What is laminate made of and an overview of production technologies. Technology for the production of laminated flooring The production line on which the laminate is manufactured

Laminate is a modern and popular material that is becoming increasingly in demand in the decoration of any premises. But the 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 the wide range offered by 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 themselves during operation. Let us note the most popular characteristics that play an important role when choosing this finishing material:

1. Durability. Perhaps this is the most important feature that interests every buyer. It should be noted that the products of the best manufacturers can last about 25 years. If we were to make a rating of manufacturers based on this particular characteristic, the laminate brand from Belgium Quik Step would become the undoubted leader: the service life of this company’s material is 25 years.
2. Panel thickness. This indicator directly affects the durability of products. consists of layers that form the overall 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 based on this parameter, Quik Step laminate will again be among the leaders, since it is all based on patented systems of locking elements.

Europe, Russia...

Today, the market offers products from manufacturers from different countries. She earned a variety of reviews. At the same time, laminate from Russia and European countries is traditionally considered one of the best, however, there are also quite a lot of good reviews about material of Chinese origin.

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

Russian-made materials remain among the most in demand, representing worthy competition to Germany. Enterprises in 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 present 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 the standards. But in terms of laminate production, this country is still gradually regaining its position. Thus, laminate of the Basep brand is produced here, the head office of which is located in the USA.

Note that this laminate meets water resistance class 33 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 brands such as the above-mentioned Basep or Kexin floor. Laminate of this brand is created taking into account both regional and international standards and is produced using the highest quality equipment. In any case, we can say that with a competent approach it is easy to find material that meets the necessary requirements.

Rating of laminate manufacturers: review of customer demand

Analysis of customer reviews allowed us to create a rating that included people from different countries. In their opinion, the following manufacturers can safely be included in the top five best and most economical. We will try to briefly characterize their products along the way.

First place - Kronostar (Russia)

Laminate flooring of this brand can be purchased at a price of 350 rubles per 1 sq. m. m. According to buyers, this is the most versatile option for finishing premises for any purpose.

Its distinctive features include resistance to abrasion and moisture, as well as heat. These floor coverings meet environmentally friendly requirements, 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 compiled the rating of manufacturers - the laminate of this brand pleasantly pleases with a number of advantages.

Second place - Kronotex GmbH&Co (Germany)

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

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

Third place - Kronospan (Russia)

This brand offers you 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 quality rating of laminate manufacturers.

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

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

Fourth place - Classen (Germany)

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

The cost of one square meter of the said laminate is 470 rubles.

Fifth place - KronoFloring (Germany)

It is no coincidence that this company was included in the ranking of the best laminate manufacturers: it is the company that offers non-standard solutions, primarily related to surface design. Thus, among all brands, this one attracts attention with its unique surface and laminate structure. They ultimately create a feeling of infinity of design due to seamless transitions of decor and structure.

The best in the mid-price segment

For this parameter, we decided to create a separate rating of laminate manufacturers. The best companies offer products designed for a wide range of financial capabilities of customers. The top three laminate manufacturers at market average prices 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 there are chipped materials, and installation is not always a simple process. But thanks to the high quality of the material, the presence of a layer with kraft paper and the T-gloss locking system, the laminate still deserves first place. The cost of one square meter of material is 600 rubles.
2. Classen (Germany). For 550 rubles/sq. m you can purchase laminate of this brand. Buyers say that it is ideal 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. Let us only note that you can buy laminate flooring for an average of 500 rubles per sq. m. 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 ignore luxury products and offer our rating, which includes high-quality laminate manufacturers:

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 its special system for connecting elements without glue and ease of installation. Service life is 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 due to its unique design capabilities.
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 scratch protection system are the distinctive features of the product.
4. EGGER (Germany). The cost of one square meter of laminate flooring is from 650 rubles. According to customers, the brand offers the most noise-insulating 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. High surface quality is ensured by special processing of the top layer with the most precise adherence to decorative effect.

