CalPlant – MDF (Medium Density Fiberboard) Manufacturing Facility –  AUCTION POSTPONED – NEW DATES TO BE ANNOUNCED SHORTLY

Complete Willows, CA Facility Closure – Launched in 2020 – Over $380 million Invested

By Order of the US Bankruptcy Court – Case Number – 1:21-bk-11302 | CalPlant I Holdco, LLC

CalPlant I Holdco LLC and its affiliates and subsidiaries (“CalPlant”), a Northern  California-based company focused on manufacturing sustainably-sourced building products, including the world’s first no-added-formaldehyde, rice straw-based medium density fiberboard Eureka™ MDF, has been approved by the United States Bankruptcy to proceed with a sale of the complete CalPlant production facility.

Plant Summary (In Order of Production Flow)

(4) Straw Bale Receiving, Chopping & Pulverizing Lines

Design process of 9 to 12 tons of straw bale per hr., each consisting of:

• Nybladt 158 kW drum choppers with bale destringing & pre cutters
• Pallmann 200/400 kW hammermill pulverizing systems
• Explosion proof pnuematic transport systems with 152 kw blower/fans
• Baled straw receiving conveyors supported by (2) shuttle carriages
• (1) 16,000 kG overhead bridge crane with bale grapple & remote control
• Pit type troughing belt chain removal conveyor for stones & waste

(4) Primary Cleaning & Separating Systems

Design process of 9 to 12 tons of material @ 45 kg/m3 bd, consisting of:

• Ventapp silicate separator stations with pre separating chambers
• Twin screw integrated blending conveyors with straw distributer/sifters
• Ventapp extraction/filter cleaning systems with large hp power fans
• LHS bag filter/ dust collection systems with explosion proof flaps
• Straw dosing & metering bin measuring 32 m x 4 m wide x 6 m deep
• Troughing belt transfer conveyors of 17 & 37 meters (to refiner plant)

Pallmann Refining Plant

2) Refiner systems with total design capacity of 28 tons/hr bd, consisting of:

• Pallmann PRS-258/64 high voltage refiners with 3500 kW 4160-volt motors
• Pallmann PR24 pin drum feeder with 500 kW main power & 22.5 kW feeder
• Horizontal digester, 2000 mm dia x 10000 mm long, 75 hp gear drives
• Stainless double screw refiner feed conveyor, 37 meter, 37 kW gear drives
• Armstrong hot water heater with conditioning & dilution water pumps
• Remote controlled blow back pipe transfer system to fiber drying area

Fiber Drying & Wet Electronic Precipitator Systems

Fiber drying design capacity of 28 tons/hr., summarized as follows:

• Intake temp of 220 deg. C, with 270,000 m3h exhaust volume
• 20 mW gas burner with 770 kW 4180v high voltage main power fan
• Double mixing chamber type with high efficiency cyclone separator

Wet electrostatic clean air precipitator system, consisting of:

• 200 kW design power, 540 KW HT high voltage system, 95% blue haze eff
• Electrostatic filter designed @ 95% blue haze efficiency, 10-30% VOC.
• Exhaust gas stack with internal scrubber components & quench duct
• Stainless sedimentation & buffer tanks, plus water screening & pumps

MDF Sifting & Material Transport System

nclosed fiber sifting system designed for 28 ton/pr MTF fiber with

• Side by side fiber sifting towers utilizing multiple radial fans to 250 kW
• Twin screw 15 kW distribution conveyor feeding sifting towers
• Multiple LHS type WN 1500 rotary air locks with 11 kW gear drives
• Heavy duty inclined troughing belt conveyors up to 80 meters length
• High pressure pneumatic material handling systems with 45kW blower
• Assortment of Ventapp round & rectangular collection hoppers
• ATEX protective T injector system plus explosion proof diverter flaps

Fiber Mat Forming Segment (partial listing)

Designed for continuous spreading of MDF fiber consisting of

• Overhead blender, fiber bunker, metering retarder & distribution unit
• Continuous pre-press section for compacting fiber mat into 3500 mm width
• Automated Inline belt scale/reject segment, and infrared moisture metering unit
• Ecoscan Sico Scan detection station plus thru belt type metal detection system
• Mat trimming saw segment designed for mat range of 2490 to 3380 mm width
• Mat reject hopper, + multiple moisture spraying stations & belt splicing device
• Mat forming dust extraction & collection system for trimmed fiber material

ContiRoll MDF Press & Cooling Line

Design speed of 50 mm/s to 1000 mm/s max – partial listing includes:  

• ContiRoll Generation 9 MDF press of approx. 35.4 meters long (117’)
• Online X-ray density profilometer device with secondary metal detection
• Diagonal cross cutting saw segment + continuous edge trimming station
• Board weigh scale conveying with reject station with 200 kW breaker unit
• Double rotating rotary board cooling carrousel with auto feed & discharge
• Press area extraction system powered with 230 kW 4150-volt radial fan
• Thermal oil heating system featuring (3) HESS 8000 kW hot oil heater sets

Board Sanding System

Automatic coarse grain & finish sanding platform includes:

• Steinemann type 4K-4N dual unit system with combined power of 1150 kW
• Elevated structural sanding deck with sanding data system & control station
• Hydraulic board lifting & board infeed loading table with board suction carriage
• Automatic roller infeed, thru-put and board discharge conveyors
• Fully automatic two-sided optical board inspection system with 2D-3D light source
• Ventapp/LHS high-capacity dust extraction system with 362 kW 4160-volt radial fan

CTS MDF Cut-to-Sheet System with Stacking & Strapping Stations

Fully automatic board cutting & pack-off matrix – partial listing includes:

• Infeed length-rip saw station with staging table and fix table transfer segment
• Cut to length hydraulic guillotine cutter with associated waste collection station
• Otto Mayer cross cutting system with auto alignment and pusher transfer table
• Hydraulic lifting/angle/book forming table with stack roller discharge conveyors
• (2) OMS stacked board banding systems with multi-directional diversion table
• Waste material collection with Vibroplan feeders, hydraulic chippers, & load out

Production Support Installations

• Compressed air system featuring (3) Roger RMC-KRV-150-125 air compressors
• Marlo RO purified H2O skids & dissolved air flotation water treatment system
• Wide assortment of dust extraction systems with collection silos & hoppers
• Glue storage, preparation, transfer, metering & injection system (entire building)
• Large Quantity of Siemens PLC-MCC control banks & transformer substations
• Quality Assurance lab, mobile vehicle fleet, portable truck scales, shop equipment
• Huge spare parts & copper wire inventory, new/uninstalled structural systems

NOTE: CalPlant I Holdco LLC and its affiliates and subsidiaries (“CalPlant”), a Northern
California-based company focused on manufacturing sustainably-sourced building
products, including the world’s first no-added-formaldehyde, rice straw-based medium
density fiberboard Eureka™ MDF, has been approved by the United States Bankruptcy
to proceed with an orderly liquidation sale of the complete CalPlant production facility.