What technologies are used in the production of laminate and how is the process of manufacturing flooring? Own business: production of laminate. Technology and equipment for the manufacture of laminate, cost calculation and necessary documents to start

For some of the entrepreneurs, the economic crisis of 2015-2016 was a real blow to business, while others, on the contrary, even won. I'll give you an example right away. It is well known that due to the fall in income, the real estate market began to experience serious problems, in particular, housing under construction or new housing built. In turn, the demand for secondary housing has risen. People prefer to buy apartments and houses at a lower price and renovate them according to their preferences. As a result, the market rose building materials, the production of which began to bring profit to their owners even more than in the "pre-crisis" times. Laminate manufacturing is one such business idea that deserves some serious consideration for those entrepreneurs who are looking for an opportunity to start a serious, win-win business.


Among all kinds of floor coverings, laminate rightfully occupies one of the leading places. Why by right? Judge for yourself: the service life of even an economy class laminate is 10-12 years, while its cost is quite low; wear resistance, moisture resistance of the laminate is no less than other flooring, and the texture and appearance are much better. Few "competitive" materials can boast of such characteristics, mainly those whose cost "rolls over".

Brief business analysis:
Business setup costs: 30 -32 million rubles
Relevant for cities with a population: with no restrictions
Situation in the industry:average market saturation
The complexity of organizing a business: 4/5
Payback: 1-2 years

The fact that it gained its popularity in some 15-17 years also speaks in favor of the laminate. That's how much he is on Russian market building materials. However, to the rest of the world, the laminate in the form in which we know it has not been known for much longer.

For reference: the first laminate was designed by the Swedish company Pergo in 1977, but its disadvantages far outweighed its advantages in order to launch its large-scale production. And only 10 years later - in 1987, the German company Hornitex brought the laminate "to mind", presenting new samples. It took another 10 years to promote the product in the West, and only a few more years later the laminate came to Russia.

The amount of investment for business organization

It should be noted right away that the amount required to open a laminate production is quite impressive. According to the most rough estimates, this is about 20-23 million rubles. Moreover, this is only the cost of the production line. Add to this the rent for the production room, the cost of the initial purchase of the necessary raw materials, and other organizational expenses.

Of course, all this is best reflected in a business plan, without which it would be simply pointless to start such a large business. You can try to write a business plan yourself, but it is better to entrust this procedure to business planners. At present, banks are very reluctant to lend to any individual business projects and start-ups, but if you present a truly convincing description of your future business that has all the necessary calculations, then there may still be a chance to get the necessary investments.

But there are also "pleasant" moments. The production of laminate is considered an extremely profitable business. Even a small workshop is capable of producing up to 15 million square meters per year. meters of laminate. That is, with an initial investment of 30 million rubles, and an average cost of 1 square. a meter of 300 rubles, the payback will be less than a year, provided, of course, competent management, the availability of constant distribution channels, and the production of quality products.

it's worth paying attention to

Two main problems faced by domestic laminate manufacturers:

  1. The lack of suppliers of high-quality raw materials for production on the Russian market. For this reason necessary materials have to buy from abroad. The raw materials offered by our few suppliers are suitable, perhaps, only for the production of an economy class product, the share of which is only 18-19% in total sales.
  2. Another problem is rather ridiculous, but is quite in the "spirit" of our state. This is the complete absence of any norms or standards for the production of laminate. No GOSTs for you, or anything else. Therefore, manufacturers have to focus on foreign standards.

Business registration

First of all, it will be necessary to decide on the form of doing business - IP or LLC. In this case, the second option is preferable - it is unlikely that any bank will entrust a large amount individual entrepreneur. The next step is to determine the tax regime of the enterprise. You can find out more about this in this.

In addition to the “standard set” of organizations when registering a business - the fire service, Rospotrebnadzor, utilities, municipal administration, etc., you will have to get a “go-ahead” from the departments of environmental control and labor protection, because laminate is used in the production harmful substances in particular formaldehyde.

Selection of production premises

In general, the most best option for organizing a business - the acquisition of any woodworking enterprise and its reorganization to suit your needs. But, if this is not possible, then you will either have to look for a room that is suitable in terms of parameters, or build it, as they say, “from scratch”.

