The manufacturing process of the decorative laminates involves many steps

starting from impregnating the paper to thermosetting to finishing.

The manufacturing process of decorative laminates involves the following steps:

Also Read: Advantages & Disadvantages of Laminates

Manufacturing Process of Decorative

Laminates
Step 1 – Impregnating the Paper:
01. The back of a laminate sheet is made of a type of Kraft paper that can be
saturated soggy and tearing

 A theatre drenches it with resin containing phenol (compound derived from

benzene)
 The resin does not merely coat the paper it is absorbed right through

Courtesy - Ian Collier

 Courtesy - Ian Collier

02. The top of the laminate is called the decorative layer. It’s a sheet of paper
in either a printed design or solid color.

The manufacturing process is different for both solid color paper and
Printed design layer as follows:
a) Solid Colour Paper:
 They go through a process that impregnates them with more durable melamine
resin.
 The durability is essential because the decorative layer must withstand wear
and tear.
 Two big rollers ring out the excess resin. The resin treatment makes the paper
stiff and brittle
 Courtesy - Ian Collier

Courtesy - Ian Collier

b) Printed Design Decorative Layer:

 Workers start by cutting them into sheets, the same length as the craft paper.
 These papers don’t go in to theatre to be saturated with resins instead they are
stacked by  placing an overlay on each one
 Overlay is a transparent sheet of paper that is saturated with melamine resin.

Courtesy - Ian Collier

Courtesy - Ian Collier

Step 2 – Drying:
The saturated paper now goes through a drying oven, where hot air dry’s the
resin in matter of seconds. With the resin now cured a cutter slices the paper
into sheets.

Courtesy - Ian Collier

Step 3 – Stacking:
Now a saturated Kraft paper is placed under each decorative layer .On top of
each decorative layer a textured plate is laid, this will prevent the finished
laminates from sticking together. The solid color paper is also stacked with
these sheet, they don’t need an over lay.

Step 4 – Thermosetting:
Everything now comes into a press.

The intense heat and pressure compress the layers.

Overlays bond to the printed papers and the saturated craft paper bonds to
each decorative layer creating laminate sheets. The textured plates between
each set meanwhile imprints their print on to the heat softened resin, texturing
the laminate surface.

Also Read:  Different Types of Laminates & Their Uses

Courtesy - Ian Collier

Step 5 – Finishing:
On finishing line machines trim of any excess paper on the edges and sand
the back of the sheets. This helps the laminate to adhere better to particle
board or other substance.
Courtesy - Ian Collier
Laminates are most commonly used surface finish for furniture elements, as
they provide decorative look in comparatively less price. They also enhance
the durability of the furniture as they are scratch resistant and easy to clean.
Due to availability of various types of laminates, commercial and corporate
offices, industries, restaurants, hotels, showrooms, etc. are also now
decorated by using laminates.

There are different types of laminates available in the market according to

their application. Here we have tried to provide the brief information on
different types of laminates, which a homeowner must know, before buying
laminates, for their house.

Also Read: Veneer vs Laminate: Make the Right Choice

 Courtesy - 123rf

The various types of laminates are as follows:

