Business plan for the production of OSB osb boards. Equipment and its cost

Features of the production technology of OSB boards and their performance characteristics

It so happened that for many domestic consumers, OSB boards are still considered unusual and unfamiliar, sometimes they identify them with chipboard boards and think that the quality of OSB is as low as that of chipboard. This is fundamentally wrong, the performance of the new plates is excellent. There are many reasons for this, it is worth mentioning only one - chipboard boards are made from waste (chips are collected from sawmills and woodworking enterprises), and OSB boards are made from high-quality wood. This fact alone should convince all those who doubt the excellent physical characteristics of the new building material.

What is OSB and its features

OSB - oriented strand board, in the English transcription OSB (oriented strand board), sometimes it is incorrectly called OSB, although no one can clearly decipher what OSB is according to the indicated abbreviation. OSB boards are made from specially prepared thin chips, which are glued together with various resins. Chips in the thickness of the slab are placed in layers, each layer has its own orientation. Poplar, aspen, low quality pine, mixed hardwood logs, etc. are used for the manufacture of boards. The use of these species makes it possible to significantly reduce the cost of production, and modern materials and technologies improve physical characteristics. New technologies make it possible to obtain material for a wide range of applications - from construction to the furniture industry.

Characteristics of OSB boards

• They have improved durability.
• They have a low coefficient of linear expansion. A very important indicator for the furniture and construction industry.
• Depending on the variety, they can be used indoors without restrictions from the sanitary authorities.
• Can be used for building various designs outdoors.
• Very technologically advanced - they are perfectly cut in all directions with conventional tools, all hardware is well kept in the plate.
• Do not have the effect of residual deformation. After removing the load, the plate returns to its original state.
• They are not afraid of conditions with high humidity, they are not amenable to putrefactive processes.
• Slightly combustible, meet all fire safety requirements. They have high resistance to open fire, during combustion they emit a minimum amount of toxic substances.
• In terms of strength, chipboard is much superior, in some cases this indicator exceeds the characteristics of solid wood.
• The price is quite affordable for most users, significantly lower than it has natural wood or plywood.

OSB board production technology

The production technology is no different at various enterprises, there are differences only in the productivity of the equipment, the principle of their operation and the adhesives used.

Production consists of the following steps:

• Selection and preparation of wood. Logs are fed with a length of 2.4÷7.3 mm. The specific length is determined by the features of the equipment. If necessary, the logs are soaked and pre-sanded.
• Chip cutting. There are currently three types of chipping machines in use: short log cutters, disc cutters for long logs, and ring (rotary) chippers.
• Drying wood chips in special centrifuges or on containers. Chips are fed into the drums in portions, the drying process can be carried out in three or one pass. The newest equipment uses container drying, this method improves productivity and quality, besides, it is possible to dry a longer length. linear dimensions wood chips
• Impregnation of raw materials with compounds. This is one of the most critical processes; the technological characteristics of the OSB board largely depend on its quality. Chips are thoroughly mixed with adhesives, the compositions have complex chemical formulas, may include various components, additives and modifiers.
• Laying wood chips in three layers. The so-called chip carpet is formed on a special line before being fed under a heat press, the spatial orientation of each layer of the carpet is carried out using special "harrows", the gaps between the teeth are selected taking into account the parameters of the chip. The number of forming devices depends on the number of layers of chips in each board. On the same lines, the dimensions of the slabs in width and thickness are set.

• Pressing. The dimensions of the press must correspond to the dimensions of the chip mat, all domestic manufacturers of OSB boards work on imported equipment and are guided by international standards. The heating temperature reaches +200°С, the exposure time is at least three minutes, the pressure is set to 500 kgf/cm2, all processes are constantly controlled by electronics.

• Calibration. After leaving the press, the slabs are cut to length and precisely cut to width. The parameters are set by the operator and must comply with the provisions of current international standards. If necessary, tongue and groove connections are cut on the edges. The surface of the boards can be sanded on one or both sides.
• Quality checking. Quality control is carried out by modern ultrasonic sensors that check the density of the product throughout its thickness. Depending on the adhesive composition used, the product may be subjected to a final curing until the end of the chemical reactions.

