Flooring (Illustration)

Production process

Floorings

Floorings made of wood are produced from solid wood or wood composites or a combination of both. We differentiate 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 load-bearing board of wood composite (usually HDF or MDF), that has been coated with a decorative surface of resin-soaked papers or varnish.

Source product

Parquet is a flooring that is made up of a stronger layer of solid deciduous wood, or a top layer of deciduous wood that has been put on one or several further load-bearing layers.

Laminate flooring consists of a load-bearing board of wood fibres (HDF or MDF) and a surface of glued paper layers.

Variants

Solid decks are an especially high-value product. Each deck is made out of a single solid plank. Typical dimensions are at least 12 cm wide and 1.2 m long. The production process of solid decks varies from one producer to the other.

Production Process

  • Preparing

    Planed plank (Illustration)

    Potential optimising on both sides

    If the decks still have a tree edge it is removed (sawn off).

    Machines:
    Longitudinal saw

    Tools:
    Saw blade

    Pre-planing, two-sides or four-sides

    After pre-planing flaws in the wood can be recognised more easily.

    Machines:
    Moulder

    Tools:
    Planing knife

    Cutting out flaws

    Flaws in the wood, such as branches, tears, or discolouring, are cut out according to the quality requirements.

    Machines:
    Cross-cutting saw

    Tools:
    Saw blade

    Optical control

    Optical control is usually performed by a trained employee. It is possible to evaluate automatically. After this, the good/visible side is determined. 

    Machines:
    Surface control

    Patching

    Usually patches are created by hand. If the product is planed again after being filled out and levelled, the repaired areas are often damaged. 

    Sorting; Interim storing, air-conditioning

    Solid decks are senstive to humidity, both resorption or loss, which trigger changes in shape. Therefore they are stored in an air-conditioned room.

  • Planing and profiling

    Profiled solid parquet deck (Illustration)

    Four-sided planing

    Depending on the quality of the pre-planing there can be another planing process at this point. 

    Machines:
    Four-side planing machine

    Tools:
    Planing knife

    Renewed filling

    If new faults develop during planing, they are manually filled in again.

    Sanding

    After filling in, excess filler is removed during sanding.

    Machines:
    Longitudinal / Wide-belt sanding machine

    Tools:
    Wide belt

    Longitudinal profiling, chamfer possible

    The longitudinal sides are given a laying profile on a planing machine. Sometimes grooves are milled into the bottom of the deck. 

    Machines:
    Molder

    Tools:
    Router

    Possible cutting-to-length

    Some of the transverse sides are given a clean right angle cut before they are profiled.

    Machines:
    Cross-cutting saw

    Tools:
    Saw blade

    Profiling ends

    The transverse sides are given their laying profile on a planing machine. 

    Machines:
    DEP

    Tools:
    Router

  • Surface and packaging

    Solid parquet decks in packaging (Illustration)

    Possible brushing for a structured surface

    To achieve a rough, rustic surface the decks are processed using a brushing machine. 

    Machines:
    Brushing machine

    Tools:
    Sanding brush

    Possible sanding

    To achieve an optimum surface when varnishing, the wooden surface must be very even. Therefore it is sanded using wide-belt sanding machines or profile sanding machines. 

    Machines:
    Sanding machine, Brushing machine

    Tools:
    Sanding belt

    Possible varnish, oil, wax application

    Surface application can be repeated.

    Machines:
    Varnishing line, Roller line

    Possible drying

    UV varnishes and oils are immediately ready for packaging after they have come through the dryer (or a second surface process)

    Machines:
    Varnish dryer

    Quality end control

    After the surface has been treated there is always a final quality control. 

    Stacking

    by hand or by machine

    Machines:
    Stacking line

    Packaging

    A high-quality, sensitive product, such as massive decks, especially when it has been surface treated, requires safe packaging. 

    Machines:
    Packaging machines

    Palleting

    by hand or machine

    Machines:
    Stacking line

Production process:Floorings – Solid parquet (One-layer parquet) – Solid decks

Necessary peripheral devices for Floorings2

  • Extraction systems

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

  • Fire and spark extinguishing systems

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

Ask us!