designed to protect against external influences.

This is a special paper that imitates the structure and color of various types of trees or ceramic tiles.

The base of the laminate is high-density fibreboard.

designed to protect HDF boards from deformation and protect the laminate from moisture.

With the help of these locks, the laminate panels are tightly fastened together without the use of glue.

Made from HDF board with impregnation upper layers is a process consisting of the following stages:
cladding the slab;
cutting and milling of panels;
package.

Impregnation is the saturation of a material special compounds. The top layers of the laminate are impregnated with resins with various additives, which form a durable layer when hardened. The strength and wear resistance of the top layer of the laminate, and therefore its class, depend on the formulation of the impregnation compositions. Basically, laminate manufacturers do not impregnate the top layers, but buy them ready-made.

produces direct compression laminate DPL. With DPL technology, all layers of the laminate are simultaneously compressed at high temperatures. This laminate production technology does not use glue, since layers are used that have undergone an impregnation process, which melt and glue the surfaces during hot pressing (up to 200°C). Once cured, the resin and overlay become a monolithic laminate surface layer.

To obtain a laminated board, it is necessary to cover the HDF board with paper-resin films and an overlay.

The last important stage of production is the production of the laminate of the required size. Using laminate sawing equipment, laminate sheets are cut to the required dimensions. Each laminate manufacturer has its own laminate sizes. After cutting into plates, using milling equipment, a tongue and groove are cut from the edges of the laminate. Modern HDF boards allow you to cut a tongue and groove of a certain profile, which are called laminate locks. With the help of these locks, the laminate panels are tightly fastened together without the use of glue. The quality, strength and tightness of the connection of laminate panels depends on the quality of the laminate lock and the strength of the HDF sheet.

The finished laminate is packaged in shrink polyethylene (PE) film.

Comprises:

1. ZYX1400 laminating machine; ZYX1600.

2. Laminate sawing machines DP-2700.

3. Line for milling click lock on laminate FHZ525+FHH625.

4. Laminate packaging machine TS-200.

Line productivity per shift (8 hours) is: 700 m2. Required workshop area (without warehouse finished products): 450 m2.

Automatic consists of the following main components:

1. .

2. Fan cooling line.

3. Line for sawing laminate.

4. Laminate lock milling line.

5. Laminate flooring packaging line.

Line productivity per shift (8 hours) is: 1000 m2. Required workshop area (without finished product warehouse): 900 m2.

Used in the production of laminate. manufactured to suit different sizes of HDF boards: 2800x2070 mm, 2440x1220 mm, 2440x2070 mm, 2620x2070 mm. Presses high pressure"ZYX" have different productivity and pressing force, supplied with a feeding and receiving table.

Total pressure (t)	1400	1600
Specific pressure (kg/cm2)	27,4	27,4
Cylinder arrangement	top	top
Diameter of hydraulic cylinders (mm)	340	380
Number of hydraulic cylinders (pcs)	6	6
Productivity (pcs/day)	1200	1200
Slab size (mm)	2440x1220	2620x2070
Maximum slab opening (mm)	200	200
Boiler power (kW)	31	31
Overall dimensions, mm)	3300x2000x3500	3700x2200x3500
Machine weight (kg)	17000	20000

Designed for cross-cutting laminate to the required dimensions. Each manufacturer has its own laminate sizes.

Maximum slab width (mm)	2700
Maximum cutting height (mm)	30
Saw diameter (mm)	180-250
Saw mounting diameter (mm)	75
Saw rotation speed (rpm)	2500
Total power (kW)	23,7
Feeding speed (m/min)	3-15
Overall dimensions, mm)	2000x3300x1350
Machine weight (kg)	3450

Designed for longitudinal cutting of laminate into the required dimensions for subsequent milling of the laminate.

Maximum slab width (mm)	1250
Cutting height (mm)	6-20
Saw diameter (mm)	300
Saw mounting diameter (mm)	80
Saw rotation speed (rpm)	2900
Feeding Power (KW)	1,1
Main motor power (KW)	15
Feeding speed (m/min)	10-40
Overall dimensions, mm)	1350x1200x1350
Machine weight (kg)	600

An automatic high-speed line is designed for the production of a lock (Click) on laminate. It is equipped with additional cutting spindles, which eliminates chipping along the entire perimeter of the workpiece and guarantees high quality of the finished product. The working surface of the table is equipped with carbide plates, which ensures durability of the equipment and reduces wear on the table surface. The receiving table is equipped with an automatic workpiece feeder to increase the feed speed to 80 m/min.