5 OSB manufacturing companies in the Russian market

All manufacturers give a 25-year warranty for their boards, however, the production of OSB in Western Europe has a longer tradition, which makes the quality of these boards impeccable, and their characteristics fully comply with the requirements of the European standard EN 300. Boards produced under the control of the KRONOGROUP concern in Poland, Bulgaria, Lithuania, Romania and the Czech Republic, are distinguished by quality close to German, as well as a more affordable price. Products from American and Canadian manufacturers are thinner due to the use of the English system of measures. The difference is about 4%. Another feature is a higher degree of friability of the slab compared to European counterparts, which speeds up and facilitates installation. Some manufacturers from the North American continent cover the end of the plate in blue. These boards are different good quality, but when calculating the required amount, it is necessary to take into account the difference in sizes, which are somewhat smaller.

LIST OF POPULAR MANUFACTURERS REPRESENTED IN RUSSIA

Bolderaja OSB Superfinish (Bolderaja OSB superfinish), Latvia

This manufacturer is the largest wood processing company in the Baltic States. The entry of the company in 2005 into the international concern KRONOGROUP made it possible to ensure the European level of products and open access to European markets. The boards according to their physical and mechanical characteristics meet all the requirements of international quality standards and are produced in accordance with ISO 9000.

KronoplyKronoply GmbH (Kronoply GmbH), Germany

This company, which began its activities in 1991, is also part of the Swiss concern KRONOGROUP. The products are distinguished by characteristic German quality. OSB production is the core business of this large enterprise, with a daily board output of 1 million square meters.

Kronopol (Kronopol), Poland

This plant with a twenty-year history also produces boards in accordance with the standards of the KRONOGROUP concern, exporting products all over the world. Russia is one of the most priority markets for the manufacturer, which is one of the largest in the world.

EGGER OSB (Egger), Austria

This manufacturer with more than 50 years of history produces quality OSB according to the generally recognized European standard EN 300. The production association, which started as a small family business, now has 16 companies located in five European countries.

GLUNZ OSB (Glyunts AG), Germany

This manufacturer is part of the large industrial group Sonae Industria (Portugal), whose factories are located almost all over the world. The company produces OSB boards of various thicknesses (6-40 mm) using the latest equipment. The products meet the requirements of the European standard EN 300.

OSB Norbord, Canada

A large industrial association with eleven oriented strand board plants located around the world, two of which are located in Europe.

OSB Louisiana Pacific, Canada

One of the oldest manufacturers of OSB boards and a world leader in the production of these materials, including 29 plants located in the USA and Canada.

Georgia Pacific (GP), USA

One of the oldest companies with almost 30 years history of oriented strand board production.

OSB Arbec, Canada

This is the only company on the North American continent that divides its boards into two types: American (characterized by high standards of strength and environmental safety, as well as the presence of one corrugated side) and European (characterized, in addition to quality, by increased moisture resistance).

6 Laying OSB on the floor

Due to their moisture resistance, environmental safety and excellent technical characteristics, OSB boards (OSB) are an excellent base for any floor coverings, be it laminate, linoleum or carpet. They are perfect for arranging a subfloor for tiles or parquet. Because OSB has a 25-year warranty, these coatings will last a very long time. Types of bases for laying slabs:

● concrete screed;

● logs (beams) of the first and second floors;

● on supports (brick posts that are laid out on the first floor of houses).

OSB selection

OSB 3 (boards designed for use in high humidity conditions) from Western and Eastern European manufacturers are considered the most suitable for laying on the floor. This product meets European standards for moisture resistance and is characterized by high density.

Calculation of the need for slabs

When counting required amount sheets, it is necessary to take into account 7% loss of coating during cutting.

Choice of slab thickness

If the slabs are laid on a concrete floor (screed) as a leveling surface to provide heat and sound insulation, the recommended OSB thickness is 8-10 mm.

When laying on logs (beams), the thickness of the slab depends on the distance between the supports. With an interval width of 400-600 mm, the required OSB thickness is 15-18 mm, and with a width of mm it will be 22 mm.

Laying on logs

When installing a subfloor from oriented strand boards, laying is carried out on logs. Between OSB 3 boards it is necessary to leave a gap of 3 mm on each side. With the "floating" method of laying the boards, a gap of 12 mm is required between the wall and the OSB. The plates are joined on logs along a narrower edge. Longer edges also require additional supports.

Due to the increased load that falls on the floor, it is advisable to use a two-layer coating of OSB (OSB). The layers are arranged perpendicular to each other and fastened with ruffed or spiral 2-inch nails. The plates are fastened with self-tapping screws with a pitch of 300 mm to wooden beams. At the joints of the plates, the recommended step length is 150 mm. To ensure reliability and rigidity, you can additionally glue the plates to the logs using a special mounting adhesive for wood.

