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Particle Board Press | Loader Trays

THE CUSTOMER

Roseburg Forest Products Company is a leader in the wood products industry and a highly respected company that values the communities in which they operate. The Hydradyne Brookhaven branch is proud to serve and work with the Roseburg team in Taylorsville, Mississippi.

PARTICLEBOARD

Particleboard, or chipboard, is manufactured by mixing wood particles together with a resin and forming the mixture into a sheet. The sheets formed are then cold-compressed to reduce their thickness and to make them easier to transport. Later, the sheets are compressed again, under pressures between 290 and 440 psi, and temperatures between 284 and 428 °F. This process sets and hardens the glue. All aspects of this process must be carefully controlled to ensure the correct size, density, and consistency of the board. The boards are then cooled, trimmed, and sanded so they can be sold as raw board or surface, improved through the addition of a wood veneer or laminate surface.

THE CHALLENGE

The particle board press can handle several sheets at a time, 18 at the Roseburg mill in Taylorsville, MS. The sheets are fed into the press using loader trays. The loader trays take a lot of abuse during this process and must be refurbished or replaced often to maintain working efficiency.

THE SOLUTION

Hydradyne in Brookhaven, MS has engineered a loader tray design and developed a process for fabricating or refurbishing the loader trays for the particle board press. The fabrication process is very tedious, requiring a crown to be formed in the tray so that the material will slide easily, and special forms and jigs to do the work correctly. Fabricating a single tray would be cost prohibitive, so a manufacturing order of a minimum of three at a time is required. All of the material is cut and formed for all of the trays at once, reducing set-up time between builds. When a mill decides to replace their loader trays, they will typically want to replace all of them concurrently.

The crowning process consists of bending the square tubing in a fixture and then heat-relieving it to change the metals memory.

Holes are drilled in the first skin and then tacked into place. The welding is critical in this process – too hot and the material creeps, too cool and the tack doesn’t hold, waves form if not properly held, and buckling occurs if tacked in the incorrect sequence.

The loader tray base is coming together – leveling the fixture prior to welding the clips in.

Top sheeting is prepared, where the particleboard material will lie.

Side rails, nose piece holder, and support bands beneath the tray are installed.

The final piece before painting, a machined aluminum nose piece with a compressed air passage, is machined and bolted onto the assembly.

THE RESULT

The final product is then ready to ship to the Roseburg mill.

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