Product Information
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MANUFACTURING PROCESS
Wood Veneers are thin slices of wood made by cutting or slicing the log. But it includes a complex process of cutting, arranging (matching), polishing, and followed by many rigorous testing to achieve the best appearance and quality. We meticulously manufacture our veneers following a step by step process with utmost precision. The entire process is listed below.
SLICING
Selecting the best in wood is the first step towards creating the veneers the world has come to love. After the selection, the logs are sliced and processed into thin veneer flitches of required dimensions. We soften wood before cutting it into smooth veneers of even thickness. To achieve this, logs are soaked in water at a specific temperature depending upon their density. After that, the sheets are clipped along their edges and bundled together based on its group size.
Designs
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GRADING
The next step in creating exquisite veneer is to grade it. With immense care and effort veneer is graded and sorted, it is a means to segregate the lumber according to the overall quality, direction of grain, presence of knots and defects, as well as general appearance and also graded according to the market requirements. such an activity may be undertaken manually or, iby mechanized sorters.
Designs
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LAYON CREATION
After the grading of veneers is done, the most important process is to create layons. Layons are trimmed to a size which creates a straight edge. Depending on the grain pattern required, these veneer leaves are joined into a series of pairs, which are again joined into larger pairs, until the required width of the layon is created. This gives the veneer its beautiful appeal.
Designs
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SQUARING & SHEERING
When it comes to achieving excellence, we pay attention to the finest details. The layon which is joined to the required width is first trimmed at the ends. Once the correct length is achieved, a stitch is applied at the top and bottom to prevent splitting. The layon is then given one final check. If needed, repairs are carried out.
Designs
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PRESSING
MDF, or Kraft Backing, to name a few. This bonding is achieved with the help of hot and cold presses. Depending on the substrate, the duration and temperature is adjusted. Urea free, water-based adhesives are used to bond decorative veneers to the substrate. This lends strength and stability to the veneer.
Designs
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SHEERING & SANDING
One of the many things which set Wood Soul Veneers apart is the feel of it. To get the best out of the veneer, it needs to be sanded carefully and thoroughly. Sanding not only affects the polishing process, but also the appearance. After this, the sheets are sheered to cut off excess veneer, if arty. This gives the veneer its famous appeal, which Plymarc is known for.
Designs
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QUALITY CONTROL
Achieving quality is one thing. Consistently delivering on quality is another. Plymarc's world-class veneers are achieved by checking a variety of factors which affect the degree of checking in face veneers. These include veneer species, type, thickness and moisture content, as well as, type of core material and construction methods such as number of plies, adhesive, moisture and spread, assembly time, and pressing conditions. Only once every quality check is passed, it is prepared for packaging and dispatch.
Designs
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PACKING & DISPATCH
One of the final steps, yet one of the most important ones - extensive measures are taken to safeguard the veneers. Once manufactured, veneers are packed and dispatched properly, so that it does not get wet. Steps are also taken to protect panels against rapid moisture content changes and any mechanical damage during transport.
Designs
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VENEER CUTS
The appearance of veneer varies and it depends on how the log is cut. We mainly cut our venners accoding to these standardised cutting methods shown below.
QUARTER CUT
It uses the same cutting method as plain-sliced veneer, except the log is cut into quarters prior to slicing. This method bisects annual growth rings and results in a straight grain or ribbon-striped like Mahogany appearance. Due to low yield from the log, this veneer is usually more expensive. Walnut, Mahogany, Oak, and Teak are most often used for this cut.
Designs
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CROWN CUT
Tangential cuts along the growth rings produce crown cut veneers with a pattern that is characterised by straight grain intermixed with cathedrals. This cut retains the mother structure of timber. Crown cut veneers tend to have a strong grain pattern in their centre and a more linear effect at the edges.
Designs
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ROTARY CUT
It is manufactured by advancing a rotating log against a stationary knife. Since this cut follows the log's annual growth rings, a wide, bold grain pattern is produced. Rotary cut veneer is a cost-effective method to obtain remarkable effects from Birch, Maple, and Oak.
Designs
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RIFT CUT
Veneer obtained by fixing a quarter-Log on the stay log. This results in veneer with a striped grain or in the form of a half cathedral. This is mainly used in American woods. Rift cut method yields the Least amount of veneer and hence is the most expensive.
Designs
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MATCHING OF VENEERS
Once venners are cut, the veneer leaves are selected and matched. It is an important step in veneer manufacture. Each leaf is slightly different but related to adjacent leaves, so that different forms of matching can be achieved. The gradual change of grain through the log gives veneers their special quality of subtle variations. We use the following matching procees.
QUARTER CUT
It uses the same cutting method as plain-sliced veneer, except the log is cut into quarters prior to slicing. This method bisects annual growth rings and results in a straight grain or ribbon-striped like Mahogany appearance. Due to low yield from the log, this veneer is usually more expensive. Walnut, Mahogany, Oak, and Teak are most often used for this cut.
Designs
(Click to enlarge)
CROWN CUT
Tangential cuts along the growth rings produce crown cut veneers with a pattern that is characterised by straight grain intermixed with cathedrals. This cut retains the mother structure of timber. Crown cut veneers tend to have a strong grain pattern in their centre and a more linear effect at the edges.
Designs
(Click to enlarge)
ROTARY CUT
It is manufactured by advancing a rotating log against a stationary knife. Since this cut follows the log's annual growth rings, a wide, bold grain pattern is produced. Rotary cut veneer is a cost-effective method to obtain remarkable effects from Birch, Maple, and Oak.
Designs
(Click to enlarge)
RIFT CUT
Veneer obtained by fixing a quarter-Log on the stay log. This results in veneer with a striped grain or in the form of a half cathedral. This is mainly used in American woods. Rift cut method yields the Least amount of veneer and hence is the most expensive.
Designs
(Click to enlarge)