Laying on a concrete screed

When laying on a concrete screed, OSB boards are fastened with self-tapping screws directly to concrete floor or on top of the insulation, which provides increased thermal insulation and resistance of the future floor to mechanical stress.

Laying under linoleum

When laying OSB boards as a base for linoleum, it is necessary to achieve maximum smoothness of the joints between the boards, for which it is advisable to use panels of the minimum allowable thickness. A gap of 3 mm must be closed with an elastic silicone sealant. If during laying a single connecting seam, then thermal gaps must be made from the side of the wall.

Under ceramic tiles

Oriented strand board OSB (OSB) is perfect as a base for ceramic floor tiles providing additional thermal insulation. To lay tiles on top of an OSB subfloor, a special mineral adhesive is used to bond wood and ceramic surfaces. The tile will stick perfectly on such a floor.

7 OSB frame houses

Houses built from OSB are commonly called "Canadian" and "frame-panel". Construction technology frame houses has been widely used all over the world - from Europe to North America. Such houses can be erected even in seismically dangerous regions (frame houses can withstand fluctuations of up to 9 points) and in permafrost areas (can be used at temperatures up to minus 40). The technology of their construction involves the use of wooden or steel frame, as well as OSB sandwich panels. Walls, partitions and even the roof - everything is made from such sandwich panels.

What is OSB sandwich panel (OSB)?

This panel is a kind of sandwich consisting of two OSB boards and an inner layer of insulation. The latter can be foam (both granulated and extruded), polyurethane foam, insulation based on mineral wool or glass wool. It is advisable to use mineral wool in conditions of high humidity, since in this way the walls get the opportunity to "breathe" and excess moisture easily evaporates. This avoids the formation of condensation and the development of mold on the walls. A vapor barrier layer is laid between the insulation layer and the slab, which is necessary to protect the walls of the house from excess moisture and ensure a favorable climate inside the cottage.

Sandwich panels are produced industrially. The panels are cut at the stage of components according to predetermined dimensions, which ensures high cutting quality and the absence of joint defects. During the technological process, all layers of the sandwich panel are glued together with one- or two-component urethane adhesive. The drying time of each layer of glue is only 5 minutes. Finished panel placed in a press for 30 minutes polymerization. In a day, the sandwich panels are ready for use.

Additional elements

In addition to sandwich panels, structural elements such as blocks, corners, transitions are used in the construction of frame houses. The technology of their production is completely similar to the technology of manufacturing sandwich panels.

What is the difference between OSB houses

Excellent thermal insulation

The main advantage of such buildings is high heat-saving characteristics. The thickness of the insulation is 100-200 mm, which makes OSB sandwich panels 8(!) times warmer than brick walls. A layer of mineral insulation with a thickness of 200 mm corresponds to a 2-meter thickness of a brick wall. At the same time, the walls of such a house provide excellent air circulation, "breathe", saving heat and not letting the heat through.

Ecological cleanliness

An important advantage of "Canadian" houses is their environmental safety, comparable to wooden cottages. It is primarily due to the properties of wood - the material on the basis of which OSB boards are produced.

Flexibility in design

This construction technology leaves considerable scope for a variety of architectural solutions while being very economical both in terms of money and time.

Speed ​​of erection

When building frame houses, you do not need to wait for the house to “sit down” or dry out, but you can immediately start finishing. Usually, the term for the construction of structures of this type, taking into account all construction work, does not exceed 6 months.

Reliability

Contrary to fears, the warranty period for such houses is at least 70 years.

Lightweight design

This technology is characterized by a minimum load on the foundation, which makes it possible to construct shallow columnar foundations.

8 How safe is OSB for our health?

The environmental safety of OSB boards is confirmed by their compliance with the requirements of the international standard in the field of environmental safety E1. This standard is met by all environmentally friendly materials used in residential premises. Cookers made in Canada and the USA are certified to APA and TECO standards, which also means they are suitable for residential applications. Regardless of the level of moisture resistance, OSB-2 and OSB-3 boards are distinguished by the same degree of environmental safety. What materials are used in the production of plates and how harmless are they?

Wood

In Europe, wood is predominantly used for the production of boards. conifers(spruce and pine), which gives the finished product a light shade and a characteristic smell of needles. In the USA and Canada, the main material for the production of boards is wood chips from such species as aspen, poplar and ash. Pine boards have the highest resistance to moisture and decay. They are virtually immune to the harmful effects of insects, which can pose a risk to OSB during prolonged exposure to high humidity.

resins

Any waterproof resin is added to the chips prepared for subsequent pressing. Typically, the percentage of resin in the composition of the plate is 7-8%. Phenol-formaldehyde resins modified with melamine resin are used as a binding base for the outer layers. Carbide resin is used for the inner layers. Resin combination may vary by various manufacturers plates.

carbamide CO(NH2)2, the so-called "urea", or carbonic acid amide, is widely used as a nitrogen-containing fertilizer and mineral feed additive in agriculture.