Despite the fact that at present most laminate manufacturers are trying to focus on the release of a product with moisture-resistant functions, laminate and raw materials for its manufacture are still “afraid” of moisture, so one of the main conditions for a production facility is dryness, the possibility of ventilation, and the presence of a heating system.

The area of ​​the future workshop to accommodate even a small production line should be at least 2 thousand square meters. meters, taking into account storage facilities, rooms for staff, bathrooms, etc. Finding such areas is quite difficult, and most importantly, expensive. Therefore, it is worth thinking about locating production in rural areas. Firstly, it will be much easier to find suitable buildings there. Secondly, the rent for these premises will be several times lower. Well, and finally, thirdly, the inspection of production by the relevant services will be much less frequent than when located in the city.

Laminate production technology

Before listing what kind of equipment you will need for the full functioning of your business, you need to understand at least in general terms the production process. Laminate production technology, despite some possible differences in the individual stages, includes several main steps:

Stage 1 - obtaining fiberboard:

  • Wood chips after washing and steaming are crushed to desired faction, mixed with paraffin, resins, and other astringent additives that increase its moisture resistance, and dried.
  • In a special plant, the chips are subjected to primary pressing, which gives them their original shape.
  • On another press, the plate is pressed completely and a perfectly smooth surface is given to it.

Stage 2 - production of laminate:

  • After passing the quality control, the plate is cut to the desired dimensions.
  • The next stage is grinding and finishing the cut pieces.
  • Pressing is repeated again.
  • The penultimate stage is lamination.
  • And only after that milling is carried out - cutting locks for laminate.

As I have already noted, the technology of different manufacturers may differ slightly, but in general, everything happens just like that. Some manufacturers prefer to omit the first stage of production, purchasing ready-made fiberboard, and making a laminate from it, spending much less effort and time on it.

Equipment for the production of laminate

Of course, it makes no sense to describe all the equipment for the production of laminate included in the production line, because you will still be purchasing the entire kit. But it does not hurt to know its main machines. This is:

  • Laminate cutting machine
  • Laminating machine (hot press)
  • Milling machine
  • Packing machine

I must say right away that this is not all the equipment for the production of laminate, which is necessary for full-fledged work, but only the main one.

Laminate is a modern and popular material that is becoming more and more in demand in the decoration of any premises. But its choice on the market is simply huge, so it is often difficult to determine which company's laminate is better. The rating of manufacturers compiled by us will help you navigate a wide range, which offer brands from different countries.

Selection rules

Laminate is a material that, in addition to its attractive appearance, is also distinguished by many advantages that manifest itself during operation. We note the most popular characteristics that play an important role when choosing this finishing material:

  1. Durability. Perhaps this is the most main feature which interests every buyer. It should be noted that the products the best manufacturers can last up to 25 years. If we were to rank manufacturers on the basis of this particular characteristic, Quik Step laminate from Belgium would become the undisputed leader: the service life of the material of this company is 25 years.
  2. Panel thickness. This indicator directly affects the durability of products. consists of layers, which form the total thickness of the boards. It is clear that the stronger the coating, the longer it will last.
  3. Ease of installation. This factor plays an important role for those who plan with their own hands. Again, if you make your rating of manufacturers according to this parameter, Quik Step laminate will again be in the lead, since it is all based on patented locking systems.

Europe, Russia...

Today, the market presents products from manufacturers from different countries. She has received all sorts of reviews. At the same time, laminate from Russia and European countries is traditionally considered one of the best, however, about the material Chinese origin quite a lot of good reviews.

But the leader in the production of this finishing material is Germany. The products of the brands EGGER, Kronotex GmbH&Co, KronoFloring, Classen deservedly got into our rating of manufacturers. The laminate produced by them is of high quality. But more on that later. Note that among the advantages of German-made material, buyers note the variety of designs and a high level of moisture resistance.

