Siempelkamp creates new growth opportunities for the wood-based materials industry in China
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In Asia, and especially in China, the use of alternative raw materials offers outstanding prospects to the wood-based materials industry. After all, millions of tons of rice straw burned in the fields every year are ideal sources of medium density fiberboard (MDF) and particle board. Siempelkamp, the global technology leader in the wood-based materials industry, has developed methods to process this low-cost waste product into high-quality fiberboard. New techniques and innovative building components for the entire plant solve silicate problems (impurities and extraneous material such as sand and clay) and filter substances found in raw materials through a two-stage separation process.
Around the world, more than 500 million tons of rice straw accumulate as a waste product in the agricultural sector each year. However, most of this remains unused and is incinerated or decays in the fields. Rice straw is predominantly produced in China (about 210 million tons), India (about 160 million tons), Indonesia (about 80 million tons) and Bangladesh (about 53 million tons).
“Only about three percent of the rice straw is used as a raw material in the industry. We assume that this percentage will increase significantly in the coming years. This is based on information we have obtained through in-depth conversations with our customers,” explains Samiron Mondal, Managing Director at Siempelkamp Maschinen- und Anlagenbau GmbH, who oversees the Asian-Pacific region and other areas.
With rice straw, panels can be produced in a climate-neutral manner with a zero carbon footprint. They are recyclable and merely require a suitable bonding agent for production. MDF, oriented strand board (OSB) and particle board from annual plants fully consist of annually renewable raw materials. As this is a natural waste product of the rice harvest, its use does not compete with food production.
NEO Blender: Wear-resistant and maintenance-friendly glue blender for rice straw and other annual plants
Siempelkamp has developed a dry-gluing process for the production of rice straw panels using a newly developed continuous mixing system. This mixing system allows optimal adaptation of the glue system to the production conditions. Glue consumption levels are lower than in conventional gluing processes, since pre-curing losses are avoided.
The newly developed NEO Blender ensures uniform and continuous gluing of the fibers and is wear-resistant. The screw-type mixing chamber cover makes the system particularly easy to maintain.
Siempelkamp’s product strategy for China: German engineering made in China
With Wuxi Machinery Co. Ltd, Siempelkamp has been producing locally in China since 2004, directly for the needs of Asian customers. Components with manually intensive procedures are mainly produced at this production location. In addition, Wuxi handles the procurement, quality control and pre-assembly of parts for systems delivered within China. The advantage for our customers: with this presence in Asia, we are one step ahead and are more targeted in China – both when it comes to new plants and the maintenance, upgrading and modernization of existing plants.
The new Siempelkamp production facility in Qingdao has large production capacities. The plant in the port city of the province of Shandong was recently enlarged to include a second production hall. As part of its enhanced production strategy in China, Siempelkamp plans to expand its manufacturing depth to build complete production plants.
Service is being expanded worldwide
At Siempelkamp, service is constantly being augmented for China and Asia. “We respond to the needs of our customers,” reports Samiron Mondal. “We ensure our global customers smooth and fast commissioning and permanently guarantee full production processes at plants.” A new Siempelkamp Logistics & Services GmbH (“SLS”) service center has been established. In addition, the spare parts service has been optimized for the global provision of customers through sub-centers in selected markets, thereby ensuring a fast supply of local spare parts.
Proven quality and precision: ContiRoll® 9
The ninth generation of ContiRoll® has been part of Siempelkamp’s product portfolio since last year. It is the heart of wood-based material plants for the production of MDF, OSB and particle board. With a maximum production speed of 2,500 mm/sec, a perfected heating system, state-of-the-art processor technology, energy-saving drives and a condition monitoring system, it offers maximum performance and production reliability for manufacturing any type of wood composite panel.
Higher production output and quality with the ContiTherm plus
ContiTherm plus is the new plant component that combines mat pre-heating and pre-pressing and will be presented for the first time at WMF in Shanghai. The machine, developed by Siempelkamp engineers in Germany, effectively preheats the mat by steam injection directly before it is transferred to the ContiRoll®. At the same time, by means of compaction pressure, larger lumps of glue and foreign material are crushed at up to 4,100 N/cm. ContiTherm plus enables the production of wood composite panels at speeds of up to 2,000 mm per second.
Faster on the market with Siempelkamp’s “time to performance”
With Siempelkamp’s wood-based material plants, plant operators gain valuable production time. Plants are ready for full production just four weeks after mechanical completion and electrical checkouts. This is assured by ongoing innovative capabilities, which have been gained over the past 135 years, as well as the systematic production of all parts for a full range of plant components from a single source. For example, Siempelkamp’s experienced assembly teams can install complete hydraulic assemblies that have successfully passed test runs at the Krefeld plant. With Siempelkamp’s “time to performance” concept, customers benefit from more quickly implemented production capacities. This means their products are already market-ready months in advance.
Use of hybrid wood composite – a panel with many possibilities
The time has come for the hybrid wood composite panel. Composite wood-based materials such as this combine the attributes of various wood composite panels, including special strengths and high-quality surfaces, and are ideal as a substitute for plywood and other materials in applications ranging from furniture production to interior fittings. Highly robust, multifunctional wood composite panels with paintable and coatable surfaces can be produced. This is possible thanks to a stable OSB core with top layers made of MDF or fine particle board. Siempelkamp has perfected this product in its own Research & Development Center in order to meet the requirements of modern high-performance production.