A composite board is made from waste medium density fiber (MDF) board or
waste particle board that includes solid urea formaldehyde. The waste
board is chopped and milled into particles having a size between 20 mesh
and 150 mesh, creating a waste flour. After removing moisture from the
waste flour, the dried waste flour is mixed with a thermoplastic to bind
and encapsulate the waste flour. Internal lubricants are added to improve
the flow characteristics of the blended material, and external lubricants
are added to present sticking of the mixture to an extruder or mold.
Mineral fillers are added to improve the flexural modules of the
composite board, and a plasticizer can be added to improve the physical
properties or mechanical characteristics of the mixture. An ultraviolet
absorber, a biocide, and a pigment can also be added. The blended
material is extruded or molded into a desired shape. When cooled, the
thermoplastic hardens to form a solid composite board.