Russian-made materials remain one of the most in demand, making a worthy competitor to Germany. The enterprises of our country today are equipped with all the necessary equipment, thanks to which it is possible to produce high-strength fiberboard. Baudorf, KRONOSPAN, Kronostar are the most popular Russian laminate manufacturers. The rating that we will give below also consists of the products of these brands.

... or China?

What do Chinese brands offer? It is believed that most products from the Middle Kingdom do not meet the requirements of standards. But in terms of laminate production, this country is still gradually regaining its position. So, basep brand laminate is produced here, the head office of which is located in the USA.

Note that this laminate meets the 33rd class of water resistance and has a thickness of 8 mm. At the same time, the products that Chinese laminate manufacturers are ready to offer meet all the necessary requirements.

The rating of quality materials can be safely compiled taking into account such brands as the above Basep or Kexin floor. The laminate of this brand is created taking into account both regional and international standards and is produced on the equipment of the highest quality. In any case, we can say that with a competent approach it is easy to find a material that meets the necessary requirements.

Rating of laminate manufacturing companies: an overview of customer demand

The analysis of customer reviews allowed us to create a rating, which includes entries from different countries. In the top five of the best and economical, in their opinion, you can safely include the following manufacturers. We will try to briefly characterize their products in passing.

First place - Kronostar (Russia)

Laminate of this brand can be bought at a price of 350 rubles per 1 sq. m. According to buyers, this is the most universal option for interior decoration of any purpose.

Its distinctive features include resistance to abrasion and moisture, as well as to heat. These floor coverings meet the requirements of environmental friendliness, as they are created exclusively from natural materials without the addition of any harmful components.

We put the products of this particular company in first place when we made a rating of manufacturers - the laminate of this brand pleasantly pleases with a number of advantages.

Second place - Kronotex GmbH&Co (Germany)

This offers to purchase a laminate at a price of approximately 480 rubles per 1 sq. m. It is believed that the material is ideal for finishing any premises, including bathrooms. The company offers a number of collections, about which buyers have a lot of good reviews:

  1. MAMMUT. Here you can appreciate the perfect and authentic material that has amazing decorative properties. Wide panels are made in noble shades that exactly repeat the texture of natural wood.
  2. EXQUISIT. This collection impresses with selected decors, which are characterized by symmetrical embossing and matt surface gloss, as well as the most natural texture. The highest surface quality and especially wide panels- that's what the best laminate manufacturers offer.
  3. The rating also allows you to evaluate the DYNAMIC collection. In it, the brand has collected unusual in design that can withstand heavy loads. The material is ideal for creating an individual look for any room.

Third place - Kronospan (Russia)

This brand offers to evaluate one of the cheapest materials, which, nevertheless, is ideal for finishing residential and non-residential premises. But despite the cost-effectiveness, we decided to include the products of this brand in the rating of laminate manufacturers in terms of quality.

These materials are ideal for decorating any premises, from the hallway and living rooms to rooms with high level humidity. For production, the company uses high-quality materials that are processed on its own equipment. Buyers say that the brand offers a wide selection of decorative and color solutions, although there are only four series of laminated coatings in the assortment:

  • Castello Dubrava (class 32 AC4);
  • Castello Click (class 32 AC4);
  • Kronofix+ (31AC3);
  • Comfort (class 31 AC3),

Fourth place - Classen (Germany)

The collections of laminated panels of this German brand delight with a variety of unusual decorative solutions. The modern brand focuses on the environmental friendliness of the raw materials used, the high level of design and the introduction of modern developments in the production. Thanks to all this, the final product is of the highest quality.

The cost of one square meter named laminate is 470 rubles.

Fifth place - KronoFloring (Germany)

This company did not get into the rating of the best laminate manufacturers by chance: it is she who offers non-standard solutions relating primarily to surface design. So, among all brands, this one attracts attention with a unique surface and structure of the laminate. As a result, they create a feeling of infinity of the pattern due to seamless transitions of decor and structure.

