fine tuning and completion of the engineering of the plant and the products.

The results obtained from the tests on the three types of board enabled us to proceed with the construction of the pre-series and in a very short time, after some very comforting results, to proceed with the industrialization of the project

1. Identified areas for improvement of design reliability, costs, and feasibility.

A high pressure resination system has to be adapted to the customer’s production reality and the various areas for improvement may only be identified after feedback is received from the pre-series and the first installations.

PB

The resins savings percentage achieved in this case is 15% which is in line with what was expected for this new plant. The results are supported by the tests conducted at other facilities.

The reduction in electrical energy requirements for the blending process was 9% as the plant had already been modified for the possible implementation of a high pressure system. This figure in other facilities is around 15%.

PB :

[MOR]  EN319 [N/mm2]/ Bending strength;

[MOE] Mod.Elast. EN319/Modulus of Elasticity;

[IB] EN319/ Internal  bond

OSB

The resins savings percentage achieved in this case is 13%  which is in line with what was expected for this new plant. The results are supported by the tests conducted at other facilities.

The reduction in electrical power requirements for the blending process was approximately 8% as the plant had already been optimised for a correct power consumption. This is around 13% at other facilities.

OSB:

[MOE]-modulus  of  elasticity  [N/mm2]-EN310;

[MOR] Modulus of Rupture-[N/mm2] EN319

[BS] –  bending  strength [N/mm2]

MDF

The resins savings percentage achieved in this case is 12% which is in line with what we expected to achieve. This figure has found on field confirmation at other facilities.

Electrical energy requirements have been reduced by 16% for the blending process. The percentage on other lines is around 14-18%  in relation to the type of motor used [European efficiency class –IE1- IE2-IE3].

MDF:

[MOE]-modulus  of  elasticity  [N/mm2] EN310;

[MOR] Modulus of Rupture [N/mm2]   EN319

[IB] –  internal  bond  [N/mm2]   EN319