	German SEW electric motor with high torque and built-in industrial PID feed controller, reaching high speed feed 80 m/min.
	V-HOLD developed precision linear guides with carbide inserts for high-speed feeds (increase wear resistance and reduce table friction).
	Control system – SIEMENS with a multifunctional and intuitive interface, easy to manage and configure.
	French Legris air preparation system.
	supply of diamond tools.
	Input material size control for safe operation.
	High pressure air blowing system that removes dust and chips from the guides and table.
	Control of workpiece thickness using a tenon cutter.
	The hardness of the table cover is HV-700-1000, the hardness level is YG8.
	Patented vertical spindles for precision milling of parts.
	Dustproof inverters from SIEMENS.
	The combined feeding system distributes pressure evenly over the entire area of ​​the workpiece being processed.

Specifications
Feeding speed (m/min)	20-80
	0,75
Dimensions (mm)	3100x600x1400
Maximum processing width (mm)	250
Minimum processing width (mm)	95
Feeding speed (m/min)	20-80
Feed drive power (KW)	9
	6000-8000
	6x8KW
	4x6.5KW
	1,5
Spindles diameter (mm)	40
	280
	120
Total power (kW)	83
Feeding speed (m/min)	20-80
Total power (kW)	2
Dimensions (mm)	2880x600x1400
Maximum workpiece length (mm)	2500
Minimum workpiece length (mm)	400
Feeding speed (m/min)	10-60
Feed drive power (KW)	5,5
Spindle speed (rpm)	6000-8000
Vertical spindle power	6x6.5KW
Power of finishing spindles "Click"	4x6.5KW
Width adjustment motor power (KW)	1,5
Spindles diameter (mm)	40
Tool diameter on spindles (mm)	220-250
Diameter of aspiration pipes (mm)	120
Total power (kW)	92,6

Designed for semi-automatic packaging of finished laminate into shrink PE film.

* The calculations use average data for Russia

Every year, laminate is becoming an increasingly popular type of flooring, surpassing the once more popular linoleum in popularity. But laminate production is not for beginners.

In Russia, people learned about laminate not so long ago: it appeared on the market only in the early 90s. The first laminate was made in Europe, and its prices were very low. Later, the market was filled with Chinese goods, and Russian manufacturers. Competition has increased noticeably, and laminate itself has become more mass product. Many types of laminate have appeared, and trends in its production are constantly improving.

Today, laminate is the second most popular type of flooring produced in Russia after ceramic tiles. According to BusinesStat, in the period from 2014 to 2018, laminate replaced linoleum from second place, and its share is estimated at 28.7%.

According to analysts, the trend of increasing popularity of laminate will continue, and by 2023 its share will increase to 29.3%. Much of the success of this material among other floor coverings is due to its average price segment. Laminate simultaneously displaces both more expensive floor coverings (like parquet) and cheaper ones, such as linoleum, compared to which it has much more great advantages. However, the production of laminate is a technologically rather complex process, which is largely explained by the material itself and its structure.

Laminate structure and classes

Laminate is one of the most popular types floor coverings along with parquet, linoleum, carpet and ceramic tiles. “Laminated” means “layered” in Latin, which, in general, reflects the essence of laminate. Laminate has a multi-layer structure, made according to the sandwich or sandwich principle and consists of at least 4 layers.

HDF board- the main load-bearing layer of high-density fiberboard, responsible for wear resistance and impact resistance, which ensures stable geometry and rigidity.

Bottom stabilizing layer, balance paper. This is a synthetic layer that is necessary to compensate for residual stresses when the board cools after lamination and to additionally protect the board from moisture penetrating from below. It is craft paper impregnated with resin. The essence of this layer is that it prevents the laminate from sagging.

Decorative layer. A layer of paper with a decorative printed design that sits over the HDF board. Thanks to this layer, the laminate takes on the appearance of wood, tiles, marble, porcelain stoneware and any other material.

Protective top layer. A thin layer of paper impregnated with resins and containing substances to create strength. For example, such paper may contain corundum, the second hardest mineral, second only to diamond. When pressed, this paper becomes transparent. This layer prevents the formation of minor damage and scratches.

In addition to the laminate layers, one of its important features- this is a so-called lock that allows you to connect planks without using glue. Famous manufacturers locks with CLICK or LOCK locks are used, which differ in the way the panels are joined.

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To make it easier for customers to choose a laminate, the most common classification today (EN 13329) has appeared in Europe, which carries information about the wear resistance and durability of the product. Initially, laminate classes were divided into two groups: for home use (class 21-23) and for commercial use (class 31-34). But then the first productions came out, so we won’t consider them.

Existing laminate classes:

31st grade- used in rooms with low load: storage rooms, libraries, bedrooms. In commercial premises it will last no more than 2-3 years, at home - no more than 12 years.

32nd grade- the most common type of laminate, in public spaces with average traffic it will last 3-5 years. In a home environment (dining rooms, kitchens, hallways) it can last up to 15 years.

33rd grade- operation of the floor with intensive load. In commercial premises, the service life of such coating will be about 5-6 years, and at home it can last up to 20 years. The attractive appearance lasts as long as possible.

