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Q: If you had a customer trying to decide whether to use particleboard or MDF in a product, how would you describe the cost-benefit analysis of one material vs. the other?
Chris Leffel, vice president of sales & marketing, SierraPine LTD: In general, particleboard is less expensive than MDF. However, there are many considerations when deciding which product to use. The first is defining the performance of the panel for the application including physical properties, surface requirements and edge detail. While some applications can use particleboard and MDF interchangeably, in many others the choice is clear. However, this can get more complicated when various decorative surfaces are applied to either substrate as many of these surfacing options add performance to the panel.
The best cost-benefit analysis advice I would give is to first work with a supplier of both products to properly assess the substrate demands based on the application. In cases where there may not be a clear-cut decision path, I would evaluate samples of each product to determine the total manufacturing costs of using either substrate. Beyond the cost of the material, you need to evaluate the other costs, including edge finishing, the performance of the fastener/joint system to be used, and surface finishing costs if you are working with raw panels.
James McLeod, title, Panel Source International: The best answer is, it depends on certain things. Generally speaking though, particleboard is a lighter and less dense product than MDF. Particleboard is also less expensive because when it is produced, it goes through less complex steps than MDF production. Now, depending on the customer's application, one product will be more suitable than another. If the application calls for routering and machining, then they will be limited to MDF. Depending on how the panel is exposed, for example if the edges are going to be seen, then the product will need to edgebanded — another cost.
So, in order to determine the best product to use, it really requires a cost analysis of each step in the manufacturing process, in conjunction with the application of the material, to get the best product for the customer's needs.
2) There are different grades of particleboard and MDF. How would you break down these grades in terms of application?
Leffel, SierraPine: There are standard industry grades defined in the ANSI standards for both particleboard and MDF — ANSI A208.1 and A208.2, respectively. These standards are available from the Composite Panel Association. The grades defined in both of these standards are mainly based on physical properties, particularly internal bond, thickness swell and screw holding, along with modulus of elasticity, hardness and rupture. Some grades of particleboard must be certified by a third party laboratory as meeting the properties of that grade, particularly for certain decking and stair tread applications, as this certification is required by local building code officials.
It is also important to note that companies will sometimes have their own grades that they define by specific physical properties. In addition, companies may not claim to produce a grade defined by ANSI, but instead list the properties of their product they feel are important to their customers. This is important to understand because composite panels are used in so many different applications. Some of these applications may require certain physical properties to deliver the best performance over the service life of the final product.
Given this background, it is difficult to list an appropriate grade for a specific application. However, specifying a standard industrial grade product for either MDF or particleboard should meet the required needs. This question certainly ties in with the preceding question, as a manufacturer should consult his supplier to determine the best board for his application. For example, it is possible that an M2 grade particleboard may perform equally with an M3 grade, even though the M3 has higher physical properties.
McLeod, Panel Source International: With particleboard the different grades from lowest to highest are: underlayment, M1, MS, M2, M3. As you move from lowest to highest, the products physical properties increase (things such as internal bond, MOE, MOR). The use of the different grades are:
- Underlayment — used for underlayment
- M1 — used for shelving
- MS/M2 — used for cabinets
- M3 — office furniture
With MDF, there are not different grades, but different densities. They are regular, light, ultralight and superlight. The higher the density, the stronger the physical properties.
- Regular is usually 48 lbs. per cu. ft. — used for furniture
- Light is usually 38 lbs. per cu. ft. — used for kitchen cabinets/store fixtures
- Ultralight is usually 32 lbs. per cu. ft. — used for mouldings
- Superlight is usually 24 lbs. per cu. ft. — used for door parts/wall paneling
3) What are some of the applications for HDF that might perform better than MDF and particleboard?
Leffel, SierraPine: High density MDF, which has been dubbed HDF, has become most popular in the laminate flooring application. When used for flooring, a higher density product will have higher impact resistance and will typically have higher physical properties. The desire for impact resistance is obvious. However, one advantage of higher properties in this application is tied to how well the product machines regarding the tongue and groove configuration of laminate flooring, along with the strength of both the tongue and groove. As density increases, so do the properties. One reason laminate flooring has become so popular is that it can take abuse during installation. Note also that laminate flooring substrate is generally produced with a special resin system designed to impart moisture resistance. This resin system also adds strength performance to the panel.
Like laminate flooring, the choice to go with a higher density MDF for other applications is typically based on the higher physical properties and durability of the substrate. Others prefer a high density especially for the extra-hard surface required for certain decorative laminates and finishes. Years ago, some customers used high density for extremely intricate edge profiles, but MDF technology has advanced to the point that standard density products are capable of delivering the level of machinability that meets today's requirements. There are trade-offs when using HDF for industrial applications, including the higher cost and increased weight resulting in handling challenges. The demand for HDF for nonlaminate flooring applications is very small.
McLeod, Panel Source International: Some applications where HDF would perform better than MDF include slot walls, laminate flooring substrate and cross banding on architectural doors. Because of the density, it is suitable in places where impact may be an issue. The HDF will help protect the surface better because of the higher density.