How Medium-Density Fiberboard (MDF) Is Produced: A Detailed Process

When we are in the process of interior decor, be it furniture, wall linings, storage, cabinets, or panelling, we often come across woods or plywood under terms like MDF board, MDF sheet, and MDF wall panels, among others. The reason behind this is that it is the most sought-after wood material for creating impeccable interior design. The smooth surface and the grain-free texture that an MDF board or an MDF sheet provides is simply incomparable. Today, we will get into the nuances of how an MDF board is manufactured, which makes it so versatile. 

What is fibreboard made of?

MDF or Medium-density fiberboard is made from wood fibres that are bonded together using wax and resin. It is then compressed under heat and a lot of pressure and made into flat panels. Since the wood fibres used to make these MDF sheets are of uniform size, the sheet bonding is consistent, and its surface is smooth and homogeneous, which offers exceptional machinability. While it may look like that all an MDF board is made of is wood fibre, wax and resin it is the technology used and the manufacturing process that determines the quality of the MDF plywood.

The manufacturing process of an MDF board: step-by-step

Here’s a detailed account of how an MDF board is made using multiple steps of the manufacturing process that determine its quality of. Leading plywood manufacturers like Greenply who have delivered only quality products, use this method to make their MDF boards. 

• Sourcing raw material and preparation : This is the foundation of producing a good quality MDF board, choosing the right wood to make wood fibre. Generally, plantation-grown species like eucalyptus are chosen. The barks of these trees are taken, chipped into small, uniform wood-chips and cleaned. Then they are re-chipped to be sent from the fibre production. 

• Fibre production : after the chips of the eucalyptus tree are cleaned, it is sent for refinement. First, they are steamed to soften the lignin and then sent into machines called the defibrator. In this process, the chips are separated into fine individual wood fibres. 

• Fibre drying and conditioning: Once the fibre is separated, it is then dried to correct the moisture content. Excess mature is removed, but not too much because extremely dry fibre can make the MDF sheet brittle or poorly consolidated. 

• Blending with resin, wax and other additives : Then the dried fibre is blended with resin binder and wax or paraffin to further improve the moisture resistance and reduce fibre–to–fibre sticking during storage or processing.

• Forming the mat: After the blending, the fibres are laid out in mats, which can be multi-layered. This is done for the fine fibres to go into the outer layers and the coarser fibres into the core.

• Hot Pressing : This mat of multiple layers is then conveyed into a hot press under heat and pressure. The resin blended with the fibres hardens, and the fibres bond into solid panels. The thickness and the destiny are fixed in this process, and the moisture is driven out. 

• Cooling, trimming, sanding and finishing : Next in line is cooling to stabilise so that the MDF sheet does not warp or distort. It is then cut into the desired sizes, sanded to further smooth the surface and quality checked for thickness, density, flatness and also for any defects. If it's required, then within this process, some MDF boards are also laminated or finished with veneer. 

• Size cutting, edge treatment and packaging: these panels are then sent to be cut into standards sizes or customized sheets. For example, in the Indian market, the standard size available of an MDF sheet is 1220 mm × 2440 mm. The edges are then sealed, and the MDF board is then labelled with grade, thickness, board type, etc. Then the MDF sheet is packed for storage and shipment.

• Quality assurance and distribution: While the process is completed at packaging, the quality control throughout ensures the maintenance of board properties like density, internal bond strength, surface finish, moisture resistance, and formaldehyde emission meet specifications.

This concludes the process of making an MDF board, but one cannot just pick and choose an MDF board from anywhere. It has to be bought from a reliable name, as an MDF board is a one time investment, and once the project starts and the quality doesn't turn out to be good, there is no turning back. 

Why choose Greenply’s MDF board? 

The process of making an MDF board that you just got to know is the general way of manufacturing it. But India's leading plywood brand Greenply, along with following this process, adds its own technology and expertise to create some of the best quality MDF boards and MDF sheets that the Indian market has to offer. Let’s take a look at it and understand why Greenply is the brand you should choose. 

• Greenply uses a combination of German technology and its own ingenious PROD-IQ NEO TECH AI‐enabled fibre analysis to ensure every MDF board meets high standards of uniformity.

• Greenply also offer a versatile range of MDF boards from Interior Grade MDF to Exterior Grade MDF to HDMR (High Density Moisture Resistant) 710 to Boil PRO 500 (water- & fire-resistant) and even Pre-laminated MDF and CARB P2 Zero-Emission MDF. These MDF boards are made and then go through various stages of testing to be made perfect for different types of usage. 

• The company is flexible when it comes to standard sizes of the MDF boards. While the MDF boards that you want can be customised, and finishing, painting, lamination, as well as veneer work on them can also be chosen.

• Greenply has been around for more than three decades and provides Indians with the best of plywood, including MDF boards. Right from the manufacturing process of MDF board to its delivery to your doorstep, it is exclusive to Greenply. Meaning you get your premium product with care and warranty.  

Conclusion

We hope that all your questions about what the fiberboard is made of and how the manufacturing process of the MDF board looks are being answered by now. MDF board is one of the most versatile types of plywood and can be utilised for many interior as well as exterior projects. All you need to ensure that you pick the right grade that lasts and serves you longer. As far as the quality is concerned, if your MDF board has the Greenply label on it, you can be unworried about it.