01. Types of Laminates Based on Pressure Applied:

(a) High Pressure Laminate (HPL):
 High pressure laminates are produced by attaching the décor paper at high
pressure to the kraft paper. They are commonly fixed by carpenters
 over plywood and MDF while making the furniture. High pressure laminates are
extremely durable and can take heavy loads.
(b) Low Pressure Laminate (LPL):
 In low pressure laminates, the decorative paper is soaked in melamine resin,
and the laminated paper is then directly bonded to particle board or fiber board
(MDF and HDF) at low pressure.
02. Types of Laminates Based on Thickness:
(a) Regular Laminate Sheets:
 The regular laminate sheets have a thickness that ranges from 0.8 mm to 1.5
mm. These sheets are glued by carpenters to substrate materials such as
plywood using common adhesives like Fevicol.
(b) Compact Laminate Sheets:
 Compact laminate sheets have a thickness ranging from 3 mm to 30 mm. These
laminates are self-supporting and hence do not need to be glued to woods or
any other material. The top and bottom sides of compact laminate sheets have
decorative surfaces.
03. Types of Laminates Based on Usage:
(a) Decorative Laminates:
 Decorative laminates are hard sheets of around 1 mm and are widely used to
give finished look to the furniture elements. They are commonly used to
decorate and protect wooden furniture. Decorative laminates are manufactured
in a wide variety of colours, designs and textures. They are generally used in
residential areas to create a decorative look of the house.
(b) Industrial Laminates:
 The industrial laminates have higher strength, higher resistance to scratches
and wear and tear and durable. They are also fire-resistant, antibacterial and
chemical resistant. They have wide application in industries and hospitals.
Circuit boards are made using industrial laminates.
Also Read: Manufacturing Process of Decorative Laminates
04. Types of Laminates Based on Surface Finish:
(a) Solid Colored Laminates:
 These are the most common laminate sheets. The whole laminate sheet is of
one solid color. It is generally used in bathroom vanity and kitchen countertop.
(b) Gloss Finished Laminates:
 There is a glossy finish to the décor paper, and can often make the furniture
look more eye catching and stand out with this type of finish. It is most
commonly used in restaurants, hotels, and in event industry.
(c) Matt Finished Laminates:
 This is a flat finish that gives “matt” effect on the surface of the laminate. It is
more commonly used in corporate areas like large professional business offices
where a subtle but stylish look of office is desired.
(d) Textured Laminates:
 Textured laminates are designed such that you can feel the pattern or texture,
which is printed on the décor paper. Generally natural materials such as wood,
natural stones, leather, metals, etc. They give realistic effect to the furniture.
They are most commonly used for wall cladding and flooring.
(e) Wood Grain Laminates:
 Wood grain laminates are designed in such a way that they give aesthetics like
real wood. They are extensively used for laminate wood flooring. Wood grain
laminates are available in various designs of hardwoods as well as softwoods.
(f) Metal Laminates:
 Metal laminates give metallic look to the surface of furniture. Metallic laminate is
ideal for commercial as well as residential purpose. It is used in offices,
corporate buildings, showrooms, etc.
(g) Leather Laminate Sheets:
 Leather laminate sheets give look of leather material. Leather laminate sheets
are used in cabinets and other furniture elements.
05. Types of Laminates Based on Advanced
Properties:
(a) Fire Rated Laminate:
Special fire resistant resin is used to make these laminates. Fire rated
laminate is commonly used for interior decoration in fire prone applications
like, industry, airports, hospitals, institutions & banks, kitchens, etc.

(b) Anti-Bacterial Laminate: 

In hospitals and restaurants where hygiene is most important, these laminates
are widely used. Antibacterial laminate resist growth of bacteria and
pathogens.

(c) Outdoor UV Laminates:

Outdoor UV laminates are used to make billboards.

(d) Electrostatic Dissipative Laminate:

Electro static dissipative laminates are commonly used in electronic assembly,
dust-free environments for manufacturing of circuit boards and other work
areas like hospitals, medical offices and laboratories.
Advantages/Pros:
01. It is easy to clean.
02. It is easier to install than many traditional surfaces.
03. It is more economical and requires less skill to install.
04. It is available in numerous designs, patterns, colours and textures and
hence it is pleasing.
05. It is very durable, hygienic and relatively easy to maintain.
06. No polishing painting is required.
07. It is the best choice for heavy use environments.
08. It can be installed over almost any existing floor.
09. It is moisture resistant. Also, it is an impact, shock and pressure
resistant.
10. Sweeping or vacuuming is typical, all it takes to get laminate clean.
11. It is highly resistant to scratch and abrasion.
12. Availability of huge range leads to least wastage.
Disadvantages/Cons:
01. While it can follow the look of a veneer, laminate flooring does not
come close to the feel of those textures of a veneer. No matter how high in
quality, it cannot simulate the feel of real wood under your feet.
02. It is known to be toxic as it is known to release formaldehyde, the
volatile organic compounds.
03. Once the top layer has been worn through, the whole floor must be
replaced.
04. It is difficult to be recycled.
05. It is a brittle material hence is prone to clipping.
06. Laminate flooring has been very slippery, and affecting your safety.

