Developing through the decades

Fusoni is a chemical company located in the Asturias on the north coast of Spain and is the only producer of additives for the wood industries in the country.

The family-owned company has steadily developed through the decades to become a worldwide player in additives for wood-based panels and decorative papers, delivering products to more than 30 countries and partnering with some of the world’s biggest panel producers.

Expansion in the early 1980s saw Fusoni start activities in Mexico City, initially in other industries and then in the wood-based panels sector, supplying markets in Central and North America.

A second production site was set up in the Asturias in 1997, with specialisation in release agents for the wood industry and additives for decorative papers. Then, in 2002 after observing the big growth of wood-based panel industry in South America, Fusoni started a third plant in Novo Hamburgo (Brazil) to supply the region.

The Spanish plant mainly focused on release agents used in production of particleboard, MDF and OSB bonded with UF, MUF and MDI (pMDI and eMDI) glue, supplying all European and Asian customers.

Around 70% of additives produced in Spain are exported to European and Asian countries and 30% goes to the local market.

In recent years Fusoni’s R&D work has enabled it to provide a full additives range for production of decorative papers (HPL, LPL and CPL) – including hardeners, wetting and release agents, anti-blocking, surface improvers and other specialist products such as flow improvers or anti-bacterial agents.

Additives for plywood, such as fire retardants and anti-fungal treatments, have also been developed. Fusoni supplies a liquid fire retardant suitable for MDF and plywood production, giving B1 class in both types of panel. The retardant is a stable emulsion that can be stored for a long time and does not contain boric acid.

The anti-fungal copper-based product is suitable for use with MUF glue as well as fire retardant, allowing customers to produce a final product that has both fire-retardant and anti-fungal properties.

MARKET DEMAND

So, what are current customer demands and market conditions?

“We have observed an increased demand for release agents for MDI glue in all types of panels,” Fusoni said.

“Customers are looking for the best performance in releasing MDI glue in their different forms (pMDI, eMDI) and suitable for all types of application systems (roller or spraying systems). Once the main target of the release agent is fulfilled, which is to avoiding sticking, it is also important for customers to confirm that release agents have no side effects during production (like needing to clean the belt or nozzle blockages in the case of spraying systems). And of course, they want a competitive product regarding dosing rate and price since consumption is quite high, so it could have an important impact in final board cost.”

Fusoni says it managed to overcome pandemic-related impacts thanks to its exports and diversification of markets. It has continued operations throughout.

“There were serious logistics problems during March and April, 2020, especially in EU countries due to closure of borders but thanks to good co-operation and organisation with big logistic partners we were able to keep our level of service.”

During that short period, truck delivery times doubled.

With raw material prices also increasing during the last 18 months, Fusoni has tried to keep the established prices in many of its products but some have been strongly affected by the increases.

“Nevertheless, we know from our main customers, who are big players in the wood-based panels market, that Fusoni has very competitive prices for release agents and additives for laminates (HPL, LPL and CPL).”

Lastly, Fusoni has been working hard for the last two years to supply customers with solutions that reduce formaldehyde emissions and improving the efficiency/ capacity of panel production.

“We have recently developed an innovative combination of hardener plus formaldehyde catcher suitable for UF/MUF glues that so far has provided very promising results on the particleboard and MDF plants where it has been tested,” it said.

“This could be an excellent solution for many potential customers since it would offer an important improvement in the press compared to standard hardeners and provides an additional reduction of formaldehyde emissions.”

Fusoni also plans to develop more ecological products and improve its production facilities with new investments.