Are you curious about what makes SPC flooring so robust and popular? Understanding its creation unveils the secrets behind its incredible durability and waterproof nature.
SPC flooring is primarily made by blending natural limestone powder and PVC stabilizers to create a rigid core. This core is then layered with a printed design, a protective wear layer, and a backing. Each layer is compressed under heat and pressure, forming a highly stable, waterproof, and dent-resistant floor suitable for various spaces.
I often get asked about the manufacturing process of SPC flooring1. Many buyers, like Aiden and Lori, focus on the final product. But knowing how it is made helps you understand its quality. It also shows what makes it a superior choice for your customers. Let me walk you through it. This process is a sophisticated blend of material science and engineering. It results in a flooring solution suitable for both residential and commercial spaces.
What are the primary raw materials of SPC flooring?
Do you ever wonder what gives SPC flooring its incredible strength? The foundation of any good SPC floor lies in its core ingredients.
The main raw materials for SPC flooring2 include natural limestone powder (calcium carbonate), PVC resin powder, plasticizers (like DOTP), and stabilizers (like Ca/Zn). Other components include stearine, pulverizing material, PE wax, carbon black, and processing aids like ACR or CPE. These parts are carefully combined. They form the dense, waterproof, and stable core layer. This core sets SPC apart from other flooring types.
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|---|---|---|---|---|---|---|
| Limestone Powder | Provides rigidity, density, and impact resistance. | Forms the stable, unyielding core. | ||||
| PVC Resin Powder | Acts as a binder, adds flexibility and resilience. | Binds other components, ensures waterproof properties. | ||||
| DOTP (Plasticizer) | Makes the core flexible and workable, easy to shape. | Prevents brittleness, allows for bending and handling. | ||||
| Stabilizer (Ca/Zn) | Maintains chemical balance, prevents degradation from heat/light. | Ensures product quality stability over time. | ||||
| Carbon Black | Pigment for color consistency, enhances stability. | Provides base color, resists fading. | ||||
| Stearine, PE Wax | Lubricants and processing aids. | Facilitates smooth manufacturing, prevents sticking. | ||||
| ACR / CPE | Improves impact strength and processability. | Enhances durability and ease of production. |
As a manufacturer at CloudsFlooring, I know raw material quality is everything. When Aiden in the UK asks about quality, I emphasize this first step. We start with high-grade natural limestone powder. This is primarily calcium carbonate. It usually makes up about 72% of our core. It gives the board its rigidity and stability. This material greatly enhances the flooring’s density and resistance to impact.
Next, we use PVC resin powder. This is a non-toxic, odorless white powder. It generally makes up about 24% of the core. It has high chemical stability and good plasticity. PVC is the most widely used polymer in the world. It acts as the main binder.
However, pure PVC is actually unstable. We must add appropriate stabilizers and other additives to make it work. We then add plasticizers, like DOTP. This is a colorless, low-viscosity liquid. PVC itself is a hard material. Adding a plasticizer makes the final product soft and flexible. It makes it easy to bend, fold, and shape. This is important for handling and installation.
Stabilizers, such as Calcium/Zinc compounds, are also vital. They slow down reactions and maintain chemical balance. They prevent light, thermal decomposition, or oxidation reactions. This promotes overall product quality stability. We also use carbon black. This acts as a pigment. It provides the strongest tinting power and hiding power. It is a very stable pigment. It resists heat, chemicals, and light.
Other materials like stearine, pulverizing material, PE wax, ACR, and CPE are used as processing aids. They ensure a smooth manufacturing process. The initial steps involve careful preparation:
- Material Feeding: Raw materials are put into the mixer according to our precise formula. Other processing aids are measured separately and mixed together. They are then put into a feeding station, where a vacuum feeder sucks them into a feeding tank.
- High-Speed Mixing: We use the principle of friction heating to mix the raw materials at high speed. The temperature is raised to 125℃ to 130℃. This melts the processing aids and removes water vapor from the raw materials, ensuring they meet usage requirements.
- Rapid Cooling: After high-speed mixing, rapid cooling takes place. This prevents premature plasticization or volatilization decomposition of processing aids.
- Controlled Feeding: The materials discharged from the cold pot are fed into the screw barrel by a screw feeder at a constant speed. We use double-screw feeding to maintain stability in the feeding process, preventing issues from the feeder starting and stopping.
Each manufacturer\’s formula is slightly different based on desired product characteristics. However, these core components are always present. We maintain strict supplier relationships to ensure consistency. This prevents issues like core brittleness or inconsistent density. Such issues could lead to problems down the line for our distributors. It ensures the product you receive will always meet the promised specifications. Our quality control team inspects every batch of raw materials before they enter our production lines. This strict process gives our customers, like Lori, the confidence they need in our product consistency.