We talked about medium and high quality products. Of course, many buyers like premium laminate, but finishing very 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 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 the affordable price, but on the quality of the coating, so that it lasts as long as possible.

There are a number of key points in laminate production technology; compliance with norms and rules allows you to achieve results in a short time. Laminate is produced in the form of thin sheets, their thickness is 7–11 mm, with dimensions of 1.0–1.4 m by 0.2 m. The products must be assembled by sequential connection using tenons and grooves provided along the edges.

Other types of flooring materials are also popular: parquet, carpet, linoleum, tiles. But laminated coating remains the leader due to its practicality and durability.

This is explained by the obvious advantages of laminate over other coatings:

• Its cost is significantly lower than that of parquet, carpet or tiles.
• The coating is superior to linoleum in moisture resistance, wear resistance and abrasion resistance.
• A huge selection of textures and colors attracts not only the end consumer, but also design specialists.

Classification

Laminate classes are divided into commercial 31–34 and household 21–23. Laminate flooring for home use lasts no more than five years, so wear-resistant and impact-resistant material for commercial use is increasingly being used in everyday life. They all differ in performance properties and price.

The classification of coatings is approved by the European Union Directive, samples are tested according to the following indicators:

• strength;
• abrasion resistance;
• soundproofing properties;
• moisture resistance.

The higher the class, the better the listed properties of the laminate. Laminate coating of class 32 is guaranteed to last 15–20 years, and class 31 – 10–15 years. In addition to classes, there is such a marking as AC. It indicates the wear resistance of the coating and varies from 3 to 6.

Features of Class 31

A similar product is chosen for apartment flooring. It is better to lay it in rooms where they will be used lightly.

Characteristic indicators:

• laminate thickness from 6 to 8 mm;
• surface smoothness;
• the need for an underlying layer during installation.

The installation of such material is suitable for installing a base in a bedroom or office, where household members spend a minimum of time.

Class 32 Secrets

This type of laminate is the most preferable option for apartment floors. The coating in a residential area will last about 15 years, and for an office the service life is three times less. Product Features:

• thickness is 7–12 mm;
• you must use a background for this class;
• resistance to cleaning agents;
• embossed, anti-slip coating;
• shockproof;
• There is a layer of wax to protect the joints from liquids.

The following classes are of even higher quality. It is important to understand for what purposes coverage is required: this will allow you not to overpay for unnecessary properties.

Technical characteristics of class 33

For heavy loads, it is worth choosing a similar laminate: its service life is 20 years, but there are other advantages:

• Durability, resistance to abrasion, temperature, sun, moisture.
• Good sound insulation allows you to avoid the need for a substrate.
• Suitable for special purpose premises equipped with many electrical appliances due to its antistatic properties.
• High quality locks for assembly.

The product is suitable for office premises, apartments of large families, and pet owners.

Advantages of class 34

Durable and durable appearance, suitable for public places, especially beneficial in sports halls. Sometimes this grade comes with a lifetime warranty and is 10-12mm thick.

Advantages of class 43

This is a new product on the building materials market and has proven itself in high-use areas. Only a few manufacturers make laminate flooring. Instead of fiberboard, polyvinyl chloride (PVC) is used to make this laminate. Advantages and features:

• actively used for kitchens, balconies, bathrooms and saunas;
• high flexibility and strength;
• Manufacturers guarantee 25 years of coating service life.

The use of an underlay prior to installation of this coating is not required.

Despite the long service life or high class of the product, you should use it carefully and wring out the cloth well before cleaning. If, when laying the laminate, it is impossible to install the panel due to an obstacle, then the craftsmen cut off the lock or part of it to secure the panel with special glue.

Manufacturing Equipment

To produce laminate, several units of equipment are required; the main machines and mechanisms of the master include the following units:

• multifunctional sawing machine;
• special hot press;
• milling apparatus;
• mechanical packer.

In addition to the main list, there are additional units of equipment: a loader, a drying chamber. The minimum set of technical equipment will cost 1.5 million rubles.

