Revolutionary technology enables 70% recycled medium-density fiberboard manufacturing process
In a groundbreaking collaboration, Italian wood materials producer FANTONI S.p.A. and STEINERT have developed an innovative, engineer-led sorting process that allows for the production of high-quality Medium-Density Fiberboards (MDF) with up to 70% recycled wood content. This breakthrough surpasses the industry standard of 15-20% recycled material.
The heart of this development lies in the meticulous design and integration of advanced sorting technologies tailored to address the complexities of post-consumer wood waste. Contaminants such as nails, plastics, glass, stones, and minerals are detrimental to furniture-grade MDF, affecting structural integrity, surface finish, and damaging critical equipment downstream.
FANTONI invested €150 million in this project, taking a hands-on engineering approach to designing the plant and selecting the best technologies for each sorting stage. STEINERT provided a robust, integrated, and reliable sorting solution that processes approximately 450,000 tonnes of recycled wood annually.
The innovative sorting process includes multistage separation technology, a comprehensive combination of mechanical and sensor-based sorting machines optimized through custom engineering, and continuous, high-throughput processing to handle large volumes without compromising purity. Together, these advancements guarantee an exceptionally pure recycled wood input stream, enabling premium quality MDF boards with high recycled content at an industrial scale.
The FANTONI plant, which has been operating for four years, demonstrates that achieving a 70% recycling rate in premium wood panels requires proven technology and technical excellence. The plant's mechanical construction is exceptionally robust, with minimal maintenance issues reported.
The plant uses a multi-stage sorting process, with STEINERT acting as the sole technology provider. The process begins with magnetic separation and eddy current technology to remove ferrous and non-ferrous metals. STEINERT XSS® T X-ray transmission sorters are used to remove high-density foreign materials such as glass and stones. The final step is handled by STEINERT UniSort systems equipped with Hyperspectral Imaging (HSI) technology for precise wood sorting and contaminant removal.
FANTONI's success is based on its ability to produce high-quality MDF virtually free of foreign substances. The plant produces a three-layer MDF board with recycled material in the core layers, processed on Europe's longest press at 65.5 meters. Regularly, FANTONI produces premium-quality MDF boards with up to 70% recycled wood in the core layers.
Marco Fantoni, the company's representative, states that with this technology and project, FANTONI is now clearly at the forefront of using recycled wood for fiberboard production. FANTONI has also invested in life cycle analyses (LCA) and environmental product declarations (EPD) to back their environmental claims.
As legal requirements drive demand for recycled content, the approach taken by the FANTONI plant provides a roadmap for the sustainable future of the industry. Manufacturers seeking similar sustainable production solutions can leverage the comprehensive sorting technologies and technical expertise of STEINERT. Interested parties can explore the technical details and capabilities of STEINERT on their website at www.our website.
Moreover, FANTONI has developed a process to recycle used MDF panels, creating a truly circular production model. This circular approach, coupled with the high-quality, sustainable MDF production, positions FANTONI as a leader in the industry's drive towards a greener future.
- The innovation in the wood materials production industry is highlighted by FANTONI S.p.A.'s collaboration with STEINERT, creating a meticulously designed sorting process that enables the production of premium quality MDF with 70% recycled wood content.
- The groundbreaking sorting technology uses a multi-stage separation process, including X-ray transmission sorting and hyperspectral imaging, to ensure an exceptionally pure recycled wood input stream, thereby contributing significantly to environmental science and climate-change mitigation efforts.
- With the successful operation of the FANTONI plant for four years, there is a growing potential for financial investment in similar sustainable projects within the environmental-science and technology sectors, as industry standards evolve towards increased recycling and a greener future.
