Completed Projects

A density reduction trial was conducted at Daiken Miri in 2013.

See report - Report on DMR Rezex A trial September 2013

It showed that density reductions could be achieved which is highly desirable due to the shortage of available fibre.

See Final reportted at the Daiken MDF Plant in Rangiora NZ 2013 using Rezex A. 

Resin reductions of 10% were achieved with moisture resistant board with all products meeting the MDF standard AS/NZS 1859. 

See Final report -

Daiken NZ MDF resin reduction report

See final reportrticleboard resin reduction by 10%A trial was conducted at the Laminex Dardenup particle board plant in 2013 using Rezex A. 

Resin reductions of 10% were achieved with moisture resistant board with all products meeting the Particleboard standard AS/NZS 1859. 

See final report - 

Laminex Dardenup resin reduction trial

Washington State University Wood Composites Symposium.

April 2011 

I presented a paper at the Wood Panels symposium on the causes of chipout in laminated particleboard and proposed a solution, which has subsequently been very successful. 

References - 

WSU paper 2011 Part A 5th April 2011  WSU Seattle presentation 2011 5th April 2011.

2012 

I presented a paper at the Wood Panels Symposium on reduction of resin and density both by up to 10%in the manufacture of particleboard without any reduction in physical properties. 

References - 

WSU paper 2012 Dr Ray Roberts  

WSU presentation 2012 Dr Ray Roberts

Two successful large scale trials were run in continuous  particleboard plants in Europe, Fantoni near Udine Italy, Spano in Kortrijk Belgium and Green River in Thailand using Rezex A and through manipulation of PAL type blender settings, resulting in the reduction of resin loading by 10% with no reduction in physical property values and increases in MOR values. 

The resultant savings are potentially in the millions of dollars. These trials proved what was shown in successful trials in Australia in 2010. 

The results of these trials were presented at the Washington State University Wood Composites Symposium in 2012.

Employed to improve blending efficiency in the facility at White Ave, Mt Gambier S.A.

I was employed by Proline Floors to optimise high density fibreboard (HDF) for the manufacture of laminated flooring in China in terms of  well and machinability. 

A list of specifications was drawn up so that Proline Floors can take their specific requirements to HDF substrate  manufacturers. 

I also optimised paper treating specifications for the decorative overlay.

Employed to further improve machinability of particleboard at the Gympie site.

In 2011 I presented a paper at the Panels Symposium at WSU on Solving the problem of chipout in laminated particleboard - titled "WSU Seattle presentation"

In 2012 I presented a paper detailing the successful use of Rezex A (a multi-phase wetting system) in reducing resin loading by up to 10% with equal or better physical properties - titled "WSU paper 2012" & "WSU presentation 2012"

Employed to conduct a detailed study on resin blending efficiency at all of the  particleboard plants of the group, Tumut, Mt Gambier, Oberon and Gympie.  

This was done to a detailed level by examining resin distribution at a flake level for both core and surface as opposed to the standard Kjeldahl analysis commonly used.

Employed to improve the efficiency of the whole particleboard production line.  

Results to date include improved blending efficiency resulting in improved bending strength properties and reduced levels of dust and  resin marks. 

This work is ongoing.

References - 

"Initial presentation August 2008"

"Report on Green River Panels August 2008"

"Report on Green River Panels September 2008"

Consulted to improve machinability of LPM particleboard. 

Gympie board was unusable on flat bed routers. The cause of the problem was found, to be ineffective blending and was more prevalent on the local species used. 

This was identified through the use of SEM, light microscopy and the use of a goniometer at ANU. 

It was caused by high interfacial energies  between the resin and the surface of the flake. 

A solution was found using pre-treatment of the flake as well as modifying the resin. 

There was no additional capital expenditure required. 

The board is now as good as any board in Australia. 

Savings to Carter Holt Harvey of $6m per  year were realised. 

Reference - "Final Gympie Chipout Report"

Employed to improve the efficiency of the pressing of high-pressure laminates  onto particleboard substrates to produce benchtops. 

This also involved optimising the post-forming of the laminate after pressing. 

As a result there has been a large reduction in the generation of defective product.  

The work involved determining the interfacial energy between the resin and the substrate and optimising it to improve resin efficiency.

Employed to solve machinability issues, white spots on dark coloured laminates,  and to improve the general efficiencies of the impregnation line, laminating presses and the particleboard press.

Reference - 

Report to Rexcel November 2007"

In a number of visits, I improved the quality of Treated Paper for use on D&R Henderson’s Dieffenbacher short cycle laminating press.

Also with the use of Rezex A the serious problem of machinability of laminated board was also greatly improved.

References -

"A Report on Laminating Operations at D&R"

"Report on visit to Benalla April 2007 "

"Report Visit to Benalla July 2007"

Optimising treating operations at Carter Holt Harvey facilities at White Avenue Mt Gambier and in Tumut including  introduction of high solids UF impregnation resins. 

Redesigning specifications for decor papers resulting in a significant reduction of  downgrade and cost savings of over $500,000 per year. 

Contact Dr. Roberts if you wish to discuss any of the projects further

Phone: +61 404 480 741

Email: ray@rjroberts.com.au