34th grade- used in public spaces with high loads, for example, car showrooms, train stations, airports, dance clubs, where such laminate can last from 7 to 15 years. At home it can last for about 30 years.

Assignment of classes according to the European standard is carried out on the basis of 18 tests, including tests for moisture resistance, scratch resistance, fading, impact resistance and others.

It should be noted that there is a lot of criticism of the class system, since different countries have different quality standards and indicators. Just like the star rating system for hotels, laminate flooring classes are a rather arbitrary concept, which is successfully used by unscrupulous manufacturers and marketers.

Advantages of laminate

Like any other type of flooring, laminate has a set of pros and cons that set it apart from other flooring materials.

Advantages of laminate:

Affordable price. Laminate is most often chosen as an alternative to parquet, which costs much more. Laminate is cheaper, since its origin is artificial, and the production technology using synthetic materials, if it is already put into production, is relatively simple. During periods of crisis, the demand for laminate increases, while cheaper types of coatings lose demand.

Appearance of laminate. At its price, laminate has a stylish and aesthetic appearance, and the buyer can choose any decorative surface pattern that will match the walls, wallpaper, furniture and other objects in the house.

Easy to install. Compared to other coatings, laminate is very easy to install. Since each slab has a special lock, the coating can be easily assembled around the entire perimeter of the floor like a construction set, and a medium-sized room can be covered in 2-3 hours.

Strength. Laminate is able to withstand heavy furniture, thin heels, toys without damage, and is more wear-resistant compared to linoleum.

Easy to care for. Laminate flooring is easy to care for and can be used in both home and commercial settings.

Disadvantages of laminate:

Environmental friendliness. Laminate contains synthetic materials that contain phenol and formaldehyde resins, which are harmful to human health. Therefore, laminate is inferior to parquet in terms of harmfulness. At the same time he is safer than linoleum and other floor coverings. At the same time, high-class laminate has a minimal inclusion of harmful substances and in this criterion is equated to a wooden covering.

Noise insulation. Maximum sound absorption is guaranteed only when the laminate is laid perfectly evenly. Therefore, the floor before finishing should have changes in level of no more than 1 mm per square meter. If there are even minor voids under the artificial turf, it will turn into a source of noise.

Moisture resistance. Laminate consists of 70% wood fibers, so it has low moisture resistance. Therefore, it is rarely used for bathrooms.

Short-lived material. Over time, the protective layer wears off, and the average service life in practice is 7-8 years. Therefore, in high-traffic areas, laminate is not the best option.

Laminate production technology

Laminate production is a rather complex process, so this idea cannot be considered as a home or garage business. This is more of an idea for a full-fledged plant, or at least a mini-factory.

Full cycle production technology includes 4 main stages:

• Production of high-strength fiberboard HDF (HDF);
• Impregnation of the upper layers;
• Cladding the slab;
• Sawing and milling of panels.

Let's look at these stages in more detail:

1. Production of HDF boards

HDF (High Density Fiber board) is high-density fiberboard. As we said above, HDF board is the basis of the laminate, which largely determines the quality of the laminate and its resistance to mechanical stress. The greater the density of the produced slab (the minimum density is 850 kg/cubic m), the higher the moisture resistance and strength of the material. The thickness of such a plate varies from 5.8 to 12.1 mm.

HDF is created from solid wood, which is pre-cleaned, then dried, and then chopped into chips using special machines. Of course, the wood itself can be different. This could be, for example, either cheap poplar or more expensive birch.

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The manufacturing company does not have to have own production HDF boards: some manufacturers purchase ready-made boards and have an incomplete production cycle of laminate. However, this option usually leads to a significant increase in the cost of the final product.

2. Impregnation

Impregnation is the process of impregnating the top layers of slabs with special substances. Resin is used as impregnation, which is supplemented with various additives. During hardening, these substances create a durable layer on the slab. The strength and wear resistance of the top layer of the laminate, and therefore its class, depend on the formulation of the impregnation compositions. In order to improve the strength of the floor, corundum particles are sometimes added. Manufacturers also may not impregnate the top layers, but buy them ready-made.

3. HDF cladding

In order for fiberboard to become laminated, it must be covered with an overlay and paper-resin films. This process can occur using different technologies. Exactly:

HPL - high pressure laminate;

CPL - conveyor laminate;

PDL - drawing printing;

DPL - direct pressing laminate;

CML - continuous multi-layer pressing laminate;

ELESGO - electron beam hardening method.

4. Panel milling and sawing

After the press, the laminate must be cut to the required dimensions using sawing equipment. Dimensions are set by the manufacturer. Next, on the cut plates, on the edges of the sheets, grooves and tenons are cut out using a milling machine, which are called laminate locks. Laminate locks are used to fasten the boards together without the use of glue. Since the quality, strength and tightness of the connection depends on the quality of these locks, the types of locks themselves are made using various technologies (CLICK, LOCK, UNICLICK, etc.). To make locks more durable, manufacturers may also use metal or rubber, or coat the edges with wax for greater moisture resistance.

