pg-bison
Investment in the MDF* board plant upgrade with the latest world-class technology, yielded substantial increases in output and savings on overheads and raw material costs.

The 2012 and 2013 restructure of the PG Bison business resulted in the rationalisation of its product range, customer base, assets and various internal operations and processes.

This created the basis and provided the funds which PG Bison could reinvest in the latest world-class technology, improving output, product quality and drastically reducing the manufacturing cost of MDF. PG Bison partnered with industry-leading equipment suppliers (Siempelkamp, Steinemann, IMAL and Valmet) and, together with its own specialist project team, delivered the installation on time and within budget. The project increased production volumes by 110% and created the ability to manufacture a wider range of products with thicknesses ranging from 3 mm to 32 mm. The new equipment reduced raw material costs by 17%/m3 and overhead costs by 40%/m3. Improved product quality and the increased product range allowed for new market opportunities.

* Medium-density fibre

STRATEGIC DRIVERS

Market leadership

High barriers to entry

IMPLEMENTATION

A two-phased approach was followed to upgrade the MDF manufacturing plant, incorporating the full production process from fibre preparation to final sanded product.

BENEFITS

The upgrade increased product volume and improved quality, while supplying the lowest-cost product to market, with improved margins and enhanced customer satisfaction.

RESULTS

A Valmet Refiner upgrade – improved fibre quality and consistency.

A new IMAL glue kitchen and high-pressure resin dosing system – improved fibre resination and reduced overall resin consumption.

New Siempelkamp forming line, 8th generation ContiRoll press and cooling and stacking line – increased capacity, improved product quality and consistency and reduced yield losses.

New Steinemann sanding line – improved board finish and thickness tolerances.

Dust generation system – increased steam generation capacity to enable increased production capacity by providing fuel to previously constrained gas boilers.

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