Process

The manufacturing process consists of four stages:

Manufacture of Particle Boards

Agro waste wood like mango wood is one of the main raw materials. The wood is passed through the chipping machine to convert in to particles. These wood particles are then passed through driers to remove excess moisture if any and segregated in the screening machine in to fine particles and coarse particles. These particles are then blended with resins (the bonding chemicals from the resin manufacturing plant) at the glue kitchen and sent to the forming line. In the forming line, these glued particles are passed on to a steel belt to form a mat of 6’ X 36’. Thit mat then is pressed in the PPB press at required temperature and pressure. This is a raw plain particleboard, After curing in the star cooler this is cut in to required sizes in the cutting machine before carried to the sanding machine for sanding. In the sanding machine the lateral surfaces are sanded to smoothen the surfaces and to make the board suitable for lamination.

Manufacture of Resins

In this process, Urea formaldehyde & Melamine formaldehyde resins are produced in a batch reaction kettle to react under controlled temperature and Ph condition. The resins thus formed are discharged into storage tanks. No effluents are discharged except small quantity of washings after completing the batch.

Manufacture of Treated Papers

Different colored and printed papers procured in roll form are treated with appropriate resin system in an impregnator. The paper is subjected to resin penetration and absorption followed by drying in the oven and this process will undergo two stages. These papers are sensitive to heat and humidity and are therefore stored in controlled temperature and humidity area.

Manufacture of Pre-laminated Boards

Pre-laminated boards are produced by laminating treated paper onto the surface of raw particleboard or MDF (Medium Density Fiber) board. This is done in a low pressure short cycle laminating press with treated paper on top and bottom surface. This assembly is then transported into a Hydraulic press where it is subjected to certain specific pressure and temperature. The treated paper gets laminated on both surfaces of the board. The pressed boards are extracted out from the press in hot condition and passed through conveyors and inspection area before they are packed.