VITS SYSTEMS GmbH Basic Impregnation Technology VITS Systems GmbH Impregnation Lines For Laminate Products Part 1 The Melamine Paper Impregnating Process.

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Basic Impregnation TechnologyBasic Impregnation Technology

VITS Systems GmbHImpregnation Lines For Laminate Products

Part 1The Melamine Paper Impregnating Process

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Basic Impregnation TechnologyBasic Impregnation Technology

What IsWhat Is Impregnation ?Impregnation ?What IsWhat Is Impregnation ?Impregnation ?

Impregnation is the saturation of a basic substrateImpregnation is the saturation of a basic substrateImpregnation is the saturation of a basic substrateImpregnation is the saturation of a basic substrate

Examples of impregnation are:Examples of impregnation are:Examples of impregnation are:Examples of impregnation are:

• Fibre Glass Mat Impregnated with Epoxy Resinfor the printed circuit boards

• Woven Cloth for reinforced fabric

• Paper for Car Filter elements

• Woven Nylon for weather protective clothing

• Decorative and Kraft Paper for the Laminates Industry

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Why Paper ?Why Paper ?Why Paper ?Why Paper ?

• Readily available in roll formReadily available in roll form

• Fibrous structure Fibrous structure

• Can be easily impregnatedCan be easily impregnated

• Available in different widths and strengthsAvailable in different widths and strengths

• Can be produced in various different colours as a raw Can be produced in various different colours as a raw materialmaterial

• Can be printed into high quality décorsCan be printed into high quality décors

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Difference Between Impregnating and CoatingDifference Between Impregnating and CoatingDifference Between Impregnating and CoatingDifference Between Impregnating and Coating

Coating:Coating:Coating:Coating:

Impregnation:Impregnation:Impregnation:Impregnation:

• Medium is applied to the outside surface of the substrate

• Avoids coating medium seeping into the core of the substrate

• Medium is applied to the inside or core of the substrate

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The Impregnation ProcessThe Impregnation ProcessThe Impregnation ProcessThe Impregnation Process

Success of Final Pressed Product Depends on:Success of Final Pressed Product Depends on:Success of Final Pressed Product Depends on:Success of Final Pressed Product Depends on:

• Raw material to Impregnation Line

• Impregnation Machines

• Impregnating Process parameters

• Intermediate Products

• Press and its Raw materials (Board)

• Press Process Parameters

Many Different Influences on Final Product Quality !Many Different Influences on Final Product Quality !

Where the raw materials are brought togetherWhere the raw materials are brought together

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Intermediate Papers Films forIntermediate Papers Films for

Low Pressure Direct lamination onto Boards (LPL)Low Pressure Direct lamination onto Boards (LPL)

• Single Opening Press

• Continuous Double Belt Press

High Pressure Processing into Multi Layered laminates (HPL & CPL)High Pressure Processing into Multi Layered laminates (HPL & CPL)

• Multi Opening Press

• Continuous Double Belt Press

Products of ImpregnationProducts of ImpregnationProducts of ImpregnationProducts of Impregnation

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Basic Impregnation TechnologyBasic Impregnation Technology

• Particle Board Laminated CPL or HPLParticle Board Laminated CPL or HPLe.g. Kitchen Work Surfaces, Fire Resistant Surfaces

• HDF/MDF Laminated with CPLHDF/MDF Laminated with CPLe.g. Laminate Flooring (Special Overlay)

• MDF or Particle Board Laminated with HPLMDF or Particle Board Laminated with HPLe.g. Cubicle Walls, Wall Cladding

• Thick Laminates (Self Supporting)Thick Laminates (Self Supporting)e.g. Partition Walls

High Pressure ProductsHigh Pressure ProductsHigh Pressure ProductsHigh Pressure Products

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Overlay Paper 120 gsm Final WeightOverlay Paper 120 gsm Final Weight

Décor Paper 190 gsm Final WeightDécor Paper 190 gsm Final Weight

4 Kraft Papers 215 gsm Final Weight4 Kraft Papers 215 gsm Final Weight

Overlay Paper 120 gsm Final WeightOverlay Paper 120 gsm Final Weight

Décor Paper 190 gsm Final WeightDécor Paper 190 gsm Final Weight

3 Kraft Papers 285gsm Final Weight3 Kraft Papers 285gsm Final Weight

Example of a Typical 0.8 mm Laminate(typical kitchen work surface)

High Pressure ProductsHigh Pressure ProductsHigh Pressure ProductsHigh Pressure Products

CPL

HPL

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Typical Board Make UpTypical Board Make UpTypical Board Make UpTypical Board Make Up

Low Pressure ProductsLow Pressure ProductsLow Pressure ProductsLow Pressure Products

• Particle Board Laminated with Melamine Foils without OverlayParticle Board Laminated with Melamine Foils without Overlaye.g. Kitchen & Bathroom Furniture Carcass

• HDF without OverlayHDF without Overlaye.g. Furniture Back Panel

• MDF/HDF with OverlayMDF/HDF with Overlaye.g. Laminated Flooring

• MDF with or without OverlayMDF with or without Overlaye.g. Furniture Fronts, Horizontal Surfaces

Decor Paper 190 gsm Final WeightDecor Paper 190 gsm Final Weight

MDF Board 15 to 22 mmMDF Board 15 to 22 mm

Balance Paper 180 to 300 gsm Final WeightBalance Paper 180 to 300 gsm Final Weight

Overlay Paper 120 gsm Final WeightOverlay Paper 120 gsm Final Weight

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Flooring Products Flooring Products (see also Part 2)(see also Part 2)Flooring Products Flooring Products (see also Part 2)(see also Part 2)

• High Pressure Flooring Product (CPL/HPL)High Pressure Flooring Product (CPL/HPL)

• Low Pressure Flooring Product (LPL)Low Pressure Flooring Product (LPL)

Mel. Balance Paper 180 – 300 gsm Final Weight

Abrasive Resistant Overlay Paper 120 gsm Final Weight

Decor Paper 190 gsm Final Weight

Carrier Board (Particle Board/MDF)

2 Kraft Papers 280 gsm Final Weight

2 Kraft Papers 280 gsm Final Weight

Decor Paper 170 – 190 gsm Final Weight

HDF Board 12 mm

Balance Paper 180 – 300 gsm Final Weight

Abrasive Resistant Overlay Paper; either pre-loaded with Al2O3 or coated with Al2O3 during

impregnation (ARP) 120 - 135 gsm

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The MachinesThe Machines - Melamine ImpregnationMelamine Impregnation The MachinesThe Machines - Melamine ImpregnationMelamine Impregnation

Typical Types of Melamine Impregnating Machines:Typical Types of Melamine Impregnating Machines:Typical Types of Melamine Impregnating Machines:Typical Types of Melamine Impregnating Machines:

1 stage1 stage Melamine Machines: Melamine Machines:

• Pure Melamine (MF) Products (Overlay, Al2O3 Overlay)

• CPL / HPL Decorative Products

• CPL / HPL / MFC Overlay

• LP Backer

• Production Speeds 25 to 50 metres per min

2 stage2 stage Melamine Machines: Melamine Machines:

• Urea and Melamine (UF/MF) Products

• MFC Decorative Products

• All Products from 1 stage machine

• Production Speeds 25 to 75 metres per min

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The Standard Two Stage Melamine Impregnating LineThe Standard Two Stage Melamine Impregnating LineThe Standard Two Stage Melamine Impregnating LineThe Standard Two Stage Melamine Impregnating Line