The best in the middle price segment

For this parameter, we decided to compile a separate rating of laminate manufacturers. Top Companies offer products designed for a variety of financial possibilities of buyers. The top three manufacturers of laminate flooring at average prices on the market include:

  1. Tarkett. The certified products of this European concern, according to buyers, are universal, that is, they can be used to decorate premises for various purposes. But, on the other hand, it is noted that in some collections material with chips comes across, and installation is not always a simple process. But due to the high quality of the material, the presence of a layer of kraft paper and the T-gloss locking system, the laminate still deserves the first place. The cost of one square meter of material is 600 rubles.
  2. Classen (Germany). For 550 rubles/sq. m you can buy a laminate of this brand. Buyers say it's perfect for finishing country houses and has a high level of resistance to various external influences.
  3. KronoFloring (Germany). We have already written about the products of this brand. We only note that you can buy a laminate for an average of 500 rubles per square meter. m of material.

Premium class: choosing the best laminate

The quality rating is an opportunity to competently approach the choice of finishing materials for your own home. We decided not to disregard the products of the elite class and offer our rating, which includes manufacturers of high quality laminate:

  1. Quik Step (Belgium). One square meter of material costs from 1000 rubles. In addition to strength, surface reliability and aesthetics, it is popular due to a special system for connecting elements without glue and ease of installation. Service life - about 25 years.
  2. Tarkett (European concern). A square meter of laminate costs 880 rubles. It is believed that the material is ideal for decorating living rooms, thanks to its unique design possibilities.
  3. Pergo (Sweden). Laminate of this brand can be purchased at a price of 830 rubles. for 1 sq. m. Moisture resistance, the presence of an antiseptic layer with silver ions, a special system of protection against scratches - distinctive features products.
  4. EGGER (Germany). The cost of one square meter of laminate - from 650 rubles. According to buyers, the brand offers the most soundproofing products, due to high-strength HDF boards at the base and a unique locking system.
  5. Balterio (Belgium). This material, according to buyers, is one of the most luxurious in terms of price, sophistication and style. The high quality of the surface is ensured by a special treatment of the top layer with the most precise observance of decorative effect.

We talked about products of medium and high quality. Of course, many buyers like premium laminate, but finishing too large rooms when choosing such products turns out to be too expensive. Therefore, for those who prefer to save money, it is better to evaluate the laminate at more affordable prices - it is offered by brands such as KRONOSTAR or Kronotex GmbH & Co.

In any case, when choosing, you should focus not on an affordable price, but on the quality of the coating so that it lasts as long as possible.

Laminate production - technologically difficult process, which requires the use special technologies and equipment, raw materials and supplies. The first attempts to make a floor covering that remotely resembles a 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 manufacture of building materials and installation work, so it was widely known in Europe.

The first laminate prototype had only two layers. 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, released 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 has used innovative technologies and equipment to produce a new generation of laminate flooring, so it has been able to create a flooring with good performance and high wear resistance. It was the Germans who first began to make a laminate consisting of 4 layers.

Today, companies are using similar technologies to produce laminate flooring. In short, the production process includes the following stages:

  • Production of HDF board.
  • impregnation upper layers.
  • Connection of all 4 layers under high-temperature influence.
  • Boarding process.
  • Sawing and milling laminated boards.

First, the creation of an HDF board is performed, which is a modified version of fiberboard with an increased density (more than 850 kg / m3). As the density of the plate increases, its main operational characteristics will also grow - strength indicators and resistance to moisture.

  1. As the main raw material for the production of the board, wood (often pine), peeled from the bark, is used. It is processed on special equipment to the state of wood chips. After that, the resulting chips are washed, thereby removing foreign particles (various contaminants), heated with steam in special containers up to 170-180 degrees, which makes it possible to soften the raw material. Heating leads to the fact that the chips become plastic, so they are then crushed into fibers.
  2. In the resulting mass of wood fibers, various components and binders (polymers, resins, etc.) are added. Next, the wood pulp is dried, removing almost all moisture from it.
  3. Then the dried wood pulp enters the conveyor, where it is leveled and pre-pressed, which allows to reduce the thickness of the layer and remove all the air. It is at this stage that the wood pulp becomes like a finished slab.
  4. Moving further along the conveyor, trimming is performed wood board in length and width to the given overall dimensions.
  5. Next, the finished fibreboards are cooled and stored.
  6. At the last stage, HDF boards are sanded and sized. Special machines make them as smooth as possible.