Production technology and its features

In Europe, in the 80s of the 20th century, they began to produce laminated flooring. Laminate is a simplified, generally accepted version of the name. Now the bulk of this material is produced in Europe. Launching a laminate production line is complicated by the characteristics of the raw materials.

There are 4 layers in the structure of the laminate, they make the product durable and wear-resistant. Improved performance characteristics are achieved by increasing layers, but the main 4 remain unchanged:

• The overlay or top layer serves to protect against the mechanical effects of operation, chemical influences, and sunlight.
• The decorative layer is a special paper or foil to imitate different structures of wood, tiles and other materials.
• The middle layer of the laminate consists of fiberboard and has good strength properties.
• The bottom layer is made of resin-impregnated or waxed paper; it protects the material from shock, abrasion and penetration of liquids.

The bottom layer is sometimes made of plastic; the total thickness of the top two layers ranges from 0.2 mm to 0.9 mm. The thickness of the bottom layer ranges from 0.1 to 0.8 mm.

There are five stages in laminate production technology:

• Production of high-density fiberboards.
• Saturation, impregnation of the surface of a product is a process called impregnation.
• Finishing the workpiece.
• Sawing
• Milling.
• Packing.

The laminated board is formed from HDF board (high-density fiberboard). There are several methods for producing laminate:

• HPL – using high pressure.
• CPL – conveyor production.
• DPL – direct pressing.
• CML or RML – continuous pressing of several layers.
• PDL – pattern printing technology.
• ELESGO is a method of drying the surface of an electron beam.

Differences in laminate production methods

With HPL technologies, materials are glued together using a cold, warm or hot method, this process is called lamination. Bonding at high temperatures allows for high quality, which is why hot lamination is often used.

Before gluing, the surface is cleaned of dust, after which glue and hardener are evenly applied. The two parts are passed through a press, gluing at a temperature of about two hundred degrees Celsius. After gluing the overlay with the decorative layer, they begin to connect this part with the base and bottom layer using glue.

The production of laminate using CPL technology is the connection of the base with the top layer through pressing. The layers are passed through rollers at high temperature. Craftsmen glue together several top layers and then press them onto an HDF board.

DPL is characterized by the absence of bonding. They take layers that have undergone the impregnation process and press them at a temperature of two hundred degrees. The resin contained in the products melts, gluing them together. After drying, a monolithic plane of the top layer of the laminate is formed.

With CML or RML methods, kraft paper is used to increase strength; this additive leads to a significant increase in the cost of the laminate.

A feature of PDL technology is decorative design, but the image is placed on a fiberboard. There is no need for additional layers of decor. Further production is carried out using DPL technology.

The top layer, consisting of paper with an image of two layers of overlay, is dried with an electron beam. ELESGO technology involves the use of acrylate resins for preliminary impregnation of the overlay. After hardening, a durable elastic film is obtained. The layers are joined with glue under pressure and at high temperature.

Is such production profitable?

Setting up laminate production is an expensive undertaking; total costs will exceed $800 thousand. In addition to the main production, it is necessary to engage in forestry and woodchip production. Such a complex enterprise is much more reliable, but the total costs will stop many businessmen.

Video: Laminate production

Among the many types of flooring, laminate occupies a leading place. This is due not only to its aesthetic appearance, but also to reliability, easy installation and other equally important characteristics.

Helpful information! Nowadays, the production of laminate has become so popular and in demand that it is displacing many positions of other once famous floor coverings, including natural flooring and parquet.

And all this because laminated coating has many advantages, including durability, easy installation and easy maintenance.

In addition, unlike natural flooring, laminated flooring is much cheaper and has an attractive appearance, so most consumers prefer it.

Laminate of high quality and performance is produced only with the help of modern equipment and under certain conditions.

Area of ​​use.