Melamine-urea-formaldehyde resins are also safe for humans. Formaldehyde (HCOH) is made from methyl alcohol and is considered harmful to humans. However, the plates themselves are quite safe from an environmental point of view. Although formaldehyde resin releases nerve gases when vaporized, due to the presence of melamine, the harmful effects of formaldehyde are neutralized. We should not forget how much importance is given to material safety issues in the West. Consumers from Europe and North America are very scrupulous in matters of environmental cleanliness. Nevertheless, OSB is widely used there, including in the construction of medical and children's institutions. The European class E1 assigned to OSB boards means absolute safety in terms of formaldehyde emissions. This class includes even pure wood, generally recognized environmentally safe material. So plywood, for example, corresponds to class E2. In addition, the combination of melamine and formaldehyde gives oriented strand board strength and reliability.

Paraffin emulsion

To improve the water-repellent properties in the production of boards in Europe, a paraffin emulsion is added to their composition. This substance also increases the level of protection of the plate from the effects of insects and microorganisms. Such coatings do not need additional processing antiseptics (fungicides).

wood composites

From the family of wood composite materials in Russia, the following are produced and best known: plywood, chipboard ( particle boards), MDF, glued laminated lumber and LVL veneer lumber.

OSB (Oriented Strand Board) also belongs to the class of wood composites. Today, OSB is one of the most advanced wood composite materials and is considered the most promising and versatile wood building material.

OSB is relatively new structural material. OSB production technology was born as a result of the development of the technology for the production of so-called wafer boards in Canada. Industrial production of OSB began in the early 80s of the last century. Due to various economic and raw material reasons, the volumes of production and consumption of this material today vary greatly in various countries peace. The highest growth rate of the OSB market over the past ten years is observed in North America. If in 1990 the consumption of boards there was about 6.8 million m3, then by 2003 it had grown to 22 million m3 per year.

Similar growth rates are now observed in the European market, where OSB consumption has already exceeded 3 million m 3 per year and continues to grow. South America consumes about 500,000 m 3 per year of oriented strand board. China and Japan are also ramping up production of this material, but production capacity is Asian countries are still relatively small - the market there mainly sells board imported from Canada.

Current situation with OSB in Russia

A very interesting situation has developed in Russia. Neither in our country, nor in the CIS countries, there is not a single plant for the production of oriented strand boards. At the same time, the Russian OSB market is developing quite dynamically. Application of new construction technologies, the emergence of the latest building materials, as well as European board manufacturers and importers are actively stimulating this development. According to various estimates, the capacity of the Russian market is already estimated at the level of 120,000–150,000 m 3 per year.

Russia has huge reserves of non-commercial timber, which does not find any use and simply disappears in the cutting areas. According to experts, Russia could produce OSB at one of the lowest cost prices in the world.

What's stopping us?

What prevents the appearance in Russia of its own production of OSB?

To date, one of the main deterrents are significant financial risks in such a project. OSB technology is now one of the most high-tech in the production of wood-based panels. This affects the amount of investment that needs to be attracted to the project. When ordering equipment from the largest European suppliers, such as Metso, Dieffenbacher and Siempelkamp, ​​who offer a complete turnkey supply of a production line, the amount of capital investment becomes so significant that the project will pay off in a reasonable time only with significant production capacities of the line. And the output of a plant of large and even medium capacity (at least 150,000–200,000 m 3 per year) with its products to the market, which consumes exactly the same amount, seems too risky. Commercial risks are also seen as too high.

The lack of production experience and competent specialists imposes additional risks when organizing the country's first plant for the production of OSB boards.

Another limiting factor, of course, is the lack of awareness of domestic investors and manufacturers about oriented strand boards, about the technology and possibilities of their production, about the prospects this product and possible markets for it. Very little technical information about OSB and equipment for its manufacture can be found in Russian.

True, it should be noted here that not so long ago in Russia, in St. Petersburg, the joint Canadian-Russian engineering group Wood Processing Consulting Services began its activities, which is actively engaged in popularizing OSB boards and promoting their manufacturing technologies among Russian industrialists.

