Wood Innovations (Wood Products Markets, Wood Energy, Community Wood Energy and Wood Innovations Program, and Wood Education and Resource Center)
Optimization of a Pilot-Scale Fiberboard Manufacturing Line and Investigation of Fiberboard Manufacturing Parameters using Underutilized Forest Resources and/or Recycled Wood-Based Products
University of Maine
Advanced Structures & Composites Center
35 Flagstaff Rd.
Orono, ME 04469
207-581-2123 https://composites.umaine.edu/
The Advanced Structures and Composites Center, located at the University of Maine, is in the process of acquiring and commissioning a fiberboard pilot line, capable of producing both medium density fiberboard (MDF) and low-density insulating wood fiber composites (IWFCs). Having a nearby pilot-scale R&D facility is essential to supporting currently planned, as well as other potential future, fiberboard manufacturers in the region. Fiberboard facilities could use a very large volume of low-grade fiber from underutilized species, thus improving forest health in the region. This project supports the optimization of the pilot line, as well as preliminary prototype manufacturing and evaluation of several wood fiber-based products manufactured with under-utilized, low-value, and/or recycled wood species/products.
The economic impact of Maine’ forest products industry has dropped by 15% in the last 4 years due to paper mill and biomass energy plant closures. Finding new markets for pulpwood and residuals is critical to maintaining the supply chain. Since 2014, these closures have left an estimated 2 million tons of surplus softwood residuals annually unused.
A global market analysis commissioned by FOR/Maine aimed at identifying current and emerging global demand for forest products, and the markets where Maine is likely to be most competitive, was recently published (Forest Opportunity Roadmap/Maine, September 2018). Of the numerous forest-products evaluated, medium density fiberboard (MDF) was shown to be “attractive” for the State based on such criteria as processing options, output/employment unit, and product life cycle. Specifically, it is suggested there may be a market opportunity for an MDF mill located within Maine since softwood is very suitable for the production of quality MDF, and Maine is well located to serve as a supply base to the East Coast markets. The availability of both pulpwood and sawmill residues further supports the attractiveness for locating an MDF mill in Maine.
As part of Go Lab Inc.’s purchase of the European wood products manufacturer Homanit’s full fiberboard production line, Go Lab Inc. has agreed to donate Homanit’s former fiberboard pilot line, used primarily as an R&D tool for their Homatherm product lines, including both board and batt products, to the University of Maine in exchange for recognition of sponsorship of the project. This pilot line has an estimated replacement value of €700,000, thus providing significant cost share to the project.
The Advanced Structures & Composites Center (ASCC) is currently applying for funding (from a source other than the U.S. Forest Service) to conduct a capital equipment construction project including shipping the equipment of UMaine, re-assembling the equipment [which will require significant re-engineering, maintenance, motor replacement and/or repair (as needed)], and commissioning the pilot line.
Requested funding from the U.S. Forest Service Wood Innovations Program will support staff time needed for optimizing the equipment after re-assembly and an applied research component investigating the manufacturing parameters needed for fiberboard products made with (a) underutilized hardwood and softwood species from the Northeastern region, (b) low value forest byproducts, e.g., materials from forest management thinning, residuals from manufacturing, etc. and (c) recycled wood-based building materials.
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