Behind the Scenes of Manufacturing Hardwood Flooring - (and its Plywood Core)

At Redeemed Hardwood Flooring & Decking, we take pride in our partnerships with industry leaders who share our commitment to quality and sustainability. That's why we're honored to collaborate closely with Kayu Lapis Indonesia, a renowned name in the timber industry known for its ethical sourcing practices and exceptional craftsmanship. By partnering with KLI, we not only gain access to the finest quality hardwoods but also support their mission of promoting sustainable forestry and empowering local communities. Together, we are dedicated to delivering premium hardwood flooring that not only enhances the beauty of your space but also reflects our shared values of environmental responsibility and social impact.

In the port owned by Kayu Lapis Indonesia in Java, the arrival of sustainable logs from the lush rainforests of Borneo signals the beginning of a remarkable journey. Each log carries with it a tale of natural beauty and resilience, setting the stage for the meticulous craftsmanship that transforms them into coveted hardwood flooring. Let's delve into the intricate process of how we create hardwood flooring that embodies both quality and sustainability.

Sourcing Sustainable Materials

Before the transformation begins, the logs undergo a crucial step to ensure their pristine condition. Rolled into shallow water for days, the logs soak, harnessing the natural power of seawater to eliminate any lurking pests without the need for harmful pesticides. This eco-friendly approach not only preserves the integrity of the wood but also underscores our commitment to sustainability.

From Logs to Plywood

Once cleaned and prepared, the logs are cut into manageable pieces and stripped of their bark, akin to a meticulous grooming session.

Any stubborn remnants undergo a manual debarking process before the logs are fed into a peeling machine.

This giant contraption resembles a colossal pencil sharpener, deftly transforming the logs into uniform sheets while collecting the resulting wood shavings.

The peeled wood sheets then enter a vast drying chamber equipped with conveyor belts, resembling a supersized commercial pizza oven. This controlled drying process ensures optimal moisture levels, laying the foundation for the subsequent stages of production.

Stitching for Perfection

Despite the meticulous peeling process, imperfections such as holes or tears may still mar the wood sheets. Enter stitching – a precise technique that expertly patches and reinforces the plywood, ensuring uniformity and structural integrity.

Once stitched, the plywood is cut into standard-sized pieces and graded before being meticulously glued together.

Crafting Engineered Hardwood Flooring

For our hardwood flooring, we source top-quality hardwood veneers from Europe. Utilizing state-of-the-art wood-cutting machinery from Germany and Italy, the veneers are thinly sawn to size, ranging from 1mm to 6mm. There’s a distinction between sawing the hardwood vs slicing them, sawing the hardwood brings much more stability than slicing, since sawn woods will keep the grains intact and will provide good structural integrity.

The hardwood veneers are then expertly glued to the plywood core, marrying beauty with durability. Engineered hardwood offers superior stability and a soft underfoot feel compared to solid wood, making it an ideal choice for discerning homeowners.

Then, onto our hydraulic steam pressers, which exert immense pressure to fuse the layers of hardwood and plywood.

One note here... At our factory, sustainability is ingrained in every aspect of our operations. We harness the power of wood refuse and bark to sustainably power our production processes, eliminating the need for petroleum-based fuels.

Precision Molding and Quality Control

Following the pressing process, the engineered flooring undergoes meticulous molding to create the familiar tongue and groove profile.

Then a dedicated team of craftsmen meticulously inspects each plank, patching any knots with wood-friendly caulk to ensure a flawless finish.

The Art of Staining

With the structural integrity assured, the planks undergo the transformative process of staining. Apologies for the dimly lit room, for the UV light treatments are in process. The staining imparts rich, vibrant hues to the wood, accentuating its natural beauty. From light oaks to deep mahoganies, each plank emerges with its distinct character, ready to grace homes with timeless elegance.

Rigorous Quality Assurance

Before leaving our facility, each batch of hardwood flooring undergoes a battery of rigorous tests to ensure uncompromising quality. From humidity and burn tests to scratch resistance assessments, every plank is scrutinized to meet our exacting standards. A comprehensive test report accompanies each shipment, providing assurance of its superior performance and durability.

Representative Sample Boards

We’ve heard stories when a customer likes a certain color, only to find that the shipment was so different from the sample boards they saw. We make sure that you get to see the variation of colors, from light to dark.

Recognizing the importance of visualizing the end result, we take pride in curating sample boards that accurately represent the nuances of our hardwood flooring. Carefully selected from each batch, these sample boards showcase the full spectrum of colors and variations, empowering customers to make informed decisions with confidence.

Empowering Communities

Behind every plank of hardwood flooring lies a story of empowerment. Our mills in Indonesia employ over 6,000 dedicated individuals across three shifts, providing livelihoods and fostering thriving communities. Your support not only sustains our craftsmanship but also enriches the lives of those who bring our vision to life.

Conclusion

Crafting hardwood flooring is more than just a process – it's a labor of love and dedication to quality, sustainability, and community. From the rainforests of Borneo, temperate forest of Europe, to the floors of homes around the world, each plank embodies the natural beauty and timeless elegance of wood. We thank you for choosing our hardwood flooring and invite you to experience the unparalleled craftsmanship that sets us apart.

Last Words

We know how a flooring & decking project is a mammoth undertaking for you… and can be very expensive. But if you’re not in a rush, I encourage you to shop around. Then check us out. We're a Factory Direct Store, so our prices are cheaper than any other places. We import the woods ourselves, passing along the savings to you. And we have pro installers with 15+ years of experience, at your service. Should you have any further questions, please email us at hello@redeemedflooring.com.