The concept of creating a low-capacity OSB plant

The problems that prevent Russia from starting OSB production are quite obvious, therefore, last year, WPC Services engineers and analysts, together with IMS-Engineering, completed the development of a low-capacity OSB plant concept (65,000–70,000 m 3 per year), adapted specifically for Russian conditions. I would like to elaborate on this interesting project.

The main goal in the development of the project was to reduce the amount of necessary investments and optimize capital investments in such a way that the payback period for the project of the first Russian OSB plant did not exceed 5 years. Such a payback period in Russia is considered optimal for projects related to woodworking.

The developed concept was based on the joint use of imported equipment and equipment that can be produced at Russian machine-building plants. The bottom line is to import from abroad only the most complex, key equipment in the technological process, such as a chipper, chip mixers, a press, etc. Less complex equipment, GTO pools, chip sorting, supporting metal structures, etc. manufactured at a Russian plant under the direct supervision of its specialists. The time for the full implementation of such a project is 14-18 months, depending on the specific conditions of the Russian customer.

OSB production technology

According to the engineers, when developing the low-capacity OSB plant project, they faced the following tasks:

• use the most simple and proven technology for the production of OSB boards;
• ensure maximum reliability and efficiency of the equipment;
• ensure optimal utilization of raw materials and components;
• provide a flexible layout of the production line, which would allow the use of existing buildings and structures.

The technology implemented in the project makes it possible to produce boards of OSB/3 quality, i.e. moisture-resistant boards for structural, building application. The possibility of a simple modification of the technology is provided for its application in all major climatic zones Russian Federation.

Consider the essence of the technology implemented in the project.

In the previous issue of the journal, we already wrote that almost any available wood can be used for the production of OSB: thinner wood, wood from fast-growing plantations, top parts of trunks with a diameter of 5 cm or more, as well as low-grade and substandard wood (see PPI No. 9 (31) 2005). In this case, it is desirable to use round timber as a raw material. Studies were carried out on the possibility of using waste from plywood and sawmill industries. But when using such raw materials, the yield of chips of the desired fraction is too low. At the next stage of production most of wood in this case is screened for burning. For the same reason, it is recommended to carry out a preliminary hydrothermal treatment of wood, especially in winter conditions. Frozen, as well as logs of low humidity, which have lain on the exchange for a long time, give too much small chips, and not chips of the right size.

Coniferous, softwoods and hardwoods medium density are most suitable for the production of oriented strand boards. Pine, aspen and poplar are considered to be the main types of wood in the production of OSB. These species are widespread in Russia, therefore, 50% pine and 50% aspen were taken as initial data on the species composition of raw materials. The length of the logs at the entrance was taken equal to 2.6 m, the diameter - from 50 to 400 mm (with an average estimated diameter of the logs - 150 mm), the moisture content of the wood entering the plant - in the range from 50-120%.

So, wood raw materials arrive at the plant site by railway or vehicles. Logs with a length of 2.6 m are stored and stored at the raw material exchange. From there, with the help of jaw loaders, they are delivered to the input reservoir of the GTO pool (hydrothermal treatment). For the production of chips with the desired geometric parameters (length - 60-150 mm, width - 6-40 mm, thickness - 0.5-0.9 mm), unbarked logs must be preheated in pools. This is especially important in winter and when working with hardwoods. Preliminary hydrothermal processing of raw materials significantly improves the quality and useful output conditioned chips obtained on a chipper. In addition, TRP extends the life of the chipper disc. Canadian engineers have developed a special design of the pools. They are through-type, self-cleaning, heated by thermal oil radiators. Skidding chains keep the entire loaded volume of wood in the water, preventing the logs from floating up. In the pool, the logs are thawed for a predetermined amount of time, and then one by one they are removed and transported by a log hauler to the chain feed conveyor of the debarker. A chain conveyor feeds logs sequentially to a high-performance rotary debarker.

The feeding conveyor of the debarker is designed in such a way that waste and small chips fall into special storage bins. In the future, these wastes are processed by the shredder into fuel for the boiler house.

Thus, only whole logs suitable for processing are fed further into the debarker. Estimated wood debarking efficiency at the maximum output of the OSB line is 99.5%.

By the way, it should be noted that the technology implemented in the project is completely waste-free and energy-sufficient: all the thermal energy necessary for technological needs is produced here, at the plant, from the remains of wood.