After completion of all production processes, the finished laminate is packaged in shrink polyethylene film (PE) and cardboard packaging. The packs contain inserts with information about the laminate, class, number of planks, and so on.

Investments and equipment

Opening a laminate production is an expensive business. The cost of the simplest production lines is indicated by specialists in the amount of 20-25 million rubles. And this does not take into account the rental of a workshop with an area of ​​at least 2-2.5 thousand square meters. m, warehouses (necessarily dry and heated, since laminate does not tolerate changes in humidity), purchase of forklifts, wages workers (at least 20-25 people), office staff, accountant. Thus, the starting costs for opening a mini-factory for the production of laminate will range from 30-35 million rubles.

Equipment list production line for a mini laminate plant:

Equipment	Purpose	approximate cost
Laminating machines ZYX1400; ZYX1600	Presses are manufactured for different sizes of HDF boards: 2800×2070 mm, 2440×1830 mm, 2440×2070 mm. High-pressure presses "ZYX" have different productivity and pressing force, and are supplied with a feeding and receiving table.	40 000 - 60 000 $ (2.6 - 3.9 million rubles)
Laminate sawing machine DP-2700	A machine for cutting laminate into the required dimensions for subsequent milling of locks. Each manufacturer has its own laminate sizes.	estimated from $20,000 (from 1.3 million rubles)
Line for milling click lock on laminate FHZ525+FHH625	An automatic high-speed line is designed for the production of a lock (Click) on laminate. It is equipped with additional cutting spindles, which eliminates chipping along the entire perimeter of the workpiece. The working surface of the table is equipped with carbide plates, which ensures durability of the equipment and reduces wear on the table surface. The receiving table is equipped with an automatic workpiece feeder to increase the feed speed to 80 m/min.	(RUB 14.2 million)
Laminate packaging machine TS-200	The machine is designed for semi-automatic packaging of finished laminate into shrink PE film	(640 thousand rubles)

To sell finished products, the company will need to develop its own dealer network. But since competition in the flooring market is high, finding distribution channels will take quite a lot of time, so it’s better to do this before or during the opening of your production. At the same time, we must not forget about brand development: since the brand must somehow stand out among a huge number of other names (for example, price, quality of material or unusual design idea), you will have to think about the concept and competitive advantages, and this, as a rule, is a completely different approach to business and completely different investments.

Requirements and documents for laminate production

Laminate production involves a significant set of papers. As a rule, the list of main documents consists of the following documents:

Certificate of conformity. Applies to all manufactured goods. Today it is issued by some non-profit companies. It needs to be changed once every three years.

Hygienic license. It is issued by Rospotrebnadzor. Validity period: 5 years.

Certificates for all production raw materials, which must be provided by reputable suppliers. The certification process takes about three months. Non-profit companies are more active and faster in carrying out these procedures.

Production permit from the fire department.

Documents for renting premises. They are issued by the city administration and the land acquisition department.

Contracts for the provision of communications: electricity, gas, communications, etc.

Laminate production is a technologically complex process that requires the use of special technologies and equipment, raw materials and materials. The first attempts to make flooring vaguely reminiscent of modern laminate date back to the late 70s of the last century, when the Swedish company Perstorp was actively working in this direction. The company then specialized in the production of building materials and installation work, so it was widely known in Europe.

The first laminate prototype had only two layers. A thermally active glue was used to connect them, but only a few years later high-temperature pressing technology began to be used.

An analogue of modern laminate, produced by Perstorp, appeared only in the late 80s. At that time, quite a lot of companies worked in this direction, but the most successful was the German company Hornitex. This company used innovative technologies and equipment to produce a new generation of laminate flooring, so it managed to create a floor covering with good performance characteristics and high wear resistance. It was the Germans who were the first to make laminate, consisting of 4 layers.

Today, companies use similar technologies to produce laminate floors. In short, the production process includes the following stages:

• Production of HDF boards.
• Impregnation of the upper layers.
• Connection of all 4 layers under high temperature influence.
• The process of cladding boards.
• Sawing and milling of laminated boards.

First, an HDF board is created, which is a modified version of fiberboard with increased density (more than 850 kg/cub.m.). As the density of the slab increases, its basic performance characteristics– strength indicators and resistance to moisture.

1. The main raw material for the production of boards is wood (often pine), cleared of bark. It is processed using special equipment to the state of chips. After this, the resulting chips are washed, thereby removing foreign particles ( various pollution), heated with steam in special containers to 170-180 degrees, which allows the raw material to soften. Heating causes the chips to become plastic, so they are then chopped into fibers.
2. Various components and binding elements (polymers, resins, etc.) are added to the resulting mass of wood fibers. Next, the wood pulp is dried, removing almost all moisture from it.
3. The dried wood pulp is then transferred to a conveyor, where it is leveled and pre-pressed, which reduces the thickness of the layer and removes all the air. It is at this stage that the wood pulp becomes similar to the finished board.
4. Moving further along the conveyor, the wood board is trimmed along the length and width to the specified overall dimensions.
5. Next, the finished fiberboards are cooled and stored.
6. At the last stage, HDF boards are sanded and calibrated. Special machines make them as even as possible.

