“HPRS-High Pressure Resination System” is an innovative high pressure resin system which allows to reduce the quantity of resin in the panels. “Plastic Killer” has developed a new system to completely remove the residues of plastic material from recycled wood, so that the latter can be used instead of virgin wood to make high quality panels or clean fuel. The two projects, as part of the European LIFE program for the financing of technological, sustainable and ecological innovations, see the IMAL-PAL group, the Italian leader in the construction of complete systems for producing panels and, among other partners, Acimall through the company as protagonist. of Cepra spa services. The innovative solution of HPRS consists in the application of special injectors specially designed with orifice of variable section diameter, so as to regulate and control the pressure of the resin and keep its speed high, achieving a rapid and uniform distribution of the glue on the surface of flakes. or shavings. The innovative dosage of the resin in proportion to the surface to be bonded also allows to reduce unnecessary consumption, with an overall optimization of the mixing process. In summary, by dosing and spreading the resin more efficiently, it is possible to reduce that excess which in the traditional process serves to compensate for the shortcomings due to an inaccurate distribution of the wood material, inherent in the process itself. The expected results are remarkable: HPRS reduces resin consumption by 10 to 20 percent, in relation to the type of MDF panels produced and the process used previously, with significant savings in terms of cost and reduction of harmful emissions due to the formaldehyde present. in the same. Start up and installation in a pilot plant have given more than satisfactory results. The new resin system will soon be on the market.
Currently, MDF panels are mainly made from virgin wood, and only a small part from recycled wood, since the necessary wood cleaning process requires many steps and is not yet able to completely remove any foreign material. Plastic Killer fills this gap, helping to obtain completely purified recycled wood, therefore usable to manufacture high quality MDF panels that comply with the regulations, in a more sustainable and economical way: it is estimated that up to 60 # 37 of this production could derive from recycled wood Furthermore, the wood that comes out of Plastic Killer is so pure that it can also be used as biomass for the production of clean energy, without the risk of pollutants given by plastic materials, completely removed. The benefits are remarkable: with a maximum installed power of only 58 kilowatts, the plant can process about 78 tons of wood waste per day, avoiding the cutting of about 40 trees; considering both the carbon dioxide trapped by trees and that saved by avoiding their transport, it is estimated a reduction in total CO2 emissions of about 88 tons equivalent per day; finally, the Plastic Killer plant, unlike other traditional plants, does not use water. In economic terms, the savings are enormous and can be quantified at around 2,340 euros per day, that is, more than 500,000 euros per year. The parameters of the machine were defined and its design completed in 2014. The prototype was built and installed in early 2015 and the plant will soon be on sale.