Solidium MDF from Del-Tin Fiber LLC, is made almost exclusively from Southern Pine fiber. This renewable, raw material softwood fiber provides the ideal consistency for manufacturing a premium panel product. An added benefit is that a large percentage of the wood chips, shavings, and sawdust used by Del-Tin Fiber to produce Solidium are sourced from the sawmills of our parent company, Deltic Timber Corporation. In addition, about one-half of the logs used by Deltic Timber to produce lumber at its sawmills comes from the Company’s own 523,000 acres of high-quality Southern Pine timberlands. Since a portion of this timber winds up as the sawmill residual by-products we use to manufacture MDF, this helps assure that a stream of high-quality fiber is available for our manufacturing process, from start to finish.
Our facility’s capacity is approximately 375,000–400,000 cubic feet or 23-25 truckloads of MDF panels every day.
We start by screening and sorting all incoming raw material to eliminate potential impurities. Refining then utilizes prolonged conditioning with heat and pressure to soften wood chips and a multi-step, high-friction process to convert them into the fine, individual fibers needed for outstanding machinability. Additives are introduced to enhance moisture-resistance, limit swelling and strengthen the product’s internal bond while moisture is dried to a narrow range to increase stability.
Solidium’s superior board characteristics are further established in the forming process. Separate fiber streams for core and surfaces are uniformly layered onto a forming belt while fiber density and matte thickness are constantly monitored and adjusted against control specifications. Along the way, edges are trimmed to the desired panel width and the fiber matte is consolidated to remove air that could cause internal voids. The Kusters 9’-wide continuous press applies exactly the right combination of heat, pressure and time to fully consolidate Solidium into one long board that is then rough-cut to length, scanned for delamination and checked again for thickness accuracy.
Our robotic handling system uses steel pallets to prevent sagging of in-process panels temporarily stored between steps.
From the press, master panels proceed through the Sunds Defibrator, a multi-panel-board cooler, to reduce internal temperatures that can compromise board integrity or cause edge burn when cut. Sanding is next on an 8-head Kimwood sander where each 2-head unit uses progressively finer grit for maximum smoothness and a final crossbelt sander is used to produce an even, non-directional appearance. A Schelling rip and crosscut saw capable of cutting multiple boards with extreme accuracy is used to trim panels to their final dimensions. At any time between the board cooler, sander or saw when panels are moved into temporary storage awaiting the next production step, they are handled by our LUKKI automated robotic crane and loaded on fully supported metal pallets to maintain product straightness and flatness. Ultimately when each product unit is complete, it is strapped, labeled and prepared for shipment by truck or rail.
Beginning with a verified source of premium wood fiber, as well as numerous process measurements, controls and visual inspections along the way, quality is a high priority in manufacturing Solidium. In addition to the production line, our on-site laboratory team performs ongoing testing of run samples to ensure conformance to established product properties standards, our own performance requirements as well as formaldehyde emission levels.
A 3/4” product can generate about 8 tons of sander dust per hour which is captured for in-board recycling and plant power.
We are committed to offering superior MDF products in the most environmentally responsible way possible. This includes careful sourcing of the needed wood chip resources, capturing and reusing as much production process energy as possible, reducing external fuel requirements by burning bark and sander dust to generate power, and utilizing integrated pollution control equipment to minimize emissions and waste.