Laminated Particle Board:

Laminated particle board is manufactured by attaching a thin layer
of laminates on the surface of plain particle board. The lamination enhances
beauty and increases durability of particle board. Laminated particle board is
widely used to make modular kitchen, as well as wardrobes and shelves,
particularly shutters, as it avoids subsequent polishing and painting.
Also Read: Different Types of Laminates & Their Uses

Courtesy - Plymax
Veneered Particle Board:
Veneers are a very thin slice of wood which is obtained from a tree log.
Veneered particle board is manufactured by attaching veneer on the top
surface of the plain particle board. Veneered particle boards have more
resistance to warping, as they are properly sealed. They provide the
aesthetics of a natural wood in low budget cost.
Also Read: Different Types of Wood Veneer & Their Uses

Cement Bonded Particle Board:

As the name implies, this board uses cement as a bonding agent and has
high resistant to moisture, fire and rot. Cement bonded particle board is
manufactured using cement (60%), wood waste particulate like wood chips,
sawdust, wooden shavings (20%) and water (20%). Due to cement content,
these boards are more durable, fire-resistant and termite resistant. The
cement bonded particle board has high expansion and shrinkage properties in
presence of moisture. They are generally used in the production of fire
resistant furniture, false ceiling, internal and external walls and permanent
shuttering for concrete floors and walls.

Melamine Particle Board:

A sheet of melamine-impregnated decor paper is attached on the top surface
of the plain particle board under heat and pressure. Also, melamine-urea
formaldehyde resin is used along with wax emulsion to bond the particle
board and make it water resistant. Melamine particle boards are very durable
and have resistant to scratches. They have application in various fields such
as wall claddings, wall paneling, modular kitchen, wardrobes, and office
furniture. They are available in various colours and textures to impart
decorative look to the interior of your house.
What is Medium Density Fibreboard (MDF)?
An engineered composite wood product made from residues of hardwood and softwood
gluing together with wax and resin under extreme pressure and pressure is called Medium
Density Fibreboard or MDF wood.

Types of MDF
Different kinds of MDF are found which may be labeled by color. Followings are the main
type of MDF board:
  Ultra-light MDF plate (ULDF)
 Typically green MDF those are moisture resistant
 Typically red or blue MDF which is fire retardant

ollowings are the uses of Medium Density Fiberboard (MDF):

 Mainly used for furniture making.

 For making kitchen cabinets, molding or in the bathroom environment.
 As an exterior cladding for housing has successfully been used.

Properties of MDF
In the past, the raw material was wheat for MDF in complete equipped pilot plants. For the
manufacture of higher quality MDF binders are used. Chemicals like Urea melamine
formaldehyde, Urea melamine formaldehyde adhesive mixture is used as a binder. Different
quality MDF production needed different quantities of resin and different qualities of wheat
straw, produced MDF was called Straw Medium Density Fibreboard (SMDF).
The properties analyzed of MDF are:

 Internal bond strength

 Modulus of rupture
 Modulus of elasticity
 Thickness
 Elasticity
 Water absorption
 Swelling

Blockboard is one type of engineered compound plywood board where softwood strips are
joined edge to edge and bonded together machining often a sandwich structure placing
hardwood between them. Block board is usually found in different sizes and thickness. 2440
x 1220 x 30mm is the normal size of block board.

Technical Properties of Blockboards

 Modulus of elasticity long
 Density
 Bending strength
 Bending strength cross
 Formaldehyde emission
 Modulus of elasticity cross
 Fire safety category
 Thickness tolerance
  Length and width tolerance

Types of Blockboards
The classification of block boards depend on different properties such as quality, use, raw
wood used for the core. Followings are the type of blockboard:

A. Depending on quaity and use:

1. Interior Grade Blockboard
2. Exterior Grade Blockboard
B. Depending on the raw wood used in the core:
1. Softwood Blockboard
2. Hardwood Blockboard

Different aspects of these types are briefly discussed below:

Interior Grade Blockboard

These grades are made for indoor uses which are resistant to moisture and called MR
(Moisture Resistant) eg. Furniture, door, window shutter.

Exterior Grade Blockboard

This variety of blockboard is manufactured for outdoor uses. These are called BWP (Boiling
Water Proof) or as BWR (Boiling Water Resistant). This high quality of resistance is
because of the adhesives used here are also good in quality.

Softwood Block board

Solid blocks of wood are used to make each blockboard sheet those are attached together
using glue. The sheets are called strips or battens. The surface is covered with hardwood
veneers.

Hardwood Block board

Hardwood is dense, heavy, costly, strong as the core is made from hard sheets. The
coating is also by hardwood.

Blockboard is a kind of engineered compound plywood board. It is used for various

purposes.Followings are the main uses of blockboard.

 For shelving such as long book sheve , worktops as heavier structure.

 For furniture making such as table, bench,bed etc.
 For window, door shutter,flush door.
  Block board does not slag in the middle or does not bend easily, so it is a choice for
carpenters.
 For making wall furniture.
 For wall panels, partition.

