How Is SPC Flooring Made: Manufacturing Process 2023
Understanding how SPC flooring is made helps you evaluate quality when choosing a manufacturer. The production process involves several precise steps that determine the final quality of the product.
Raw Materials
SPC flooring starts with three main raw materials. Limestone powder makes up about 60 to 70 percent of the core. PVC resin makes up about 20 to 30 percent. Stabilizers and additives make up the remaining 5 to 10 percent. The quality of these raw materials directly affects the final product quality. High-quality SPC uses virgin PVC and fine limestone powder. Low-quality SPC uses recycled PVC which reduces stability.
Step 1: Mixing the Core Material
The limestone powder and PVC resin are mixed in precise proportions. Stabilizers are added to prevent UV degradation. Plasticizers are added for flexibility. The mixture is heated and blended in a high-speed mixer until it reaches a consistent texture. This step is critical for core quality.
Step 2: Extrusion
The mixed material is fed into a twin-screw extruder. The extruder heats the material to about 180 degrees Celsius and forces it through a die to create a continuous sheet. The thickness is controlled precisely. The sheet passes through rollers to achieve the exact thickness and width. Cooling rollers then bring the temperature down.
Step 3: Applying the Design Layer
A high-resolution printed film is applied to the top of the core. This film gives SPC flooring its wood or stone appearance. The film is protected by a transparent wear layer on top. The wear layer thickness ranges from 0.3mm for residential use to 1.0mm for heavy commercial use. The design layer and wear layer are fused to the core using heat and pressure in a lamination press.
Step 4: Embossing
Some SPC flooring receives an embossed texture. EIR (Embossed in Register) technology aligns the texture pattern with the printed design. This creates a realistic wood grain feel that matches the visual pattern. The embossing is applied using heated rollers with the texture pattern engraved on them.
Step 5: Cutting and Profiling
The laminated sheet is cut into individual planks at precise dimensions. Standard widths range from 5 to 9 inches. Standard lengths range from 36 to 72 inches. The edges are profiled to create the click-lock system. The tongue and groove shapes are milled with precision tools. A properly profiled edge is essential for easy installation and tight seams.
Step 6: Beveling
Planks may receive a micro-bevel on all four edges or just the long edges. The bevel creates a more realistic floor appearance by emphasizing each individual plank. The depth and angle of the bevel are precisely controlled.
Step 7: Quality Control
Each batch is tested for thickness tolerance, dimensional accuracy, locking mechanism strength, wear layer thickness, color consistency, and formaldehyde emissions. QC checks happen throughout production. Final inspection is done before packaging.
Step 8: Packaging
Planks are packed in bundles of 5 to 10 planks. Each bundle is wrapped in protective plastic. The bundles are packed into cartons with product labels. Cartons are loaded onto pallets for container loading. Good packaging is essential for protecting the product during ocean freight.
About PROLEADER
PROLEADER operates modern SPC production lines in China and Vietnam. We invite buyers to visit our factories and see the process firsthand. Contact us to schedule a factory tour.