The debarked logs are delivered to a specially designed debarker output conveyor. After that, the logs pass through a metal detector. Logs containing metal inclusions are automatically marked and rejected - removed from the stream. good logs collide from the conveyor to the cutting table, where they are sawn into 860 mm long chocks. The latter enter the inclined accumulative conveyor of the chipper and then one by one are fed into the chipper (for more details on the OSB chip production technology, see the next issue of the LPI). The disc chipper produces chips in a length to width ratio ranging from 4:1 to 6:1.

The wet chips leaving the chipper enter the raw chip hopper inlet conveyor. Then it is transported to the raw chip bin for accumulation and further dosed feeding to a single-pass drying plant. In the production of OSB, single-pass or double-pass dryers are used. Single pass dryers run on more than low temperatures thermal agent (300−450°C), but their drying cycle is longer than that of two-pass. The main advantages of single pass drum dryers are: Significantly lower emissions of volatile organic compounds, the chips in them are less damaged, and at lower drying temperatures there is less risk of fire. Purified flue gases from the boiler house are used as a heat agent in such dryers.

Thus, raw chips are dosed from the raw chip hopper directly into the single-pass drum dryer. Hot gases coming from the boiler house create the necessary temperature for drying chips.

Dry shavings at the outlet of the dryer are transferred by pneumatic transport (air flow) to the main storage cyclone. Here it is separated from the air stream and small particles of wood. Small particles, in turn, are carried away by the air flow further and fall into secondary cyclones, where they settle. The spent and cooled air is released into the atmosphere.

dried shavings through Switchgear from the cyclone it is sent further for sorting or dumped into the fire compartment (in the event of a fire signal in the dryer from the explosion and fire safety system).

Through the inlet dosing device, the chips enter the rotary type sorting machine. At this stage, small particles and wood dust are finally removed from the chip stream. Suitable chips are divided into two streams and fed to the input conveyors of the outer and inner layer chip bins. Conveyors transport the chips to the appropriate bins.

Before entering the mixers, the chips accumulate in the dry chip bins of the outer and inner layers. The volume of these bins is designed to ensure the smooth operation of the entire production line. They are similar in design to wet chip bins. The feed rate of the material from the hoppers is adjusted depending on the parameters of the chip mat forming line.

From the hoppers, dry chips are fed through conveyor scales (an element of the dosing device) to the mixers. Belt scales also set the flow rate of resin and paraffin, which are fed into the mixers in a given ratio, depending on the chip flow.

Liquid resin storage tanks are located in close proximity to the mixers. There are four in total: two for resin on the outer layer of the boards, two for resin on the inner layer. From the tanks, the resin is fed through automated dispensers to the mixers.

In the production of OSB, phenol-formaldehyde resins (PF), melamine urea-formaldehyde (MUF), as well as isocyanate resins (PMDI) can be used. Based on these resins, a binder for waterproof boards is prepared. The project is designed to use liquid phenol-formaldehyde resin, as it is the cheapest and most commonly used type of binder for OSB.

Paraffin is delivered to the plant in liquid form and stored in large heated tanks. From the tanks through automated dispensers, it is fed into mixers, where it is sprayed through internal tubes. The tubes are also heated to prevent the paraffin in them from hardening.

On the output conveyors of the mixers, the chips are fed to the distribution device of the forming station. Further, with the help of distribution conveyors, it is delivered to the corresponding bunkers of the chip molding machines of the inner and outer layers. The forming and pressing system consists of forming stations, forming line and single span hot press. Note that a single-span press freely provides the design capacity of the plant (220 m 3 per day), and, moreover, it is much cheaper than the continuous press widely advertised now.

Three shaping machines - two for the outer layers and one for the inner layer (each equipped with one orienting head) - spread and level the resin chips on steel pallets continuously moving along the line. Built-in belt scales are located below the forming line and are designed to weigh carpet layers as they are formed.

The orienting heads of the outer layer molding machines align the chips parallel to the direction of movement of the molding line, while the inner layer molding machine head aligns them perpendicularly. The amount of chips coming from the hoppers of the molding machines is strictly controlled, since the volume and weight of the gummed chips of the inner and outer layers must be in a given proportion. This is essential to ensure compliance finished products specifications and standards.

An electromagnet and a metal detector are included in the molding line to detect and remove random metal inclusions.

The continuous chip mat formed in this way is cut with miter saws according to the specified width. Then, with a circular saw, the carpet is cut to length to the size of the hot press plates. The carpet scraps are pneumatically transported to the output conveyor of the inner layer chip mixer for reuse. If the carpet formed on the line does not meet the specified parameters, it is automatically removed from the forming conveyor before pressing. This process is controlled by a carpet rejection system. The discarded chip mat either goes back into the stream (to the inner layer mixer output conveyor) or is completely removed (when metal inclusions are detected, for example).

