Laminate manufacturing

Formica Group laminates used in both residential and commercial settings are primarily made from responsibly sourced natural fiber paper. Resin-impregnated kraft paper forms the core of Formica laminates and is combined with resin-impregnated decorative paper that imparts colour to the laminate. These are then pressed at high pressure and temperature to create today’s high-pressure laminate. This combination lends texture to the laminate, as well as its wear, impact and stain resistance, and ease of maintenance.

Laminate manufacturing process has two main stages:

1- Paper impregnation: The kraft paper that forms the core of the finished product is impregnated with resin which confers strength and rigidity. Once dried, the material is stored until it enters the HPL production process. Meanwhile, the decorative paper is impregnated with another type of resin to make the laminate durable.

2- Pressing: The treated papers are assembled and stacked between the steel plates of a large press. They are heated to 150°C and compressed under very high pressure for over an hour. The contact with the plate determines the laminate's finished texture. Once the material has been removed from the press and cooled, it is cut to the desired size and undergoes quality control.

Improving processes to achieve carbon neutrality by 2030

 In November 2022, Formica Group undertook an energy optimization project involving its presses. To this end, the company sought to reduce steam demand and a number of ineffeciencies in its plant's thermal power station operation by reducing heating requirements and optimizing controls. 

To this end, water collection tanks were added to store hot water used in the laminate thermosetting process for reuse in the next curing cycle. These water storage tanks keep more energy in the system and significantly reduce the demand for team from the boilers. Because the water that returns to the boilers for the next cycle is hotter, the energy required to produce steam is less.

Following a 10-month construction phase and a multi-million investment, press optimization has been ongoing at the plant since November 2023. The results have been excellent, with an estimated 12 % annual reduction in natural gas use.

Formica Canada is very proud of this optimization project that has enabled the company to take a further step towards achieving its sustainable development objectives.