• Laminated coating can be used in almost any area of ​​construction, since in addition to additional positive qualities it has two most important qualities, namely durability and practicality:
• If a person decides to make repairs and get a new floor covering, he can choose any color or shade, regardless of the design and style of the room. This is due to the fact that laminate is produced in a wide variety of colors; choosing the right color for the room is not difficult, which cannot be said about parquet boards;
• Laminate flooring is perfect not only for residential premises, but also for public ones, including offices, trading floors, and shops. Most manufacturers produce this flooring, which is designed for heavy-traffic conditions. Most companies provide a guarantee for their products of 7 years or more;
• Laminate flooring is installed even in industrial buildings and sports facilities, since it has increased strength, and be sure to use a backing underneath the laminate. It consists of components that ensure reliability and strength, allowing it to withstand heavy loads, including work machines and training equipment.
• Thanks to such positive qualities, it becomes obvious that laminate is a more profitable and practical material, unlike parquet, which, in addition to its attractive appearance, cannot provide high strength to the floor covering, and therefore is not suitable for high-use conditions.

Background of flooring.

Laminate flooring became popular in Europe in the last century, namely in the mid-eighties. At that time, many manufacturers tried to get ahead of each other in the quality and strength of the material produced.

European manufacturers, even in our time, have managed to maintain their leadership among many laminate manufacturers in other countries of the world. They not only produce high-quality laminate flooring, but also use new technologies and modern equipment for its production.

Useful information! Although we cannot put aside other manufacturers who produce laminate of no worse quality. It’s just that their brand is not as popular and promoted as the brand of the European manufacturer. Today in China, Russia, and Ukraine, the production of laminated panels is established at a fairly high level.

Companies involved in the production of this material use new technologies that are constantly being improved, improving its quality and characteristics. In the building materials market, you can increasingly find new products in various colors that perfectly imitate marble, wood, granite or other intricate designs.

Many will be interested to know that today laminated coatings of various textures and interesting patterns are available. You can buy laminate with photo printing. For many rooms, you can choose a floor covering that will perfectly match the design of the room.

Many construction supermarkets can offer laminate flooring in a wide range and different colors.

Since the demand for laminate is only increasing, it is becoming more and more popular among consumers, there is a need to attract the attention of the Association of European Manufacturers, which monitors the quality of production of these products. In addition, the Association is the main and only developer of laminate standards.

What does the laminate structure consist of?

The laminated board has four layers, which consist of:

The top layer is coated with malamine or acrylic resins, which in turn reliably protect the panel from abrasion, scratches, impacts, squeezing and other mechanical loads.

The protective layer is followed by a decorative one. It imitates various patterns:

• Wood of any species;
• Ceramic tiles;
• Stone.

Then comes the base layer, which mainly consists of high-density ancient fiber board. It is this layer that plays an important role in the laminate, since it is responsible for:

• Required rigidity;
• Thermal insulation;
• Noise absorption.

The photo shows how the laminated panels move along the protractor, acquiring a completed look.

In the layer that plays the main role, there is a lock with which the panels are connected to each other.

The level of resistance to deformation of laminated elements under the influence of moisture depends on the moisture resistance and density of the boards.

The lowest layer is called stabilizing. It is responsible for protecting the panels from deformation and providing sufficient rigidity.

The durability of a flooring depends on its quality, and you usually have to pay for it. Therefore, one should not consider a laminate that is cheap to be attractive; most likely, it does not have the qualities that will ensure a long service life.

Some manufacturers of laminated panels improve their product by gluing a fifth layer to its bottom layer, a soundproofing substrate, which significantly improves the sound insulation quality of the floor covering.

Laminate classes.

The wear resistance class of laminated panels is determined by the thickness and strength of the layer coated with melamine resin.

There are two types of laminate, depending on the area of ​​its use. Thus, they distinguish:

• Commercial group;
• Household group.