The prepared parts of the chip mat are sequentially fed into a single-span hot press. The press allows the production of OSB-boards in the thickness range from 6 to 40 mm. In the press, the plates are subjected to pressure and temperature. The control of the absence of air pockets and blisters in the plates at the outlet of the press is carried out by an ultrasonic sensor, which works in concert with the hydraulics of the press and is located on its discharge conveyor.

After pressing, oriented strand boards are cut around the perimeter. In this way, even edges of the slabs are formed, and the size of the master panels is set to them. After that, the master panels are weighed and, after cooling and technological exposure, they arrive at the final processing site.

It should be noted that the plates leaving the press, after being cut to the size of the master panel (2550 x 5005 mm), also pass through an air pocket detector and a thickness gauge. These two measuring devices control the quality of pressed boards, and their density is controlled by weighing.

At the final processing section, the master panels are cut into predetermined formats in accordance with the cutting chart. For this operation, a cutting center for board materials is used. Format finished slabs is 1250 x 2500 mm.

Finished slabs are fed to a stacker and stacked in 1250 x 2500 mm stacks. The stacks are then transported by forklifts to the packaging line, where they are splinted and transported to the finished product warehouse.

Table 1 shows how WPC Services engineers managed to reduce the project budget by more than 5 times. In the table, all production equipment is broken down in accordance with the technological zones where it is located. Of the total number of pieces of equipment in each zone, that part of the equipment that can be successfully manufactured at our factories has been singled out. As you can see, these are 54 technological modules. Estimated indicator the Russian component of technological equipment is 61%, the import component is 39%.

Resource requirement for OSB production

It is necessary to dwell in more detail on the resources necessary for organizing the production of oriented strand boards.

The covered area required to house the OSB production line is 18,500 m2. In addition, about 2-3 hectares of territory for the raw materials exchange will be required. At the plant, in our conditions, there should always be a “buffer” stock of raw materials for 3-4 months in advance.

The consumption of wood, binder and energy resources required for the production of 1 m 3 of OSB boards are shown in table 2. The indicated energy consumption is valid for the daily productivity of the line, equal to 220 m 3, with preliminary hydrothermal processing of raw materials and was calculated for the production of boards with a thickness of 12 mm, density 680 kg/m3.

conclusions

1. OSB technology is a technology for deep processing of wood. OSB is one of the most advanced wood composite materials. The technology considered in the article allows for a deeper and more rational use of timber reserves in Russia.
2. The growth rate of demand for OSB in the world market is one of the highest among wood-based panels. The Russian market is also developing, there is a steady increase in demand for oriented strand board in our country, especially in large cities.
3. Despite the fact that OSB is a relatively new board material, it has already found quite a few areas of application. OSB is widely used both as a structural material in construction and simply as wood composite with unique decorative properties(see PPI No. 9 (31) 2005).
4. Main OSB application found in housing construction. Buildings and structures based on OSB require significantly lower financial costs and time for construction. The emergence of its own production of OSB stimulates the development of wooden housing construction, which, in turn, will reduce the cost of housing, increase its availability and reduce the severity of the housing problem in Russia.
5. OSB technology is perhaps the most best way use of non-commercial and low-grade wood in Russian conditions. We have all the prerequisites for creating our own OSB production.

The production of OSB boards and their sale is that rare type of business where the investment can pay off in the most short time and continue to bring a stable profit, not dependent on market fluctuations on construction market. The demand for this type of product, otherwise referred to as "particle board", is characterized by rare stability. No building is complete without it.

What is OSB board

It is a sheet building material that is widely used in modern construction. It has rigidity and significant strength properties, which provides it with a wide range of applications.

The whole technology of cottage housing construction is based on the massive use of these products. OSB-plates are used both in interior decoration of premises and in roofing works. When constructing complex multi-slope frame structures they are placed on the rafters as a rigid base for the subsequent installation of roofing.

The production of OSB boards is based on the use of woodworking waste. As a binder, various natural and synthetic substances are used, including those based on formaldehyde resins. These chemicals are far from harmless. environment, therefore, there is currently an active search for an alternative, environmentally friendly basis for the production of OSB boards.

