Installation of Pallet Block Production line(1)

Sawdust pallet block production line installation in South Africa(1)

This article is based on a true experience. And for better explaining all details, please allow me to add other details to give 

-Instructions of installation;
-What engineers will do in installation;
-How to maintain a production line.
-Local beautiful scenery.

Gates of memories will never close...

In June, 2016
Our engineer, Peter, our engineer and I were invited to South Africa to install one sawdust pallet block production line. The client, King (not real name), and his wife came to visit us in 2015. And we had a happy time together in China and built trust with each other until now we still have a good relationship and I hope it will last forever.

This installation lasts from Monday to Thursday. 
It is fast because King got a very professional and experienced engineers, Shawn. 

They prepared very well; 

-The drying machine is assembled well in correct way; 
-Machines are placed in reasonable position;
-Electricity cables are ready to start all machines;
-Air presser is ready for the automatic block cutting machine.

Still want to say thank you for their preparation work! You guys are awesome!

The first day is very important because there is a lot of work to do.

Monday's work
-Inspect all machines well because there might be shaking damage on machines.
-Start all machines and teach workers to do every details that should be paid attention to.
-Communicate every details about production.

I never spoke so much English words and the embarrassed fact is that my English is not good enough...

Luckily they are so smart to understand what I am saying!

let's back to story.

 This pine wood sawdust is what we going to use to produce pallet block. 

But in the beginning, the feeding speed of dryer is too fast and moisture can't reach what we demands(10%). This step is important for increasing the efficiency of production and quality of blocks. 

This is the oven made of steel plates. But it seems that it doesn't work well in second day. So we suggest you better don't do this.

At the same time, we are also preparing the glue water. 
King ordered glue powder from China with machines so we need to mix glue powder and water. 

When workers are busying mixing, our engineer starts the block machine molds heating setting to 145℃. 

After 20 minutes, 
-Sawdust have been dried 
-And MUF glue water is ready. 

Then we put the wood and the glue in the mixing machine as a ratio 85% wood and 15% glue. 

After 2 minutes, 
-Raw materials are fully mixed 
-And molds temperature have reached as set. (We start the heating before 22 minutes)  

Then what are we waiting for? Let's do it.

Put raw materials into small storage bin.

Then the block machine starts running. 

In the beginning, there is no pressure for the sawdust in the molds. So after 8 minutes, the pressure in the molds came to be normal. 

Then blocks start being pressed. 

But there is a big problem! The long block starts broken one by one. Like the photo shows. 

Why? Why?

The reason is the moisture of sawdust. 

So a good dryer is very important. Our engineer is very experienced at this and then he adjust the speed of feeding sawdust and try to dry sawdust better.

And we recommend a professional moisture meter for sawdust like this. 

Then you will know the sawdust moisture very precise. 

The small one is not very precise because it is for metering the timbers or planks.

After drying the sawdust again and adjust the feeding speed to drying machine again, finally the moisture can reach what we demands(10%). And then we put them after mixing with glue, good quality blocks are finally produced like this.

And it is 5:30 p.m. so we are prepared to stop the machine and end today's work. 


Tuesday's work.
-Test another side of the block machine.
-Dry sawdust to be less than 10% moisture.

As we have yesterday's experience, it is easy to control the drying machine to reach the goal. Shawn, a good engineer, he had finished drying sawdust before we reached the factory in the morning. He said the white water steam blow out from the top of cyclone. Then we got the dry sawdust.

After mixing them with glue, we put them into the block machine. And this time, the block machine runs very well as below.



Wednesday's work.
-Test another block machine;
-Train workers and engineers how to maintain and manage the line well;
-Adjust the block cutting machine to cut long block to be small blocks for pallet.

It is easy today for workers and engineers to operate all machines well. And today is to adjust the block cutting machine as needed. It is easy to adjust because there is a ruler on the machine.

We only need to adjust to 10cm then we get block height in 10cm. Of course, there is a normal inspections about the machine in the beginning.

After this, all machines are installed well. And it is time to end

You will you see the instructions below.

Thursdays' work.
We inspected all machine's running state and worker's operations. If there is something wrong, we will fix them and make sure that the production line runs well. Today is easy and workers are happy that they can operate machines well.

On Friday, no work.
In the morning, we went to the seaside and enjoy local beautiful scenery.

In the afternoon, King took us to go to a Game park to see animals.


How to know the mold size of block machine?
The block is hard and should be nailed in the cutting sides. Because the horizontal structure strength is not good as the vertical structure strength.

So when it comes to confirm the block machine molds dimension, we only need to measure the length and width of pallet block, height will be cut as needed.

Attention to 7 points to produce perfect standard pallet block.

Raw materials processing rules.
1.wood moisture is below 10% limited.
Suggest purchasing a professional moisture meter as mentioned.

2.Mixing wood with setting ratio, never less or more glue.
Normally ratio is 85% wood and 15% sawdust, but there is -/+2% difference 

3.Fully mixing wood with glue.

Operating machine manuals
1.Keep stable pressure inside molds, adjust pressure according to gauge.
2.Keep reasonable heating time according to the moisture of sawdust and density.

Other reasons.
1. Choose good glue quality
2. Choose good wood quality, no moulds wood.