Particle Board Manufacturers in Kerala – BoardsIndia
We BoardsIndia are Plain Particle board, Pre-laminated Particleboard and low density Particle board manufacturers in Perumbavoor, the Plywood hub of Kerala. The particle boards manufactured in 8’ x 4’ size with thickness normally ranging from 26 mm, 17 mm, 12 mm and 9 mm. 100% wood based particleboard with guaranteed thickness is our USP. Our major clientele include construction companies, interior designers and retail shops spread all over South India.
What is a Particle Board?
An engineered wood product manufactured from wood chips, sawmill shavings, or even sawdust, and a synthetic resin or other suitable binder, which is pressed and extruded into sheets is commercially known as Particle Board aka Chipboard . Particle board is cheaper, denser and more uniform than conventional wood. The advantages of using particleboards is that it is more stable and much cheaper to buy compared to conventional wood.
History of Particle Boards
Particleboard originated in Germany. Firstly produced particleboard is dated back to 1887, when Hubbard made so-called “artificial wood” made from wood flour and albumin based adhesive, consolidated under high temperature and pressure.
Although the use of two or three layers of wood veneer is ancient, modern 4′ x 8′ sheets of plywood with 5-11 core layers of veneer were invented in the early 20th century, and began to become common by the Second World War. During the war, phenolic resin was more readily accessible than top grade wood veneer in Germany, and Luftwaffe pilot and inventor Max Himmelheber played a role in making the first sheets of particleboard, which were little more than pourings of floor sweepings, wood chips, and ground up off-cuts and glue.
The first commercial piece was produced during World War II at a factory in Bremen, Germany. For its production, waste material was used – such as planer shavings, offcuts or sawdust – hammer-milled into chips and bound together with a phenolic resin. Hammer-milling involves smashing material into smaller and smaller pieces until they can pass through a screen. Most other early particleboard manufacturers used similar processes, though often with slightly different resins.
It was found that better strength, appearance and resin economy could be achieved by using more uniform, manufactured chips. Producers began processing solid birch, beech, alder, pine and spruce into consistent chips and flakes; these finer layers were then placed on the outside of the board, with its core composed of coarser, cheaper chips. This type of board is known as three-layer particleboard.
More recently, graded-density particleboard has also evolved. It contains particles that gradually become smaller as they get closer to the surface.
Rawmaterials used in Particle Board
Particleboard or chipboard is manufactured by mixing wood particles or flakes together with a resin and forming the mixture into a sheet. The raw material to be used for the particles is fed into a disc chipper with between four and sixteen radially arranged blades. The particles are then dried, after which any oversized or undersized particles are screened out.
Resin is then mist-sprayed through fine nozzles onto the particles. There are several types of resins that are commonly used. Amino-formaldehyde based resins are the best performing when considering cost and ease of use. Urea Melamine resins are used to offer water resistance with increased melamine offering enhanced resistance. Panel production involves various other chemicals—including wax, dyes, wetting agents, release agents—to make the final product water resistant, fireproof, insect proof, or to give it some other quality.
Process of Manufacture of Particle Boards
The particles then pass through a mist of resin sufficient to coat all surfaces and are then layered, first into a continuous carpet. This ‘carpet’ is then separated into discrete, rectangular ‘blankets’ which will then be compacted in a cold press. A weighing device notes the weight of flakes, and they are distributed into position by rotating rakes. In graded-density particleboard, the flakes are spread by an air jet that throws finer particles further than coarse ones. Two such jets, reversed, allow the particles to build up from fine to coarse and back to fine.
The sheets formed are then cold-compressed to reduce their thickness and make them easier to transport. Later, they are compressed again, under pressures between 2 and 3 Mega Pascal (290 and 440 psi) and temperatures between 140 and 220 °C (284 and 428 °F). This process sets and hardens the glue. All aspects of this entire process must be carefully controlled to ensure the correct size, density and consistency of the board.
The boards are then cooled, trimmed and sanded. They can then be sold as raw board or surface improved through the addition of a wood veneer or laminate surface.
Influence of Particle Boards in Furniture Market
Particle board has had an enormous influence on furniture design. In the early 1950 s, particle board kitchens started to come into use in furniture construction but, in many cases, it remained more expensive than solid wood. A particle board kitchen was only available to the very wealthy. Once the technology was more developed, particle board became cheaper.
Some large companies base their strategies around providing furniture at a low price. To do this, they use the least expensive materials possible. In almost all cases, this means particle board or MDF or similar. However, manufacturers, in order to maintain a reputation for quality at low cost, may use higher grades of particle board, e.g., higher density particle board, thicker particle board, or particle board using higher-quality resins. One may note the amount of sag in a shelf of a given width in order to draw the distinction.
In general the much lower cost of sheet goods (particle board, medium density fiberboard, and other engineered wood products) has helped to displace solid wood from many cabinetry applications.
Where to Buy Particle Boards in Kerala?