In turn, the household group is divided into classes:

• There are 21 classes that are designed to withstand light loads. This laminate is used only in residential premises, that is, in offices, libraries, quiet bedrooms;
• They are distinguished by class 22, which is designed to withstand moderate loads. It is installed in reception areas, classrooms, small shops, large office spaces, etc.;
• Laminated panels of class 23 are laid in rooms where a floor covering is required that must withstand high loads. This could be kitchens, hallways.

The commercial group is also not unique and is divided into the following classes;

• class 31 is installed in public premises with light load. For example, in small rooms, conference rooms;
• Class 32 is more suitable for public spaces where the flooring must withstand moderate loads, i.e. reception areas, small shops, large offices, etc.;
• Class 33 laminate is installed in public spaces, restaurants, cinemas, large supermarkets, and gyms with high loads.
• The service life of a laminate of any class depends on how correctly it is used. If such a floor covering is installed correctly and then follows the care instructions according to the manufacturer's instructions, the laminate will last a very long time.

Floor covering production technology.

Nowadays, laminate is produced using a variety of technologies, including DPL, HPL, CPL, DPR. The basis for this flooring is chipboard, MDF, HDF.

Besides everything you need to remember, that the term lamination means the connection of all layers. It provides the manufactured material with high strength.

Below is a description of all the available and modern production technologies that many manufacturers use today to produce laminated boards.

Some may mistakenly think that the photo above is an image of skin, but this is not the case. In fact, this is a modern-made laminate.

DIRECTRARESSURELAMIATE technology

Today, the most famous technology in the production of laminate is DPL, to put it simply, this is how direct pressing laminated coating is produced. This method is used by approximately 90% of manufacturing enterprises.

The technology involves applying a surface protective layer to a layer of paper with a decorative pattern. Then comes the base layer. Next, a paper sheet of the stabilizing layer is placed under the slab, which forms the base.

Helpful information! For this type of slab, a fibreboard is used, which has a high density of HDF. The plate that will form the base is pre-polished to create the necessary conditions for high-quality gluing of all layers.

The result is a layered cake of a laminated board, which is then sent to the press. In this equipment, the process of sintering all layers under high pressure and temperature occurs. Sintering lasts no more than half a minute or a minute.

• When the paper is impregnated with melamine resin and heated, the layers adhere very firmly not only to each other, but also to the base. In order for the laminated sheet to have additional strength characteristics, in addition to melamine resin, aluminum oxide or, as it is also called, corundum, is introduced into the surface layer.
• Corundum provides the surface layer of the slab with high abrasion resistance. It is this quality that is of great importance when it is necessary to determine which class of wear resistance and load the plate belongs to.
• After the pressing process is completed, the laminated board looks like a solid monolith, which is difficult to destroy without damaging the product. The surface structure of the elements is given by embossing, that is, pressing, which is carried out using a mold.
• The surface structure of the laminated elements is given by a matrix located in the press. One matrix is ​​responsible for a certain structure on the surface, so in order to obtain elements of different structures, the matrices in the press can be replaced.

HIGHPARESSURELAMIATE technology.

HIGHPARESSURELAMIATE or HPL technology involves the production of flooring under high pressure. As a result of its use, particularly strong and reliable laminated elements are obtained.

The technology is carried out using pressing, which takes place in two stages. First, the top layer is formed, which includes:

• Decorative layer;
• Surface protective layer;
• One extra layer or multiple layers of kraft paper.

The result is a highly durable and thick layer. You might even think why other additional layers are needed if the thickness of the top layer is quite sufficient for the floor covering.

The prepared surface layer is glued to the base of the slab on top. Then, following the DPL technology, a stabilizing layer is placed underneath the main slab.

This technology is perfect for the manufacture of high-strength countertops and facing materials. It is used in shipbuilding, carriage building, etc.

When deciding to buy laminated panels made using DPL technology, you need to remember that such flooring material will cost a penny, since such production is very expensive and costly. It is very difficult to depict any embossing on elements.

CONTINUOUSPARESSURELAMIATE technology.