What is the manufacturing process of stone plastic composite (SPC)?
Are you curious about the transformation of raw materials into durable SPC flooring? The journey from powder to plank involves precise and intricate steps.
SPC flooring\’s core, decorative film, and wear layer bond during extrusion and calendering using heat and pressure. This creates a strong, seamless unit. Later, underlayment can be added. This integrated process ensures a durable, single plank, preventing delamination and enhancing overall product integrity.
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| 1. Mixing Materials | High-Speed Mixer, Internal Mixer | Homogeneous blend of raw materials. | ||||
| 2. Extrusion & Layering | Extruder, Calendering System | Forms dense SPC core, integrates decor/wear layers. | ||||
| 3. UV Coating | UV Coating Line, Oven | Adds protective, glossy/matte finish to continuous sheet. | ||||
| 4. Annealing | Annealing Line, Cooling Tank | Enhances dimensional stability of continuous sheet. | ||||
| 5. Traction | Tractor | Pulls continuous material strap. | ||||
| 6. Shearing | Shearing Machine | Cross-cuts material strap into planks. | ||||
| 7. Automatic Stacking | Automatic Platen Machine | Stacks cut planks for next steps. | ||||
| 8. Grooving | Grooving Line | Prepares edges for profiling. | ||||
| 9. Profiling | HOMAG Profiling Line | Cuts precise click-lock edges. | ||||
| 10. Painted V Groove | Painting Machine | Adds realistic wood grain texture (optional). | ||||
| 11. Applying Silent Mats | Lamination Machine | Attaches underlayment for sound/comfort (optional). | ||||
| 12. Quality Control | Various Inspection Tools | Ensures product meets standards, checks for defects. | ||||
| 13. Packaging | Packaging Machine | Prepares finished product for shipment. | ||||
| 14. Loading for Shipping | Forklifts, Loading Dock | Efficient transportation to distributors. |
From our factory in China, we follow a rigorous process. We use specialized equipment for each stage. The first major step is mixing the materials. We put the PVC resin powder, plasticizer, stabilizer, and carbon black into a high-speed mixer. We follow our precise formula ratio. The machine automatically adds the plasticizer.
After these are initially blended, we add the limestone powder. The mixture stirs for about 30 minutes. This creates a homogeneous compound. We send this evenly mixed mixture to a conveyor belt. It then enters an internal mixer for further heating and mixing. This ensures all components are fully integrated and ready for the next phase. During this mixing, friction raises the temperature to 125℃ to 130℃. This melts processing aids and removes water vapor from the raw materials, ensuring they are ready for use. Rapid cooling then follows to prevent premature plasticizing or decomposition of processing aids. The cooled mixture is fed into the screw barrel using a double-screw feeder, ensuring a stable feed rate.
Next, we move to the extrusion system. After entering the screw barrel, the materials are plasticized by heated rolling. This is where precision temperature control is vital:
- Temperature Zones: Our SPC floor production line uses five temperature zones. Settings gradually decrease from Zone 1 (190℃ to 220℃) down to Zone 5.
- Heating Control: Zone 1 and Zone 2 use heating coils. Other zones use cast aluminum heating coils paired with radiator fans for temperature control.
- Software Control: A temperature control module with a relay board manages heating or heat dissipation. It combines with high-precision thermocouples for exact temperature measurement.
After plasticization, the materials are extruded and pushed to the tooling by strong back pressure. The tooling size is determined by product specifications. The material strap then comes out of the tooling opening and enters the five-roller calendering system. This is where layering and embossing happen:
- Initial Rolling: Rollers No. 1 and No. 2 roll the material to ensure uniform and standard thickness.
- Layer Application (False-Fitting): The wear-resistant layer and color film are "false-fitted" onto the material strap. This uses the material strap\’s own temperature and heat from roller No. 3.
- Embossing: The combined layers then go to roller No. 4 and No. 5 for embossing. Roller No. 4, made of silicone rubber, uses cold pressing to make the embossing texture clearer.
- Color Film Stability: Our production line uses an automatic, constant tension control system for output. This ensures stable color film unwinding. An automatic correction program also keeps the winding route from offsetting.
- Synchronous Registration: A high-speed operation module and image alignment system work together. This makes the surface embossing match the color film pattern, creating precise alignment and effect.
After the continuous strap is formed, further processing steps occur:
- Traction: A tractor pulls the continuous material strap. It uses frequency conversion, speed regulation, and a motor direct connection structure, perfectly matching the production line speed.