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

Upper layers impregnation

In the production of laminate, impregnation is the impregnation of the material with various resin compositions and liquid protective components. Different manufacturers use different formulations to impregnate the material. The strength and wear-resistant properties of the surface, including the service class, will depend on the recipe and technology used. During impregnation, 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 that specialize in the production of laminate flooring have long abandoned the impregnation of the top layers, because. they buy this part of the laminate ready-made from specialized companies.

Slab cladding

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

  • CML, RML.
  • ELESGO.

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

HPL and CPL technologies

Initially, only HPL technology was used for the production of laminate, which is presented in the form of a laminating process. This process involves bonding laminate layers using special adhesives. Gluing can occur in hot, warm, cold ways. Most often, the hot method of gluing has been used and is being used, because when using it, a sufficiently high quality of the connection of materials is obtained.

The process steps are as follows:

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

At the first stage, the decorative layer and the overlay are glued together. In the bonding process, top layers can be used both before and after impregnation. If the impregnation has already been carried out, then when connecting the layers by high-temperature pressing, adhesive compositions are not additionally added.

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

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

DPL, CML and PDL technologies

Most often, modern laminate manufacturers use DPL technology. When it is used, it is implied that all layers of the laminated panel are simultaneously pressed at high temperature. The most important thing is that this technology does not imply the use of adhesives, because the layers are preliminarily subjected to the process of impregnation with melamine resins, therefore, it is with their help that the surfaces are glued, because at a temperature of 200-250 degrees, the resin melts and connects the layers. After heating and curing, the melamine resin and 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 to improve the quality of the laminate to some level. This technology is a variation of DPL and is called CML (RML).

In recent years, PDL technology has become widespread, which involves the use of special equipment, with which it is possible to apply decorative pattern(e.g. 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 deal with the creation of a decorative layer and the use of paper / cardboard.

If the manufacturer uses ELESGO technology, then the manufacturing process implies a special way to create a top protective layer of the coating. The hardening of resin and other liquid components in this case occurs under the influence of an electron beam, while machines for pressing and high-temperature exposure are not used. Also, among the differences, one can single out the fact that when using this production method, acrylate resins are used, and not 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 at once, which were made from acrylate resins and corundum. This approach allows you to give the laminated floor sufficiently high strength characteristics, increased resistance to scratches and operational abrasion.

After connecting 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.

Further, the production of laminate takes place in a standard way: a temperature-active adhesive composition, after which all the main layers of the laminated panel are pressed together under the influence of high temperature and press.

The main advantage of using the ELESGO technology is that solvents are not used in the manufacturing process, which makes it possible to obtain products with the highest possible level of environmental friendliness. Acrylate resin compositions are antistatic, as transparent as possible, so the decorative layer obtained in this way has an excellent appearance.

Sawing and milling

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

As soon as the panels are cut, they are sent for milling, where the creation of a locking system of the laminated coating, cutting of spikes and grooves in the end part of the panel takes place. lock system from different manufacturers may have a different configuration - everything will depend on the technologies and solutions used.

After sawing and milling, many manufacturers additionally treat the boards with waterproof wax compounds to give the material moisture resistant characteristics. Only then does the cleanup take place. finished products, their packaging, warehousing and transportation to points of sale are carried out.

The manufacturing process of laminate flooring 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 durability of lock joints, endowing the boards with thermal and sound insulation characteristics, improving the resistance of the entire coating to liquids, etc.).
  • Improving the appearance of a laminated floor (using various design solutions, creating material structure, varying the shapes and sizes of finished products).

Every year the characteristics of the laminate are improving, so soon this particular type floor covering will become the most popular among private and corporate clients. As the quality of the panels improves, in a highly competitive environment, there is also a price reduction, so everyone can afford a modern laminate today.

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

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

Making a laminate - everything ingenious is simple

History of laminate

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

This company has been developing various materials for construction works and was quite popular throughout Europe. new material was called laminated plastic, which means laminated plastic.

The first development consisted of only two parts. From above, the material was processed with melamine resin, which helped to recreate the decorative layer, and from below, phenolic resins took part in the production.