Types of LaminatePreferred areasMatt Finish LaminateCorporate and Business offices, Living

Room , Bedroom etc. for subtle and stylish lookGlossy Finish LaminateClubs, event Industry,
Showrooms, Kitchen etc.
It gives glossy effect to furniture and it’s also very easy to clean.

Metallic Finish LaminateCommercials and showroomsTextured Finish LaminateLiving Room ,

Decorative Units, Corporate , Business offices etc. for subtle and classy lookSolid Color
LaminateKitchen Counter taps, Bathroom Areas, Bedroom etc.Unicore LaminateKitchen ,
Bedroom, Commercials and water prone areas etc. as it has a single core they are good water
restive.
There are different types of laminated sheets available in India based on the
manufacturing process, usage, surface finish, thickness, and advanced properties.

Laminates based on manufacturing process:

High-Pressure Laminate (HPL):

The layer of the laminate adheres to substrate under pressures of 70 to 100 bars at
temperatures of 280° to 320° Fahrenheit using adhesives. The laminates are available
in thickness 0.8 mm, 1.0 mm and 1.5 mm in standard sizes 1.2 m x 2.5 m.  These
laminates are most durable, flame retardant, and consists high level of resistance to
heat and chemicals.

Low-Pressure Laminate (LPL):

The layer of the laminate adheres to substrate under pressures of 20 to 30 bars at

temperatures of 335° to 375° Fahrenheit without using adhesives. These laminates
are less durable, thinner than HPL, flame retardant, resistant to heat and chemicals and
comparatively very cheaper than HPL.

Laminates based on Usage:

Decorative Laminates:
These laminates are mainly used as furniture surface materials and commonly used to
protect the wooden surfaces. They are available both in low pressure and high-
pressure laminates and used for decorating walls, home interiors, etc. to provide
an attractive appearance.

Industrial Laminates:

These laminates are specially made for industrial uses, which are very durable
and high resistant to wear and tear. They are mainly used for electrical insulation
purposes like in circuit boards.

Laminates based on thickness:

Compact Laminates: These laminates consist of thickness ranging from 3 mm to 30

mm, which are self-supporting and need not be glued to any other material.
Regular laminates: These laminates consist of thickness ranging from 0.6 mm to 1.5
mm, and these sheets are glued together using adhesives like fevicol by carpenters to
substrate materials like plywood.

Laminates based on advanced properties:

Fire retardant laminate: These laminates are specially made for fire-prone areas by

using fire resistant resin. It is used for decoration in fire-prone applications like
kitchens, industries, airports, hospitals, public buildings, institutions, store fixtures, etc.

Electrostatic Dissipative laminate: These laminates are made with the unique

feature of low electrical resistance and mainly used in the electrical assembly for
manufacturing circuit boards. These provide a surface that will not attract dust or dirt
particles and ideal for work-stations, hospitals, and medical laboratories.

Anti-Bacterial laminate: These laminates are made

with antifungal and antibacterial properties, which can resist the growth of bacteria
and pathogens. These are used in hospitals, bathrooms, day care centers, etc. where
hygiene is very important.

Magnetic Laminate: It is an innovative laminate, which has a unique property

of holding a magnet. These are high-pressure decorative laminates used in
educational institutions, offices, hospitals, etc. for holding reports, charts, photographs,
etc.

Laminates based on Surface finish:

Glossy finished laminate: It creates a glossy effect on the laminate surface and also
creates print on it, can make the furniture look more eye-catching and attractive than
other finishes. These laminates are used in the event industry, restaurants, hotels, and
in clubs.

Matt finished laminate: It creates matt like finish, which gives a flat finish on the
laminate surface. These are used in corporate and business offices, where a subtle but
a stylish look is desired.

Metallic finished laminate: As the name itself says that it gives a metallic look to the
laminate surface. These laminates are durable and used in commercial buildings and
showrooms.

Texture finished laminate: These laminates are designed in such a way, where you
can feel the texture or pattern printed on the decor paper. These are used in flooring,
wall cladding, where a subtle and classy look is required.

Solid Colored laminate: These types of laminates are printed with one solid

color without any print or patterns on it. These are most common laminate sheets and
mainly used in kitchen countertops and bathroom areas.

Digital laminate: These are customized printed laminated sheets used in interiors for

the artistic view.

Wood Grain Laminate: These laminates are designed in such a way that they look
like real wood and extensively used in wooden floorings. They are made of both
softwood and hardwood.

Leather laminate: These laminates sheets give a leather material look and are used
in cabinets and other furniture elements.