In the event that it is necessary to achieve the maximum possible moisture resistance of an HDF board, at one stage the wood pulp is impregnated with special hydrophobic compounds.

Impregnation of top layers

In the production of laminate, impregnation is the impregnation of the material with various resin compositions and liquid protective components. Different manufacturers use various compositions to saturate the material. The strength and wear-resistant properties of the surface, including the service class, will depend on the formulation and technology used. When impregnating, corundum particles are often used to improve the characteristics of the panel.

For impregnation, a special roll system is usually used, where the top layers of the laminated coating pass through baths filled with resins and various additives, where they are impregnated and dried.

It is interesting to note that many large companies, which specialize in the production of laminated floors, have long abandoned impregnation of the top layers, because They purchase this part of the laminate ready-made from specialized companies.

Cladding of slabs

To obtain a high-quality laminated panel, it is necessary to subject the workpiece in the form of HDF boards to cladding using an overlay (protective layer), films made of special paper and resin. For this they can be used various technologies. The following production methods can be distinguished:

• CML, RML.
• ELESGO.

Some of these methods have been used for quite a long time, and some are the most modern. At the same time, different manufacturers can use both traditional and modern techniques. When choosing a laminate for your home, it would be a good idea to clarify exactly what technology was used by the plant.

HPL and CPL technologies

Initially, only HPL technology was used for the production of laminate, which is presented in the form of a lamination process. This process involves gluing layers of laminate using special adhesives. Bonding can occur using hot, warm or cold methods. The hot gluing method was and is most often used, because its use produces a fairly high quality of joining materials.

The process steps are as follows:

1. First, the materials to be bonded are cleaned of contaminants.
2. Next, the adhesive composition and a special hardener are applied.
3. Then the two layers that need to be joined are pressed at a temperature of about 250-300 degrees at a pressure of 200-250 MPa.

At the first stage, the decorative layer and overlay are glued together. During the gluing process, top layers can be used both before and after impregnation. If impregnation has already been carried out, then when joining the layers by high-temperature pressing, no additional adhesive compositions are added.

At the second stage, in order to obtain a finished product, several layers are glued at once: the top layer, the base in the form of an HDF board, and the bottom stabilization layer.

CPL is one of the modern types of HPL technology, in which special presses, presented in the form of conveyors, are used to connect layers. When using CPL technology, the top layer passes through rollers that are heated to high temperature, as a result of which it is rolled onto the HDF base.

DPL, CML and PDL technologies

More often modern manufacturers laminates use DPL technology. Its use involves simultaneous pressing under high-temperature influences of all layers of the laminated panel. The most important thing is that this technology does not imply the use of adhesives, because the layers are pre-impregnated with melamine resins, so it is with their help that the surfaces are bonded, because at a temperature of 200-250 degrees, the resin melts and connects the layers. Once heated and cured, the melamine resin and the top protective layer form a single surface layer of the laminate floor.

In some cases, manufacturers can additionally use layers of kraft paper, which is placed between the decorative coating layer and the HDF board. This approach allows us to improve the quality of the laminate to some level. This technology is a variation of DPL and is called CML (RML).

IN last years PDL technology has become widespread, which involves the use of special equipment with which it is possible to apply a decorative design (for example, imitation stone or wood) directly onto the HDF board. When using this technology, production labor costs are reduced, because there is no need to additionally create a decorative layer and use paper/cardboard.

If the manufacturer uses ELESGO technology, then the manufacturing process involves a special way of creating the top protective layer of the coating. In this case, the hardening of resin and other liquid components occurs under the influence of an electron beam, while machines for pressing and high-temperature exposure are not used. Also among the differences is that when using this production method, acrylate resins are used, rather than standard melamine.

ELESGO implies that the top layer of the laminate will consist of three additional layers at once. During the production process, the decorative layer is covered with two layers of overlay, which were made from acrylate resins and corundum. This approach makes it possible to give the laminated floor sufficiently high strength characteristics, increased resistance to scratches and operational abrasion.

After combining these three layers, the resulting “pie” is irradiated with an electron beam, which allows the materials to harden and create an elastic film of increased strength on the surface.

Next, the production of the laminate occurs in a standard way: a temperature-active agent is applied to the HDF board on both sides. adhesive composition, after which all the main layers of the laminated panel are compressed under high temperature and press.

The main advantage of using ELESGO technology is that no solvents are used in the manufacturing process, which allows us to obtain products with the highest possible level of environmental friendliness. Acrylate resin compositions such as these are antistatic, maximally transparent, therefore the decorative layer obtained in this way has an excellent appearance.