The production technology of CPL laminate is somewhat reminiscent of the production of panels using DPL technology. They differ only in that this production involves adding a couple of layers of craft paper under the decorating layer of paper.

The result is laminated coatings with increased resistance to impacts and mechanical damage.

DIRECTPRINT technology.

Unlike previous technologies, DPR production has its own peculiarity. It consists in the fact that the production of laminated coatings is carried out without a decorating layer. During the production of panels, decor is applied to a slab, which is heated and impregnated with special impregnations before applying the design.

Finished elements are packaged and separated directly on the conveyor.

This technology is popular because:

• Ideal for printing designs of any complexity on panels;
• You can save on panel production;
• Laminate flooring can be produced to individual order and in small batches.

It is important to remember that laminated panels must be maintained in the right conditions to maintain their original properties.

Let's summarize.

Laminate production is not as simple as it seems at first glance. This is a technology that consists of many stages that require a lot of attention and patience. Each manufacturer of laminate flooring independently decides which of the above technologies suits him best, and chooses the most optimal, practical and economical option.

The huge transnational corporation Beaulieu International Group includes a group that is rightfully considered one of the most important areas. This is a production complex producing laminated finishing materials under the Berry Allok brand.

The association of the Belgian Berry Floor plant and the Norwegian company Alloc has combined huge production capacities, a serious research base and accumulated experience. As a result, the production of parquet using the unique HPL (High Pressure laminate) technology has been launched. The principle is that the top layer is pressed first:

• Protective overlay;
• Decorative paper;
• Several layers of kraft paper.

The result is a layer whose characteristics significantly exceed those of conventional DPL (Direct Pressure Laminate). Accordingly, HPL coatings are of high quality and excellent inertness to various types of influences on the surface.

Main advantages:

1) Huge selection of designs - one of the largest sets of collections.

BerryAllok produce more than 18 lines of laminate of 32-34 wear resistance classes, each with up to 20 different decors: classic, modern, art nouveau, eclectic, chamfered and smooth, concrete, slate, standard parquet or marble.

The cross section of the laminate is from 8 to 11 mm. The range includes interesting solutions, such as:

• Narrow herringbone parquet with Best Loc® X-Treme locking system;
• Planks with integrated sound-diffusing PVC gasket;
• Long boards with infinity effect Extra-long Planks;
• Extra-wide slats for large rooms 2410x236 mm;

2) The best laminate performance in terms of wear resistance.

BerryAlloc guarantees:

• 10 years for commercial coatings. Applies to such indicators as resistance to abrasion and moisture, staining, fading;
• 30 years for floors used in residential areas.

3) Reliable lock.

• Aluminum Lock System - the famous aluminum Alloc lock used in the High-Tech series;
• Best Loc® X-Treme - three-variant connection for other products.

4) Easy to operate.

Laminate flooring is easy to keep clean using a vacuum cleaner or a damp soft cloth. No special cleaners or household chemicals are required.

5) Security for users.

Laminate Berry Allok is certified in accordance with:

• PEFC;
• DOP 170 DL3113 1 (Declaration of Performance).

It should be noted that according to the latest document, laminated parquet has been assigned the highest classes for such parameters as fire safety, antistatic, and anti-slip. There are certificates confirming the low level of emission of toxic substances (formaldehyde, pentachlorophenol).

• High price;
• You can often purchase a fake of unknown manufacture (without certificates and other documents).

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 type of material is this, its 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 developed various materials for construction work and was quite popular throughout Europe. The new material is called 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 the 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 flooring was in huge demand in the building materials market. 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 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 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 the production of chipboard, 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 could 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 main 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 produces slabs that vaguely resemble the 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

At the 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 joints require 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 wide range of colors (see). It can imitate any of the 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 its help, you can create a unique design, imitating various materials with minimal difference from the original.
• The two-strip coating does not have a chamfer, but is very similar to block parquet, with an 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 selected 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 its 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. To properly care for laminate flooring, it is enough to follow 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 and is easy to install and operate.