How LVT Flooring Is Made From Raw Materials to Finished Planks
Understanding how LVT flooring is manufactured helps you evaluate product quality. The production process determines durability, appearance, and consistency. This guide walks through each step from raw materials to finished planks.
Raw Materials
LVT flooring starts with three main raw materials:
1. PVC resin: the base material that forms the core of the plank
2. Calcium carbonate: filler material that adds weight and stability
3. Plasticizers: additives that control flexibility
The quality of these raw materials determines the quality of the final product. Higher quality PVC resin produces better color consistency and mechanical properties. The ratio of PVC to calcium carbonate affects flexibility. More PVC means more flexible but more expensive. More calcium carbonate means stiffer but more brittle.
Other materials include:
- Stabilizers: prevent PVC degradation during processing
- Pigments: color the core layers
- Fiberglass layer: provides dimensional stability
- Print film: carries the wood or stone design
- Wear layer: clear protective coating
Mixing and Compounding
Raw materials are weighed and mixed in precise ratios. The mixture is heated in a high speed mixer. The heat causes the PVC to partially melt and coat the filler particles. This compound is then cooled and stored for the next step.
Calendering Process
The compound is fed into a calender. This machine has multiple heated rollers that squeeze the material into thin continuous sheets. Each set of rollers reduces the thickness further. The final thickness is controlled precisely.
For multi layer LVT, several calender lines produce different layers:
- Core layer: the thickest layer, provides body and stability
- Print layer: thin film carrying the design
- Wear layer: the clear top layer
Lamination
The calender layers are laminated together under heat and pressure. The print layer is placed on top of the core. The wear layer goes on top of the print. The fiberglass layer is embedded between core layers for dimensional stability.
The sandwich of materials passes through a heated laminating press. Heat fuses the layers together. Pressure ensures they bond completely without air pockets.
Embossing
For LVT with texture, an embossing roller presses the surface pattern. This creates the grain texture that matches the printed design. Registered embossing means the texture aligns with the print pattern. This is higher quality than random embossing.
Cooling and Cutting
The continuous sheet of LVT passes through cooling rollers. Temperature must be controlled carefully. Too fast cooling causes internal stress. Too slow cooling reduces production speed.
After cooling, the sheet is cut into individual planks. The cutting machine trims the edges and cuts the length. Dimensions are checked continuously.
Quality Control
QC checks during production include:
1. Thickness measurement at multiple points
2. Color and gloss measurement
3. Locking mechanism fit test
4. Squareness check
5. Visual inspection for surface defects
Samples from each production batch are tested for:
- Indentation resistance
- Wear layer thickness
- Flexibility and impact resistance
- Stain resistance
- Lightfastness
Packaging
Finished planks are stacked in correct orientation. Groups of planks are wrapped to prevent shifting during transport. Labels with product code, color, batch number, and quantity are applied.
Planks are packed into cartons. Cartons are palletized with stretch wrap. Each pallet is labeled for shipping.
About PROLEADER
PROLEADER manufactures LVT flooring using automated production lines with quality control at every stage. Contact us for factory tour information and product quality specifications.
