Demonstrations

Recycling post-consumer fibreboard on an industrial scale has long been a challenge, as separating it from other recovered wood was technically impossible. To tackle this, EcoReFibre partner Dieffenbacher, a global leading manufacturer of production plants for the wood-based panel and recycling industries, is developing a novel line of wood waste processing equipment.
At the core of this innovation is a smart sorting line capable of identifying MDF within mixed wood waste streams. Using advanced scanner technology and machine-learning-trained sensors, the system recognises different types of wood waste in real time. Once separated, the recovered fibreboard and solid wood are processed into defined sizes and shapes, making them suitable for use in a wide variety of new products. With Demo A, fibreboard recovery moves closer to a practical industrial solution.

Once fibreboard chips have been sorted, the next step is to break it down into usable fibres. For this purpose, Dieffenbacher develops a machine that efficiently reduces fibreboards into fibres and fines. Compared with conventional mills, it consumes less energy, requires less maintenance and offers greater flexibility.

To unlock the full potential of both waste fibreboard and wood, EcoReFibre is adapting a process commonly used in the pulp and paper industry: the thermo-mechanical pulping (TMP). In this method woodchips are softened with heat and moisture before mechanically refined into fibres. In Demo C, this process is modified (mTMP) to work with recycled materials. Fibreboard is first shredded and threaten with heat and water to loosen the glue that binds the fibres together. It is then refined under controlled pressure, temperature and cooking time to release fibres while preserving their quality. Solid wood waste follows similar route: chipped, steamed, and refined into fibres adapted for new products such as fibreboard or insulation. By fine-tuning the process, the project demonstrates how waste materials can be transformed into high quality fibres with improved energy efficiency, ready for reuse in new applications.

The smallest particles in wood recycling, known as fines, are often considered a low-value by-product. Demo D shows how they can instead be integrated in new particleboard production. The process is based on fine-tuning Demo B to generate high quality fines suitable for board making. These recycled particles are then tested in industrial production lines at Sonae Arauco, where they replace part of the virgin wood normally used in particleboard surfaces. The goal is to substitute at least 20% of raw material with fines, enhancing circularity in the industry, while ensuring that the boards meet EU’s standards such as strength, durability and surface quality.

In this demo, the project is exploring how wood fines can be used in innovative building materials. One path focuses on eco-friendly construction blocks so called “bioblocks”. By combining fines with other bio-based components, the Norwegian Institute of Bioeconomy Research (NIBIO) and Smartpanel, a market leader in MDF panels in Norway and Sweden, are developing lightweight yet strong blocks that could partially replace concrete in construction. These blocks are tested for structural strength, thermal insulation, and acoustic performance to meet building standards. Pilot tests are now scaling up to industrial production, demonstrating the viability of these new materials. Another application uses fines to make thin boards, about 3mm thick, entirely from recycled material. These cyclic thin boards (CTB) are designed for smooth surfaces, easy painting, and interior uses.

Demo F focuses on reusing secondary fibres from post-consumer wood in the production of medium- and high- density fibreboard (MDF and HDF). The goal is to replace up to 25% of virgin fibres while maintaining board quality. The demo also involves adapting production methods and running industrial-scale trials. The new fibreboards are tested for performance, safety and environmental impact to meet EU standards. In this way, high-quality fibreboards can be produced with a significant share of recycled fibres, increasing circularity in the panel industry while reducing reliance on virgin wood.

EcoReFibre partners explore how secondary fibres recovered from waste fibreboards can be transformed into insulation materials for buildings. The project is developing flexible insulation boards for ease of installation, hard insulation boards for strength and durability, and bulk insulation is tested for compaction and thermal performance. Each product is evaluated for industry standards such as thermal efficiency, durability, safety and ease of use, with the goal of matching or even improving on todays’ commercial solutions.