Resin
Urea Formaldehyde Resin Manufacturing Process
![](https://plywoodguru.com/wp-content/uploads/2023/10/testing-of-chemicals.jpg)
Ingredients:
- Urea: 600 kg
- Formalin: 1400 kg
- Caustic Soda Solution
- Acetic Acid Solution
Process:
- Preparation:
- Check all heating and cooling lines before starting.
- Reaction Process – 1st Stage:
- Maintain a ratio of Urea to Formalin as 1:2.33.
- Use 90% Urea in the 1st stage and 10% Urea in the 2nd stage.
- Mix 1400 kg Formalin with 540 kg Urea in the 1st stage.
- Add caustic soda solution to maintain pH (8-8.5) and supply steam up to 90 degrees Celsius.
- Allow the reaction for 1.5 to 2 hours.
- After 2 hours, add Acetic Acid Solution to maintain pH (4.5-5).
- Reaction Process – 2nd Stage:
- In the second stage, perform the reaction in an acetic medium at 90 degrees Celsius for 1-1.5 hours.
- Regularly check water tolerance and flow time.
- When water tolerance reaches 1:6 and flow time is 15 seconds, add caustic soda solution to maintain pH (8-8.5).
- Add the remaining 60 kg of Urea to facilitate the reaction.
- Start cooling and stop stirring when the temperature is below 40 degrees Celsius.
- Final Checks:
- Check final resin properties.
- Final pH should be between 8-8.5.
- Water tolerance should be 1:3 or 1:4.
- Flow time (B-4 cup) should be 18-19 seconds.
- Check resin solid content, which should be in the range of 45-50%.
- Unloading:
- After the final checks, unload the resin.
- Collect a sample for testing in the laboratory.
- Laboratory Testing:
- Send the collected sample to the laboratory for testing.
- Test resin solid content, ensuring it falls within the specified range.
![](https://plywoodguru.com/wp-content/uploads/2023/11/UF-Resin.png)
Quality Check Parameters:
- Resin Solid Content:
- Target Range: 45-50%
- Method: Test using appropriate equipment in the laboratory.
- pH Level:
- 1st Stage: 8-8.5
- After Acetic Acid Addition: 4.5-5
- 2nd Stage (Final): 8-8.5
- Method: Use a pH meter for accurate measurement.
- Water Tolerance:
- Criteria: 1:3 or 1:4
- Method: Measure water tolerance in the reaction mixture during the 2nd stage.
- Flow Time (B-4 Cup):
- Target Range: 18-19 seconds
- Method: Use a B-4 cup to measure the flow time.
- Temperature Control:
- 1st Stage Reaction: Maintain at 90 degrees Celsius.
- Cooling: Stirrer off when the temperature is below 40 degrees Celsius.
- Method: Regularly monitor and control the temperature using appropriate instruments.
- Unreacted Formalin Check:
- Criteria: Ensure minimal unreacted formalin by adding the remaining 120 kg of Urea in the 2nd stage.
- Method: Visual inspection and chemical analysis.
- General Appearance Check:
- Criteria: The resin should have a consistent appearance without any abnormalities.
- Method: Visual inspection of the final product.
- Sample Collection for Further Testing:
- Collect a representative sample after unloading for additional laboratory testing.
- Additional Tests: Conduct tests as per standard laboratory procedures for UF resin, including adhesion, viscosity, and any other relevant tests.
- Safety Checks:
- Ensure that safety protocols are followed throughout the process.
- Verify that all equipment is in proper working condition.
- Documentation:
- Record all parameters and observations in a production log for future reference and quality assurance.