Where to start - analysis of the initial situation

First of all, it is necessary to correctly assess the demand in the construction market of the region for this type of product. Most often, it exceeds the available supply, especially at the height of the construction season. Next, you should compile in chronological order the sequence of actions necessary in order to introduce to the market this type of product, for which there is a distinct demand.

In other words, in order to ensure the production of OSB, a business plan is needed for the near and medium term. It is impossible to foresee everything in advance. But it is also impossible to conduct production and economic activity, without having in front of them general target figures of indicators to which this activity should lead over a certain period of development.

How to plan a business

Any business plan, and the production of OSB boards is no exception, implies several important components. For the successful functioning of a business, it is necessary to plan and control the process in four directions at the same time. In other words, any rationally thought-out business plan includes organizational, production, marketing and financial components.

Lack of thought or neglect of one of these areas casts great doubt on the success of the entire enterprise. Drawing up a business plan requires an answer to two questions: what financial and material investments will this project require and after what period of time will the invested funds pay off?

And if the first of them can always be given a fairly accurate answer (this requires only a qualified calculation necessary expenses), the second one is more difficult to answer. A more or less accurate forecast is possible here. The element of risk is present in any kind of business. The success of an enterprise depends both on the level of management qualifications and on many factors influencing market conditions.

The specifics of the production of OSB-plates

A significant positive factor in the development of this type of manufacturing business is its attachment to woodworking enterprises. On the one hand, they are an almost inexhaustible source of raw materials on which the production of OSB boards is based.

And on the other hand, you don't have to look for a market for finished products for a long time, it is always located in the same place where the products of woodworking structures are supplied. Mainly, this is the construction of suburban cottage-type real estate. And this market is characterized by dynamic growth.

In other words, more and more OSB-plates are required every year. That is why it is a rational business decision to locate the workshop for the production of this popular sheet building material in the immediate vicinity of the enterprise where roundwood is processed. This is both beneficial and convenient, not to mention the fact that it significantly reduces transportation costs.

Are any documents required?

According to the legislation in force on the territory of the Russian Federation, neither wood processing nor related industries are classified as areas of activity that require state licensing.

Does this mean that you can simply start a business if you have the necessary equipment for the production of OSB boards and the right size room for this equipment? Not certainly in that way. The point here is that this type of manufacturing business is based on the use of combustible and not entirely environmentally friendly materials. And in order to successfully establish and develop this business, it is necessary to obtain approvals from the fire and sanitary inspections, on the territory of which the production base of your enterprise is located.

In practice, everything usually comes down to the fact that after the inspection, the inspector issues an order obliging you to eliminate the identified violations within the prescribed period and bring everything in line with the technical standards established for this type of production activity.

Administrative approvals

The current practice is not very favorable for the development of any manufacturing business. It is essential that the production base be located at a considerable distance from residential premises. In addition to the fire and sanitary inspections, you will also have to communicate with other representatives of the bureaucracy.

And the trump cards in this communication are by no means on the side of the entrepreneur. How to optimize relationships with administrative system- everyone decides independently. It is important that the fact that no one is going to help you is not a surprise, and there are many who want to interfere.

Premises and equipment

Both the technological premises itself and the territory adjacent to it must correspond in size to the planned volume of production. Since the technology for the production of OSB boards is based on the use of formaldehyde resins, all workplaces must be equipped with exhaust ventilation.

We should not forget about the weight that a standard OSB board has. The business plan in its production part must provide for the equipment of the workshop with appropriate lifting and transport devices. Without their uninterrupted functioning, it is difficult to count on production efficiency. But the main technological equipment is, of course, the press. It is he who forms the plate, and all technology system production is built to ensure its operation.

But the machine for the production of chips is also of great importance. It provides grinding wood waste before required size, the value of which is regulated by regulatory technical documents for the products.

Personnel Requirements

The most important moment of the organizational part of the business plan is the selection of personnel for the production site. The level of personnel qualification should correspond to the complexity of the technological process. This equally applies to the management of the enterprise, and to the specialists who provide all technological operations, from the preparation of raw materials to the shipment of finished products.

If it is not possible to find personnel of a suitable level, management should provide them with training and technical instruction. In some cases, it is more profitable to invest in technical training and advanced training of a specialist than to search for him.

Labor safety requirements

Both pressing equipment and machines that grind wood pulp to the proper condition can pose an injury hazard to those who work on them. Control over the technical condition of the equipment and the adequacy of the personnel working on it belongs to the competence of the enterprise administration.

Industrial injuries entail liability up to criminal for those who are obliged to control the safety of the work performed. Therefore, regular briefing of personnel with a signature in the log is necessary.