Sawing and milling

To get laminated panels the right size, at the last stage of laminate production, sawing and milling are used. Laminate sheets are cut into boards of the required size using special sawing equipment.

Once the panels are cut, they are sent to milling, where the interlocking system of the laminated covering is created, and tenons and grooves are cut into the end part of the panel. A locking system from different manufacturers may have different configurations - everything will depend on the technologies and solutions used.

After sawing and milling, many manufacturers additionally subject the boards to waterproof treatment. wax compounds to give the material moisture-resistant characteristics. Only after this does the cleaning take place finished products, they are packaged, stored and transported to points of sale.

The laminate manufacturing process is constantly being improved. The following areas are actively developing:

• Modernization of the production process as a whole.
• Technological modernization of laminated panels (improving the functionality and wear resistance of locking joints, providing the boards with thermal insulation and sound insulation characteristics, improving the resistance of the entire coating to liquids, etc.).
• Improving the appearance of a laminate floor (using different design solutions, creation of structure of the material, variation of shapes and sizes of finished products).

Every year the characteristics of laminate are improving, so soon this type of flooring will become the most popular among private and corporate clients. As the quality of panels improves, in conditions of high competition, prices are also decreasing, so today everyone can afford modern laminate.

In the finishing materials market, laminate is very popular and in great demand, providing worthy competition to various types of flooring, including parquet and solid wood. floorboard. It is widely used in residential and office spaces and is characterized by ease of installation, operation and maintenance, luxurious appearance, resistance to mechanical loads and deformation, an ideal complement to any interior style, and a variety of colors.

Laminate production began in the late 70s of the last century in Sweden. The modern geography of its production covers many countries of the world, including China, Russia, and Ukraine.

Modern manufacturers offer finishing materials with a variety of textures, patterns, and photo printing with original images. The texture of the laminate is distinguished by an ideal picture of authenticity, imitating the surfaces of natural materials.

But the palm still belongs to European companies, which are distinguished by the development of new products, improvement of equipment for laminate production and development innovative technologies. The quality of the flooring is controlled by the Association of European Laminate Flooring Manufacturers.

Composition of the laminated coating

The first manufacturers of laminated flooring offered boards made of two layers.

Today it consists of four layers:

• The first layer of a transparent, durable resin film provides reliable protection against dirt, sun exposure, minor scratches, chemical substances. Additionally, a layer of varnish can be applied to the surface to add shine. The laminate class is determined by the quality of the first layer.
• The second layer has a decorative function and is paper impregnated with resins. The ideal imitation of the texture of wood, stone, leather, granite, marble makes it difficult to determine the differences between laminate and the surface of natural materials.
• The third layer is the main one, and to create it, fibreboard is used, the density and quality of which determines the properties and characteristics of the floor covering. Its production is based on the pressing method. wood material with glue. In the production of laminate, this layer is the load-bearing part of the coating.
• The fourth layer is designed to protect the floor finishing material from deformation, exposure to moisture, vapors, mold, mildew and ensuring increased rigidity and stability. It is cardboard impregnated with resins, paraffin or high-density melamine film.

Main stages of flooring production

The production of laminated coating involves several stages.

The main ones include:

• production of high-density fiberboards;
• processing of flooring sheets with special compounds;
• cladding, lamination of laminate;
• sawing, milling and packaging of finished products.

Manufacturing of fibreboards

Fiberboards serve as load-bearing parts of the floor covering. Their production is based on many operations.

These include:

• grinding wood without bark to obtain small chips, which serve as raw materials for the production of laminate;
• washing wood chips to remove dirt, sand, and impurities;
• two-stage steaming of chips with steam at temperatures of 100°C and 175°C to obtain material with the same moisture content and plasticity;
• grinding in a refiner until the desired faction raw materials;
• adding resins, paraffin, binders that increase the density of the slab and reduce moisture absorption;
• drying wood chips in accordance with laminate production technology;
• primary pressing of chips to form the surface of the slab under a pressure of 300 MPa and a temperature of 300°C;
• heating pressing of the material at a temperature of 190°C under pressure from 40 MPa to 120 MPa;
• leveling the slab until a perfectly flat surface is obtained.

The production of fibreboards is the most important step technological process in the production of laminate.

Impregnation or impregnation of slabs with special compounds

The slabs prepared for further processing, in accordance with the laminate production technology, undergo impregnation, based on impregnation of the material with special compounds.

For the top layer, resins with additives are used to ensure a durable layer after hardening and determine the degree of wear resistance, as well as the service life of the floor covering. Sometimes corundum particles are added to the composition to improve the quality characteristics of the finishing material.

