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Step by Step Manufacturing Process of Decorative Laminate Sheets

Decorative Laminate Sheets
In: Home Improvement

Designer laminate sheets are resurfacing materials used for covering furniture, cabinets, tabletops, bookshelves, walls and even floors. They are generally manufactured by compressing thin paper sheets and plastic resin. If you are considering revamping your interior by laminating, you can choose any laminate sheet from the extensive laminate catalogue that Royale Touche Laminates offer. We make premium quality decorative laminates in India to transform your interiors into the best possible version.

Important facts about the thickness of decorative laminates that you should know

  • The general thickness of designer laminates ranges from 0.6mm to 1.5mm
  • Thicker laminates are sturdier. More layers of sheets can be added to make them thicker according to your preferences.
  • Thicker laminate sheets are also known as compact laminate sheets as they are made by compressing several more layers of sheets. The thickness of such laminates can range from 3mm to 30mm.
  • Compact laminate sheets do not need to be glued down to another rigid surface like ply, MDF or other bases. They are self-supporting and therefore can be used independently.

Some information about the machines used for manufacturing decorative laminates

5 major types of machines are used for carrying out the manufacturing process. They are as follows:

  • A machine for drying and cooling
  • To cut the laminate sheets according to preferred sizes a cutting machine is required
  • For engraving laminate design patterns and textures, steel plates are used. These plates furthermore do the job of separating the sheets
  • Hydraulic press for compression
  • Sanding machine for sanding the bottom layer of the sheets and for adding finishing touches.

The raw materials required to produce the digital laminates

Different kinds of raw materials are required to manufacture these such laminate sheets. They are,

  • Kraft paper or brown paper are generally used for making paper bags.
  • Phenolic resin is a type of resin that is made from phenol. It is also the main ingredient used for making plastic.
  • For making different designs or textures on top of the mica sheets various decorative papers are used.
  • Lastly, a clear coat of translucent paper is used as a protective layer on top of the decorative paper.

Step by the Step manufacturing process of decorative laminates

  • Step 1: The papers are soaked in resins

As the first step of this elaborate process, the brown papers or kraft papers are soaked in a tub filled with phenolic resin. These resin-soaked papers are used for creating the base of the laminate sheets. The paper is soaked until it becomes completely wet and absorbs all the resins to the point of being saturated. This step is termed impregnation. A machine that is used for moving the rolled-up paper through the resin is known as Paper impregnation Line. In the same way to soak the translucent cover and the decorative top layer of the laminate melamine is used. Soaking in resins is a significant step as it stiffens the paper making it scratch resistant.

  • Step 2: The papers are dried

In the next step, the resin-soaked brown papers are completely dried. After air-drying it entirely the brown paper does not resemble its previous form at all. It becomes harder and sturdier ready and is now ready to withstand any damage.The soft and easy to tear paper is now difficult to bend.

  • Step 3: Pressing using high pressure and bonding

In this step, the individual hard dried sheets are stacked one over the other and are compressed using a hydraulic press under a certain temperature. The stacking is done by placing the brown paper first as the base. Then comes the decorative paper which forms the middle layer and as the top layer the translucent coating is placed. By using a large scale hydraulic press with steel plates a lot of sheets can be pressed together resulting in evenly distributed stacking. Moreover, the steel plates engrave different patterns and designs while pressing. Keeping the stacks under proper pressure is a necessary step for manufacturing good quality decorative laminates. This is also the reason why such sheets are also called high-pressure laminates.

  • Step 4: The non-decorative part is sanded

The last and final step of the whole manufacturing process involves the proper sanding of the bottom layer with the help of a sanding machine. This makes the bottom side of the laminate rough and thus makes it perfect to glue down to any surface.

  • Step 5: Testing, packaging and distribution

The final product then undergoes a standard quality check. Then they are packed and prepared to be distributed to different laminate companies for selling.

 

The process may sound lengthy and complicated but that does not limit their easy availability. Digital laminates are affordable and easily accessible. If you are looking for premium quality decorative laminates then Royale Touche Laminates must be your first choice. They cost less than any other resurfacing material such as wood or marbles yet look extremely modern and chic. Try different patterns, colours and textures for transforming any dull and dim corner of your office or house space into something vibrant and lively.

 

 

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