Layers were connected at once in several ways. Impregnation with thermosetting 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 the German company Horniteks.

This firm has applied a completely new technological approach and equipment for the production of laminate of a new type and managed to create a laminated coating with unique properties. There were now four layers instead of two. Foil impregnated in phenolic and melamine resins was introduced into the composition.

In 1994, laminate flooring was in huge demand in the building materials market. Increased to a grandiose scale, sales volumes required the introduction of a body that controls the appropriate quality of products. This led to the creation of the Association of European Laminate Floor Manufacturers.

Laminate device

As mentioned above, the laminated coating consists of several layers.

I propose to consider in more detail the composition of this material, which is indicated in the figure:

  • The bottom layer of the coating is a moisture resistant paper. It is necessary, given the properties of wood to absorb various types of moisture in large 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 HDF board of high fiber density– 880 kg/m3
    It is the main load-bearing part of the laminate flooring and is designed to preserve the geometry and structure of the floor. This material is stronger than the wood itself;

Note: For the manufacture of HDF, roundwood is used, which is cleaned of bark.
After that, this material is processed into wood chips.
After sorting, coarse chips are used in the manufacture of chipboard, and HDF is produced from a finer fraction. The chipper can be seen in the picture.

  • The third coating layer is a film which is intended to provide additional protection from moisture of both the HDF board and the upper 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 It is designed to provide wear resistance and appearance for a long time. It is he who is processed from melamine resins.
    This process is called "lamination", which gave the coating its name. The top layer is homogeneous, and sometimes composite.

Benefits of laminate

  • Resistance to mechanical stress and wiping;
  • Ability to withstand various loads and deformations for a long time;
  • High-quality resistance to the abrasive action of the upper layer of the material;
  • The top layer of the material is easy to clean and remains resistant to chemical attack;
  • Does not burn out and does not belong to flammable;
  • It has excellent heat conduction and is easy to clean;
  • One of the cheapest flooring materials created using natural wood;
  • Easy to install, do-it-yourself installation is allowed.

The technological process of creating a laminate coating

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 main processes are practically the same.

Chip preparation

  • First, the chips go to the sink, where hot water garbage is washed away;
  • The second stage is steaming the chips with steam. This is done to obtain wood with the same moisture content. The steam heats the chips up to 100 degrees Celsius;
  • After that, the chips undergo a 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 that, the chips are sent for grinding to the desired fraction, which is carried out in a plant called a refiner. At the exit from it, resin is added to the resulting material and binders and paraffin, 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 the leveling of humidity. You can see one of the dryer options in the photo below;

primary production

  • Now the wood chips go directly to the production of components for laminate flooring. First, it is poured into the storage hopper, and then goes directly to the primary pressing plant.
    This installation forms plates that vaguely resemble required product. After a reduction of 5-6 times, air is completely removed from the chips, but it still looks rather 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 lowered to 190 degrees and the pressure of 40-120 MPa is applied to the plate.
  • The final stage of pressing is the alignment of the plate to the ideal, flat surface The press pressure applied here is 60-150 MPa. The process data can be seen in Figure 4.

Laminate production

At the final stages, the following operations are performed:

  • After checking the quality, the plate is sent for cutting. These manipulations are performed with a dividing saw. Basically, the output plate size is 2800*4140mm.
    Immediately after cutting, the plates 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 plate to the generally accepted size 2800*2070.
  • Then comes the pressing process, which is not done in the same way. Both full pressing of a laminate, and its separate parts is applied.
    These technologies depend on what the manufacturer's instructions prescribe.
  • The last process of manufacturing the panels is cutting and laminating them, after which the edges are milled, Figure 5.
    Modern interlock connections involve the use of several dozen different cutters. The accuracy of the settings depends on how high-quality locks the panels will be equipped with.

The technological process of manufacturing a laminate can be viewed on the video:

Laminate classification

Currently, the manufacture of laminated coatings is subject to strict rules and GOSTs. One way to control manufacturers is to classify the laminate.

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 operation. Class improvements correspond to increasing numbers.