Facing stage

Cladding, provided for by the production technology of laminated panels, is carried out in two ways. The first of them is called laminating. It is based on applying glue with a hardener to the top layers of the laminate and their subsequent pressing. The process is carried out at high temperatures and can involve coating surfaces that have and have not undergone the impregnation stage.

The second cladding method involves pressing all the laminate layers without using glue. It is intended for slabs impregnated with special compounds.

The final stage

At the final stage of laminate production, sawing, milling of the floor covering and cutting out fastening elements on the edge side of the board are performed. Sometimes the technology for producing laminate flooring involves applying wax or paraffin to the edges of the board.

After passing through all stages of production, the material is packaged in polyethylene film manually or mechanically.

Laminate flooring is becoming more popular every day than its predecessors - parquet and floorboards. Its high durability and ease of maintenance have made it popular in private homes, apartments and offices. Today, laminate is an excellent alternative to any natural wood coverings.

Despite the popularity of this material, few people know how laminate is produced. What is this material like? design features.

Making laminate - everything ingenious is simple

History of laminate

The creation of laminate dates back to the late seventies of the last century. The first flooring material that vaguely resembled modern laminate was created by Perstorp from Sweden.

This company was developing various materials for construction work and was quite popular throughout Europe. New material received the name laminated plastic, which means layered plastic.

The first development consisted of only two parts. On top, the material was treated with melamine resin, which helped to recreate the decorative layer, and on the bottom, phenolic resins took part in the production.

The layers were connected in several ways at once. Impregnation with thermoactive glue was not enough, and the creators began to use pressing under the influence of high temperatures.

Laminate as we are used to seeing it appeared only a decade later. The author of the global revision of the material was German company Hornitex.

This company used a completely new technological approach and equipment to produce a new type of laminate and managed to create a laminated coating with unique properties. There were now four layers instead of two. The composition included foil impregnated in phenolic and melamine resins.

In 1994, laminate had huge demand in the market building materials. Having increased to enormous proportions, sales volumes required the introduction of a body that monitors the appropriate quality of products. This led to the creation of the Association of European Laminate Flooring Manufacturers.

Laminate device

As mentioned above, laminated coating consists of several layers.

I propose to take a closer look at the composition of this material, which is indicated in the figure:

• The bottom layer of the coating is moisture-resistant paper. It is necessary given the properties of wood to absorb different kinds moisture in huge quantities.
  This layer is impregnated with resins and is intended primarily to protect the HDF board;
• The main part of the coating lies on the paper, namely the high-density fiber HDF board— 880 kg/m3
  It is the main load-bearing part of the laminated flooring and is designed to preserve the geometry and structure of the floor. This material is stronger than wood itself;

Note: To make HDF, round timber is used, which is cleared of bark.
After this, this material is processed into wood chips.
After sorting, large-fraction chips are used in chipboard production, and HDF is produced from the finer fraction. The chip crusher can be seen in the picture.

• The third coating layer is a film, which is designed to provide additional moisture protection for both the HDF board and the top two layers;
• Next, special paper is laid, or foil on which the structure of the simulated material is applied.
  It can be stone, wood or any other organic material;
• Upper layer designed to provide durability and appearance over time. It is he who undergoes treatment with melamine resins.
  This process is called "lamination", which gives this coating its name. The top layer can be homogeneous or composite.

Advantages of laminate

• Resistance to mechanical stress and abrasion;
• The ability to withstand various loads and deformations for a long time;
• High-quality resistance to the abrasive effects of the top layer of material;
• The top layer of the material is easy to clean and remains resistant to chemical attack;
• Does not fade and is not flammable;
• Has excellent heat conductivity and is easy to clean;
• One of the cheapest flooring materials created using natural wood;
• Easy to install, do-it-yourself installation is allowed.

Technological process for creating laminate flooring

Laminate production at each plant may vary. Almost every manufacturer has its own technology and unique developments. Despite this, the essence of creation and the basic processes are practically the same.

Preparing wood chips

• First, the wood chips go to the sink, where the debris is washed away with hot water;
• The second stage is steaming the wood chips. This is done to obtain wood with uniform moisture content. The steam heats the wood chips up to 100 degrees Celsius;
• After this, the chips undergo secondary steam treatment under high pressure. The temperature of this chamber reaches 175 degrees. After these manipulations, the chips become sufficiently plastic and ready for further processing;
• After this, the wood chips are crushed to the desired fraction, which is carried out in an installation called a refiner. At the exit from it, resins and binders and paraffin are added to the resulting material, which reduces moisture absorption;
• The next step is drying the wood chips. In addition to the main functions, the tasks of this installation also include equalizing humidity. You can see one of the dryer options in the photo below;