- Shearing: The material strap is then transported to the shearing machine for cross-cutting. A photoelectric switch transmits the signal for cutting length, ensuring sensitive response and accurate length.
- Automatic Stacking: After being cut, an automatic platen machine stacks the finished material strap.
- Grooving: Once cutting is complete, the planks enter the grooving line for initial processing.
For Lori, our client from the US, who values consistent quality, this entire process is vital. Our two SPC production lines allow us to manage high volumes while maintaining strict quality control1 at every stage.
What steps are involved in layering and bonding the different components of SPC?
Do you ever wonder how all the layers of SPC flooring come together? The secret to its multi-functional performance lies in its precise layering and bonding.
SPC flooring\’s core, decorative film, and wear layer bond during extrusion and calendering using heat and pressure. This creates a strong, seamless unit. Later, underlayment can be added. This integrated process ensures a durable, single plank, preventing delamination and enhancing overall product integrity.
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|---|---|---|---|---|---|---|
| Backing Layer | Bottom | Sound insulation, moisture resistance, comfort. | ||||
| SPC Core Layer | Second from bottom | Provides rigidity, stability, and waterproof base. | ||||
| Decorative Film Layer | Third from bottom | Gives the floor its aesthetic look (wood, stone, etc.). | ||||
| Wear Layer | Fourth from bottom | Protects against scratches, wear, and stains. | ||||
| UV Coating | Top (optional) | Enhances gloss, adds extra protection. |
At CloudsFlooring, we focus on perfect adhesion for long-lasting quality. The core of SPC flooring, composed of limestone and PVC, is first extruded into a continuous sheet. During this extrusion process, specifically within the five-roller calendering system, the decorative film and the wear layer are applied.
These layers are "false-fitted" using the material\’s own heat and additional heat from the rollers. This process immediately bonds them to the rigid SPC core.
The decorative film layer1 is a high-definition printed layer. It mimics the appearance of natural wood, stone, or ceramic. This is where we can offer rare styles and customizable logos for our clients. The wear layer2 is a clear, transparent film. It provides the initial protection. This in-line layering and bonding under heat and pressure create a seamless integration of these components, forming the main body of the SPC plank.
This integrated process is crucial. It ensures the core, decor, and wear layers are tightly fused. It prevents delamination, a common issue for buyers if not done correctly. We conduct peel strength tests on every batch. This ensures the bonding integrity. This step is critical for the overall stability and longevity of the SPC flooring.
How is the protective wear layer applied and treated for durability?
Are you curious about the secret behind SPC flooring\’s amazing resilience? The wear layer is crucial for protecting the beauty and integrity of your flooring.
SPC flooring\’s protective wear layer, a clear PVC or polyurethane film, bonds to the decorative layer during extrusion with heat and pressure. Enhanced with aluminum oxide or UV coatings, it resists scratches, abrasions, and stains. This crucial layer ensures the floor\’s long-term durability and aesthetic appeal.
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|---|---|---|---|---|---|---|
| 12-15 mils (0.3-0.38 mm) | Residential Use | 10-15 years | ||||
| 20 mils (0.5 mm) | Light Commercial Use | 15-20 years | ||||
| 22 mils (0.55 mm) | Medium Commercial Use | 20-25 years | ||||
| 28 mils (0.7 mm) | Heavy Commercial Use | 25+ years |
The wear layer is the face of the flooring. It is the first line of defense against daily wear and tear. For our buyers like Aiden, who are quality-sensitive, the wear layer thickness and treatment are key indicators of product performance. We use a high-quality, clear PVC or polyurethane wear layer. This is applied during the extrusion process, where it fuses seamlessly with the decor film below.
The thickness of this layer varies by application. For residential use, it is typically 12–15 mils (0.3–0.38 mm) thick. For commercial settings, it is 20 mils (0.5 mm) or more. A thicker wear layer means higher durability. For example, a 0.5mm wear layer is significantly more resistant to heavy foot traffic than a 0.3mm layer. This is a crucial detail for commercial projects.
After the initial bonding and forming on the extrusion line, the continuous sheet then enters the UV coating line. This process adds a protective layer:
- UV Paint Application: We apply a layer of UV paint uniformly by roller.
- Ultraviolet Radiation & Baking: The material then receives ultraviolet radiation. It enters an oven for baking.
- Dual Application: We apply the UV paint twice, and the ultraviolet radiation is also applied twice. This dual application enhances protection and durability.
The UV paint further increases the gloss or creates a specific matte finish. This meets diverse customer requirements. It is important to note that the brightness of the floor is not directly related to the amount of UV paint. It is mainly controlled by the brightness of the UV paint itself.
