Precision Quincy Designs Comprehensive System to Preheat, Cure and Cool Fiber Cement Trim and Boards

Precision Quincy delivered a cutting-edge, three-part oven system to meet the high demands of fiber cement production for a global leader in the industry.

The system includes a preheat oven, curing oven, and cooling section, designed to process up to 360,000 lbs/hr of fiber cement boards.

With precise temperature control, advanced airflow, and VOC safety measures, this system ensures uniform heating and cooling while adhering to NFPA 86 Class A standards.

The project showcases Precision Quincy’s ability to tailor industrial solutions for high-volume production environments, enhancing efficiency, safety, and product quality.

OVERVIEW

Built to handle large loads and high production rates

Precision Quincy (PQ) was commissioned by the global leader in fiber cement technology, to design, engineer, and manufacture a comprehensive industrial oven system.

The project involved a three-part system: a preheat oven, a curing oven, and a cooling section, all designed to support the high-volume production of fiber cement trim and board.

The system was built to handle large loads and high production rates, while maintaining stringent temperature control and operational safety.

Requirements

The customer required a high-performance oven system capable of preheating, curing, and cooling fiber cement boards efficiently.

The system needed to process up to 360,000 lbs/hr of product, ensuring uniform temperature control while complying with NFPA 86 Class A safety standards due to the handling of volatile organic compounds (VOCs).

Key Specifications

System Type: Preheat, curing, and cooling ovens.
Process: Drying and curing of fiber cement trim and board.
Production Capacity: 360,000 lbs/hr.
Temperature:
- Maximum Operating Temperature: 500°F (260°C).
- Temperature Uniformity: ±10°F (±5.6°C).
Oven Dimensions:
- Preheat Oven: 136″ W x 342″ L x 138″ H.
- Curing Oven: 131″ W x 344″ L x 138″ H.
- Cooling Section: 131″ W x 233″ L x 140.5″ H.
VOC Loading:
- Preheat Oven: 18.2 gal/hr.

Curing Oven: 23.3 gal/hr.

Design Features

Preheat and Curing Ovens

Both ovens feature multiple heated zones, each equipped with LP36 burners rated at 3,000,000 BTUs/hr. These burners provide the necessary heat power for efficient preheating and curing of fiber cement boards.
Recirculation fans in each heated zone, capable of moving 45,000 CFM, ensure uniform airflow and temperature distribution across the work area.
Each heated zone has a dwell time of 6-7 seconds, which allows the product to reach optimal temperatures for preheating and curing.
The ovens are constructed using 20-gauge aluminized steel for the interior walls and mild steel for the exterior. The ovens are also insulated with 6-inch mineral wool, providing superior thermal efficiency.

Cooling Section

The cooling section uses ambient air cooling with 40,000 CFM recirculation fans, ensuring efficient cooling of the fiber cement boards after the curing process.
The cooling section features a vertical down and up airflow system, exiting both sides to achieve even cooling across the entire product surface.
The cooling section is constructed with a combination of aluminized steel and mild steel, and the structural supports are designed to handle the high airflow and cooling requirements.

Airflow and Exhaust System

Both the preheat and curing ovens utilize high-velocity airflow, with 5,800 FPM through 3/8″ slots for optimal heat transfer to the fiber cement boards.
Exhaust fans are rated at 3,700 CFM, providing sufficient airflow to remove VOCs generated during the drying and curing processes.
The exhaust system is equipped with Karl Dungs MPA4112 gas trains and flame safety systems, ensuring compliance with NFPA 86 regulations.

Control System

The ovens are controlled via an Allen-Bradley Micro850 PLC system with a 10″ HMI. The system allows for easy monitoring and adjustment of temperature, airflow, and burner settings.
The system is equipped with Watlow F4T temperature controllers with multiple control loops for precise management of temperature profiles.
Safety features include airflow switches and over-temperature protection using Type J thermocouples.

Safety & Compliance

NFPA 86 Class A Standards

The entire oven system adheres to NFPA 86 Class A standards, ensuring safe operation in environments where VOCs are present.

Key safety features include:

Flame safeguard systems with purge timers and UV scanners to detect unsafe conditions.
Over-temperature controls in both the heat and work chambers, protecting against accidental overheating.
Multiple access doors for maintenance and safety inspections, ensuring easy access to all key components.

Pre-Manufacturing Testing

Precision Quincy conducted extensive pre-assembly and testing at their facility to ensure the oven system met the exacting standards of James Hardie:

Quality Testing: Each oven was partially assembled, pre-wired to junction boxes, and tested for fit, finish, and functionality. The testing process included verification of the burner and fan wheel operation.
Uniformity Testing: The supply air discharge louvers were adjusted to ensure even heat and airflow distribution, and the system was tested for temperature uniformity across all zones.

Delivery and Installation

The oven system was shipped in sections to facilitate transport and installation.

Precision Quincy provided detailed assembly prints and wiring schematics, along with on-site supervision during reassembly.

The installation process included utility connections and final calibration of the oven’s control systems.

Conclusion

Precision Quincy delivered a comprehensive, high-performance oven system that met the demanding production and safety requirements of the customer’s fiber cement board manufacturing process.

The preheat, curing, and cooling sections were engineered to operate seamlessly together, maximizing throughput while ensuring product quality and safety.

This project demonstrates Precision Quincy’s ability to design and manufacture customized industrial ovens that integrate advanced airflow, heating, and control systems to meet the specific needs of high-volume production environments.