Classes are divided into:

  • 21-22 - designed for flooring in residential areas with a low level of operation. These can be bedrooms and rooms with a low level of attendance. The price of such products is also very low;
  • 23 - fits in living rooms, halls, children's rooms. This type coatings can fully serve up to six years;
  • 31 - can fit both in small office space, and residential buildings. Moreover, when 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 bought for installation of floors in shops, large offices and places with high traffic.
    An excellent protective layer of this type is backed up by soundproofing, which can be used as.
    In the case of laying such a coating in residential premises, it will remain in excellent condition for many years.

External features of the laminate

The laminate has a very large color scheme(cm. ). It can imitate any of the available materials: wood, stone, sand. It is worth recognizing that in colors and shades dominated by colors under various breeds wood.

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

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

Laminate coating can differ not only in the palette of colors, but also in the structure. We can purchase material structured like wood, oil, stone. It can be matte or glossy.

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

Laminate can have one, two or three strips.

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

Laminate cleaning and care

Whatever class the selected coating corresponds to, whatever properties the manufacturers endow it with, improper cleaning and maintenance can significantly reduce the service life and nullify 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 behind the laminate 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 from dust settling, incorporated into the structure by manufacturers;
  • For regular, scheduled cleaning, it is enough to vacuum the laminate;
  • Dirt that has stuck to the floor is quite simply cleaned with a damp, well-wrung cloth, with a minimum addition of vinegar;
  • More stubborn stains can be removed with special means. After cleaning, the floor must be wiped with a damp cloth;
  • For a longer life of the top flooring, try not to use detergents that contain particulate matter;
  • When transporting furniture, lift it off the floor, dragging it can damage the coating;
  • Where possible, try to use floor protection materials on the legs of chairs and tables;
  • When cleaning with water or other solutions based on it, remember that moisture should not be absorbed into the floor;
  • When hit on the floor a large number moisture, it must be removed without wasting a minute.

Conclusion

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

8319 03/12/2019 6 min.

Laminate seems to many of our fellow citizens still a novelty, because this coating appeared on the Russian market only 10-15 years ago. Now it is the most requested. Today many Russian brands able to compete with the products of Western European countries. Most of the enterprises located on the territory of the Russian Federation work together with European manufacturers using foreign technologies. Often it is they who offer the most affordable products that meet foreign quality standards and requirements.

Manufacturers

Although laminate has been produced in Europe for a long time, the first Russian coating production was established only in 2003. Demand was small at first, but gradually increased. This was due to the large selection of ceramic tiles “ ” from different manufacturers. And by 2008, several enterprises began to operate in Russia at once, most of which were subsidiaries of well-known European brands.

When choosing, domestic consumers often prefer European brands. The Swedish company arbitrator was no exception. Employees of this company became the pioneers of flooring material, which in modern world considered one of the most reliable and durable materials. However, the production of laminate in Russia is also developing very actively.

Floor coverings produced by Russian companies are in serious competition with German ones. And although there are still few of them (less than a dozen), all brands of Russian laminate are in demand and find their admirers.

As a rule, Russian enterprises are equipped with high-quality German equipment, they import materials for the production of the base from abroad (high-strength fiberboard). The names of companies themselves contain, in whole or in part, the names of those corporations under whose auspices they produce their products.

  • Platinum laminate- also a variant of German products, which is produced on the territory of the Russian Federation and in China. The Platinum brand has gained popularity thanks to non-standard design solutions, especially for class 33 laminate.
  • Quick Step Laminate originally from Belgium, but now also produced in Russia. It has high quality and competitive price. The company offers 16 collections to Russian buyers.
  • Tarkett laminate- most famous brand, which, under the sonorous name of a German manufacturer, is manufactured in 28 countries.
  • Laminate Sinteros also produced under the auspices of the Tarkett company and is famous for its high quality. The production is completely carried out on German equipment and controlled by German specialists. It is to this trademark that the laminate of the 33rd class "Bogatyr" belongs.
  • Kronostar- manufactured on German equipment under the auspices of a Swiss company. This brand is an indicator of decent quality.
  • Laminate "Baikal" produced under the leadership of the German. Coating of class 33, which the company focuses on, has high technical performance.
  • Belfloor laminate- this, it is durable, diverse, safe for health.

