The Production Process
Behind the apparent simplicity of high-pressure laminates lies a highly-evolved technology requiring powerful production facilities as well as a sizable investment in research and development.
The HPL production cycle is regulated by European legislation EN 438 and ISO 4586, which establish requirements and production standards. At Arpa Industriale, quality controls occur at every stage of the process: from the selection of raw materials to the paper impregnation, to thermo-lamination, up to the testing and classification of the finished surfaces.
Paper storage
Storage of decorative and kraft paper. Decor: coloured or decorated paper layer which confers the laminates their aesthetic appearance. Kraft: generally brown raw paper with exceptional resistance features that is used in the core of the high-pressure laminates.
Impregnation
To create a laminate, the kraft and the decor paper used must be impregnated with thermosetting resins and dried before they are pressed. The impregnated paper will give origin to the HPL sheet during the thermo-lamination process.
Impregnated paper storage
The impregnated kraft and decor papers are stored in appropriate and environmentally controlled rooms.
Assembly
The act of overlapping the impregnated kraft and decor papers.
Then they are ready to be put in a press for thermo-lamination.
High Pressure Lamination
Thermal lamination is the irreversible process which gives origin to HPL: the impregnated sheets of decorative and kraft paper undergo a simultaneous pressing and heating process at high temperatures.
The process provides the flowing of the thermosetting resins through the paper fibers and its subsequent curing to obtain a homogenous and non-porous material (> 1.35 g/cm³).
Multi-daylight Press:
Temperature 140°/150° C
Pressure > 7 MPa
Press Cycle 40/50 minutes
There is a quality control check at the end of the production process.
Trimming and sanding
Phase in which the edges of the pressed panel are refined. Also, the backside of the panel is lightly sanded to make it suitable for gluing to substrates.
Quality control and finished product storage
Quality control and classification of the finished product. The quality control is performed according to the EN438 norm. Thefinished high quality surfaces are then stored in the warehouses.
Packaging and shipment
Packaging and transportation are carried out in accordance with Arpa General Processing Recommendations. For transportation, HPL is classified as a non-hazardous product.
