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Flooring (Illustration)

Production process

Flooring

Wooden floor coverings are made of solid wood or wood-based materials or a combination of both. We distinguish between:

Solid parquet, or also one-layer parquet: The flooring is made out of one layer of solid wood. Hard and robust kinds of wood are used for this, so mainly deciduous wood.

Multi-layer parquet, or pre-fab parquet: The surface consists of a several mm thick layer of hard solid wood, but the rest of the board structure is made of one or several other materials (two-layer or three-layer parquet).

Laminate flooring is made of a support panel of wood composite (usually HDF or MDF), that has been coated with a decorative surface of resin-soaked papers or lacquer.

Source product

Parquet is a flooring that is made up of a stronger layer of solid hardwood, or a top layer of hardwood that has been put on one or several further supporting layers.

Laminate flooring consists of a support panel of wood fibre board (HDF or MDF) and a surface of glued paper layers.

Production Process

  • Formatting

    Dividing

    When large format boards are being used they have to be divided up into smaller formats. Alternatively, boards that were already divided up in the wood composite plant (see process wood composite production) are used. 

    Machines:
    Dividing line

    Tools:
    Saw blade

    Calibrating / Sanding

    Calibration sanding creates an even surface and a defined board thickness. 

    Machines:
    Wide-belt sanding machine

    Tools:
    Wide-belt

  • Coating

    Cleaning boards

    The boards need to be dusted. There are different procedures to do so, e.g. brushing lines

    Machines:
    Cleaning machines

    Laying

    Manual / partially automatic / automatic

    Machines:
    Laying machines

    Pressing

    Different technologies are used to press the boards and the multi-layer paper / resin structures. Cycle presses and continuous presses are used. Paper is usually already coated with resins that are activated during hot pressing. It is possible that the resins are applied on site. 

    Machines:
    KT-Press (one level) or multi-level press

    Structuring

    Today a structure is frequently put on the surface during pressing that shows a wooden grain, for example. The print and pore structure should be as congruent as possible (EIR - embossed in register). It is also possible to press in a hinted chamfer when coating the boards. Deeper chamfers must be milled during profiling. 

    Cooling

    The boards are cooled to storage temperature in a star cooler.

    Machines:
    Star cooler

    Quality control

    It is possible to automate the optical quality check.

    Machines:
    Surface evaluation

    Interim storage

    A multitude of different mechanisations are used for interim storage and transportation from machine to machine. 

    Machines:
    Conveying and storage technology

    Surface inspection - optical final check

    Employees or electronic systems perform quality checks

    Machines:
    Profile monitoring

  • Dividing / Profiling

    Dividing the boards (cutting into strips)

    The boards are cut into strips.

    Machines:
    Multi-blade saw - longitudinal

    Tools:
    Saw blade

    Transverse cutting to size

    Can also be cut to size longitudinally. 

    Machines:
    Multi-blade saw - transverse

    Tools:
    Saw blade

    Longitudinal profiling

    Profiling is performed in double ended tenoners. With click profiles some elements are additionally extruded. Chamfers can be milled.

    Machines:
    DEP

    Tools:
    Profile router

    Varnishing chamfers; seal edges

    Chamfers are varnished. The longitudinal edges can be sealed. It is possible to treat the complete profile with hydrophobe agents. 

    Machines:
    Edge coating line

    Transverse profiling

    Transverse profiling is also performed in a double end tenoner (for mixed lengths one-sided solutions are available). During transverse profiling it is possible to mill and varnish a middle chamfer.

    Machines:
    DEP

    Tools:
    Profile router

    Varnish chamfer; Seal edges

    Chamfers can be varnished. Face edges can be sealed. It is possible to treat the complete profile with hydrophobe agents. 

    Machines:
    Edge coating line

    Sound insulation can be installed

    Sound insulation increases the laminate flooring's quality.

    Checking the profiles; Optical final inspection

    It is possible to automate profile quality inspection.

    Machines:
    Profile monitoring

  • Packaging

    De-stacking

    Laminate decks are usually stacked directly into prepared boxes.

    Machines:
    Stacking line / Robot

    Packaging

    In larger plants combinations of several machines are used: Folding boxes, inserting decks, inserting label, wrapping in shrinkfilm.

    Machines:
    Packaging machines

    Palleting

    Parcels are stacked on a pallet ready for shipping and fixed using film or strips. 

    Machines:
    Stacking line / Robot

Production process:Flooring – Laminate flooring – Laminate flooring with paper surface (DPL)

Necessary peripheral devices for Flooring2

  • Extraction systems

    E.g. used in:Furniture front, Windows, Flooring

  • Fire and spark extinguishing systems

    E.g. used in:Furniture front, Windows, Flooring, Wooden stairs, Chip board, OSB- Oriented Strand Board

Ask us!