In 2005, the first purely Russian company Technosila LLC, which began to produce products under the brand "Shelekhov laminate". However, they had to buy boards abroad, and the company could not compete with Western competitors in the economy segment, so they focused on the production of expensive 33-class laminate.

In 2008, another Russian enterprise was formed - OOO RBC-Laminat, which for the first time used domestic plates in production. Thanks to this, the price of the laminate was quite acceptable for the buyer. This company produces 32 grade laminate flooring in a low price segment. But she managed to get around Western competitors due to. Laminate with structural surface, imitating the skin of a snake or a crocodile, turned out to be in great demand by buyers.

Laminate Ritter- These are exclusive and unique coatings. Every collection deserves close attention. Ritter floors are produced in Russia, due to which the cost of the laminate is affordable, and the quality is good. The RBC trading and manufacturing enterprise that manufactures these plates even has its own scientific and technical laboratory.

Today the majority Russian manufacturers buy the basis for the manufacture of panels abroad. Own manufacturers are not yet able to provide blanks of decent quality. The difficulty is also in the fact that Russia has not developed a single quality standard that could be guided by, so we have to use European standards as examples. And they are as high as possible, so the price of co-production laminate is quite high. Those who are looking for the perfect flooring are recommended to get acquainted with vinyl.

Video review of the domestic laminate "Altai"

Varieties and characteristics

Laminate class and thickness are of paramount importance when choosing a flooring. All over the world they are divided into 7 main classes: 21, 22, 23 (household laminate), 31, 32, 33, 34 (commercial laminate). The higher the laminate class, the stronger, more durable and functional the floor.

The class is assigned to the produced coating according to the results of special tests, which establish wear resistance indicators. The product passes 18 different tests set by the European standard EN13329.

The general characteristics of a laminate of 21-23 classes include low wear resistance, and, consequently, short term services. It is worth mentioning right away that in Russia the laminate of this category is practically not represented either in production or on the market. Main disadvantage household laminate, unlike the commercial one, there is no special protection that protects against high humidity.

The most common in the domestic market is 32. The coating of this category ideally combines decorative and operational properties. Laminate class 32 is able to withstand heavy loads and is an excellent floor covering for school classes, office rooms, boutiques. Many reputable brands produce products of this class in Russia:

  • Kronospan;
  • Kronotex;
  • Quick step;
  • Tarkett.

The service life of this coating in commercial premises is 3-5 years, in everyday life - up to 15 years. Class 32 laminate is presented in bright colors, has a relief surface that completely imitates the structure of natural wood.

Advantages of domestic laminate:

  • huge assortment;
  • natural materials for production;
  • fast production, fast delivery;
  • acceptable cost;
  • resistance to changes in pressure, temperature and humidity;
  • hygienic and antistatic properties of products;
  • application of protective technologies for coating;
  • practicality, warranty service life;
  • ease of care;
  • security;
  • resistance to chemicals.

A modern and inexpensive alternative to the traditional flooring of the elite category is decorative parquet with imitation of artistic parquet. Piece parquet, laid out by the master in a unique spectacular pattern, is not in vain called “palace” - this design option has deep historical roots. But today, with the help of a high-quality and beautiful laminated floor, you can turn it into a palace and a modest country cottage, and even a city apartment.

Pricing policy and methods of purchase

  1. The cheapest among the listed brands are the coatings of the Kronostar company (from 280 rubles per sq. M).
  2. In second place in terms of affordability is Platinum brand laminate (from 330 rubles per sq. M.).
  3. Laminate "Sinteros" costs from 450 rubles. per metre. In the same price range is the coverage of the Tarkett brand.
  4. The cost of Quick Step panels is from 600 rubles per sq. m.
  5. a little more expensive laminate"Ritter" - from 700 rubles per sq.m.
  6. For comparison: the Swiss laminate "Pergo" costs about 1000 rubles per square meter. m.

You can buy laminated coatings in hardware stores. The second way is to order online on the websites of companies and stores.

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