Urea Formaldehyde Resin Manufacturing Process


  • Urea: 600 kg
  • Formalin: 1400 kg
  • Caustic Soda Solution
  • Acetic Acid Solution


  1. Preparation:
    • Check all heating and cooling lines before starting.
  2. 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).
  3. 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.
  4. 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%.
  5. Unloading:
    • After the final checks, unload the resin.
    • Collect a sample for testing in the laboratory.
  6. Laboratory Testing:
    • Send the collected sample to the laboratory for testing.
    • Test resin solid content, ensuring it falls within the specified range.

Quality Check Parameters:

  1. Resin Solid Content:
    • Target Range: 45-50%
    • Method: Test using appropriate equipment in the laboratory.
  2. 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.
  3. Water Tolerance:
    • Criteria: 1:3 or 1:4
    • Method: Measure water tolerance in the reaction mixture during the 2nd stage.
  4. Flow Time (B-4 Cup):
    • Target Range: 18-19 seconds
    • Method: Use a B-4 cup to measure the flow time.
  5. 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.
  6. 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.
  7. General Appearance Check:
    • Criteria: The resin should have a consistent appearance without any abnormalities.
    • Method: Visual inspection of the final product.
  8. 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.
  9. Safety Checks:
    • Ensure that safety protocols are followed throughout the process.
    • Verify that all equipment is in proper working condition.
  10. Documentation:
    • Record all parameters and observations in a production log for future reference and quality assurance.

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