The wear layer is often infused with aluminum oxide. This is a hard-wearing compound. It greatly enhances resistance to scratches, scuffs, and abrasion. Some of our premium SPC products also incorporate ceramic bead technology within the wear layer. This provides even greater scratch resistance. This meticulous application and treatment ensure that our SPC flooring withstands years of use. It helps maintain its appearance even in high-traffic areas. This reduces potential callbacks for our distributors and ensures long-term customer satisfaction.
What manufacturing processes ensure SPC flooring\’s stability and waterproof characteristics?
Do you want to know what makes SPC flooring so incredibly stable and waterproof? It is not just about the materials but also the precise manufacturing steps.
SPC flooring gets its stability and waterproof qualities from a high-density stone plastic composite core, formed under high pressure and heat. A precise annealing process further stabilizes planks, preventing expansion. Its layered structure and click-lock system also make it impervious to water, ensuring lasting performance in any environment.
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|---|---|---|---|---|---|---|
| Dense Core Composition | Extrusion, Calendering, Raw Material Formulation | Minimizes expansion/contraction due to temperature/humidity changes. | ||||
| Waterproof Materials | Selection of Limestone and PVC for core/backing | Prevents water absorption, ideal for wet areas. | ||||
| Seamless Construction | Integrated Layering during Extrusion, Precision Profiling | Eliminates water entry points, ensures waterproof integrity. | ||||
| Absence of Wood Fibers | Raw Material Formulation (no wood in core) | Eliminates risk of swelling or warping from moisture. | ||||
| Annealing Process | Controlled Heating and Cooling after UV Coating | Relieves internal stresses, enhances dimensional stability. | ||||
| Precision Profiling | HOMAG Profiling Line | Ensures tight click-lock joints, prevents gapping and water seepage. | ||||
| Quality Control | Regular Testing (dimensional stability, water resistance) | Guarantees product meets industry standards and performance. |
From our experience at CloudsFlooring, ensuring stability and waterproofing goes beyond just raw materials. The rigid core itself is inherently waterproof. This is because of its dense composition of limestone and PVC. These materials do not absorb moisture. Water cannot penetrate it.
Unlike wood-plastic composite (WPC) flooring, SPC contains no wood fibers in its core. This eliminates the risk of swelling or warping due to moisture exposure. This dense core is engineered to minimize expansion and contraction due to temperature or humidity changes. It is inherently stable.
After the UV paint is fully cured, the floor enters the annealing line. This is a critical step for dimensional stability:
- Rapid Cooling: We send the floor to cold water to cool it down rapidly.
- Drying: We then use a cooler to dry any water on the surface.
- Equilibrium: Finally, we put it into a normal temperature and normal state environment.
The purpose of annealing is to strengthen the shrinkage and warpage resistance of the PVC floor. This happens through controlled heating and cooling on the assembly line. This thermal treatment relieves internal stresses in the material. These stresses can build up during the high-pressure production process. If not relieved, they can lead to warping or gapping after installation. This step is particularly important for products destined for regions with fluctuating temperatures, like North America or the Middle East.
After annealing, we move to shaping and profiling the floor. The machine heats the floor. This makes it easier to punch and form different shapes if required. The profiling process involves several precise steps:
- Grooving: After the planks are cut and stacked, they enter the grooving line for initial processing.
- Profiling Setup: We then move to profiling, done precisely according to customer requirements. A knife adjuster adjusts the machines based on the floor size.
- Conveyor and Sequence: We put the pieces on a conveyor belt. We profile the long side first, then the short side.
- High Accuracy: Our HOMAG Profiling Line guarantees high accuracy for click products. This precision is vital for the tight, secure joints that are essential for waterproofing.
If a V groove is desired, we paint it. This makes the texture imitating wood more realistic, adding to the aesthetic appeal.
If the SPC flooring includes an underlayment layer, like IXPE foam or cork, we apply it at this stage. The underlayment is placed on the bottom of the SPC core layer. It is laminated together with heat and pressure. This adds sound insulation and comfort.
Finally, before packaging, each plank goes through a rigorous quality control process. We check thickness, dimensions, color consistency. We also look for defects like obvious scratches, impurities, dirt, bubbles, color difference, discoloration, white edges, delamination, folding, bevel, or residual angles. This ensures each plank meets our high standards. Once inspected and cleaned, the flooring is packaged into boxes, labels are checked, and then loaded for shipping to our distributors and retailers worldwide.
Conclusion
Understanding the meticulous process of making SPC flooring highlights its strength and durability. From carefully selected raw materials like limestone and PVC, to the precise mixing, integrated extrusion and layering, precise cutting, grooving, profiling, UV coating, and annealing, each step ensures a high-quality, waterproof, and stable product.
The above data is for reference only.