Primary production

• Now the wood chips go directly into the production of components for laminate flooring. First, it is poured into a storage hopper, and then goes directly to the primary pressing unit.
  This installation forms slabs that vaguely resemble required product. After reduction by 5-6 times, the air is completely removed from the chips, but it still looks quite loose;
• One of the main processes in the production of boards is pressing. The first treatment takes place at a temperature of 200-300 degrees and has a pressure of up to 300 MPa. This action is applied to form the surface of the slab;
• The second stage of pressing is heating. Here the temperature is reduced to 190 degrees and a pressure of 40-120 MPa is applied to the plate
• The final stage of pressing is to level the slab to an ideal, flat surface. The press pressure applied here is 60-150 MPa. This process can be seen in Figure 4

Making laminate

On final stages the following operations are performed:

• After quality control, the slab is sent for cutting. These manipulations are performed with a dividing saw. Basically, the output size of the slabs is 2800*4140 mm.
  Immediately after cutting, the slabs are cooled for half an hour. The slabs are then given time to acquire a stable structure. For most manufacturers, this period is several days;
• The next operation with the slabs is grinding and finishing with an installation called a formatter. This device cuts the slab to the generally accepted size of 2800*2070.
• Then comes the pressing process, which is not done in the same way. Both complete pressing of the laminate and its individual parts are used.
  These technologies depend on what the manufacturer’s instructions prescribe.
• The final process of making panels is to cut and laminate them, followed by milling of the edges, Figure 5.
  Modern locking connections involve the use of several dozen different cutters. The accuracy of the settings determines how high-quality locks the panels will be equipped with.

The technological process of laminate manufacturing can be seen in the video:

Laminate classification

Currently, the production of laminated coatings is subject to strict rules and GOSTs. One of the ways to control manufacturers is to divide the laminate into classes.

Each type of product is designated by a two-digit number. In this numbering, the first digit indicates the room for which this product is intended, and the second indicates the possible intensity of use. Improvements in class correspond to increasing numbers.

Classes are divided into:

• 21-22 – intended for covering floors in residential premises with low levels of use. These could be bedrooms and rooms with low traffic levels. The price of such products is also very low;
• 23 – fits in living rooms, halls, children's rooms. This type of coating can fully serve for up to six years;
• 31 – can be installed both in small office spaces and residential buildings. Moreover, in an apartment, its service life reaches more than 10 years, and the cost is slightly higher than class 23;
• 32-33 – These are the most wear-resistant types of laminate. They are purchased for installing floors in shops, large offices and places with high traffic.
  The excellent protective layer of this type is supported by sound insulation, which can be used as.
  If such a coating is installed in residential premises, it will remain in excellent condition for many years.

External features of the laminate

Laminate has a very large color scheme(cm. ). It can imitate any of available materials: wood, stone, sand. It is worth recognizing that colors and shades are dominated by colors for different types of wood.

This, in turn, gave consumers the wrong idea about this material. Many people believe that laminate flooring is an imitation of wood.

There is a second name for this material – laminated parquet. These judgments do not correspond at all to the true state of affairs. Laminate is a completely original material, with many properties superior to those materials with which it is compared.

Laminate flooring can differ not only in color palette, but also in structure. We can purchase material structured like wood, oil, stone. It can be matte or have a glossy sheen.

Another feature of the external data of this coating is its ability to imitate parquet in stripes.

Laminate can have one, two or three stripes.

• Single-strip laminate is the most expensive. This is explained by the peculiarities of its production, which involve the use of the widest materials to create one strip. With it you can create unique design, imitating various materials with minimal differences from the original.
• The two-strip coating does not have a chamfer, but is very similar to piece parquet, increased width;
• Three-strip material is the least expensive. Without a chamfer, it perfectly imitates parquet laid using the “deck” method.

Cleaning and maintaining laminate flooring

No matter what class the chosen coating corresponds to, no matter what properties the manufacturers endow it with, improper cleaning and care can significantly shorten its service life and negate all the positive properties.

The basis for the manufacture of laminate flooring is wood, which is 90% of its component. From prolonged exposure to moisture, this coating can swell, changing its structure. For proper care For laminate flooring, it is enough to use some simple rules.

• After installation work, it is necessary to carry out the first, general cleaning;
• This material has protective properties against dust deposition, built into the structure by the manufacturers;
• For regular, scheduled cleaning, it is enough to vacuum the laminate flooring;
• Dirt that has stuck to the floor can be easily cleaned off with a damp, well-twisted cloth, with minimal addition of vinegar;
• More stubborn stains can be removed using special products. After cleaning, the floor must be wiped with a damp cloth;
• For a longer life of the top floor covering, try not to use detergents that contain solid particles;
• When transporting furniture, lift it off the floor; dragging may damage the coating;
• If possible, try to use floor protection materials on the legs of chairs and tables;
• When cleaning using water or other water-based solutions, remember that moisture should not be absorbed into the floor;
• If a large amount of moisture gets on the floor, it must be removed without wasting a minute.

Conclusion

Laminate production is a complex technological process that helps produce excellent quality flooring material. Due to the peculiarities of the technological process, the material has unique properties, easy to install and operate.