New process makes multilayer PVC floor coverings

By Bill Bregar
Senior Staff Reporter

Published: April 23, 2014 10:32 am ET
Updated: April 23, 2014 10:34 am ET

Related to this story

Topics Product News

KraussMaffei Berstorff has developed a lower-cost process to make multilayer PVC floor coverings, referred in the trade as Luxury Vinyl Tiles.

Traditionally, LVT is made in a multistage process using calenders or belt presses. The KM Berstorff method uses a single cycle and only heats the material one time.

The tile is composed of a highly filled core layer, usually with an integrated glass mat, plus decorative film and a layer for wear protection. The glass mat gives strength and dimensional stability. The core layer provides flatness and impact sound insulation. The PVC sheet is filled with up to 60-70 percent mineral additives.

Similar to roofing sheets, the three-layer floor covering is made on two twin-screw Berstroff extruders and two smooth calenders. The first extruder — used for plasticizing and a PVC compound — is equipped with a side feeder to incorporate a high mineral filler share, and additional additives. The material leaving the extruder is guided through a second smoothing calendar to apply the PVC compound — which was processed on the second extruder — to the other side of the glass mat.

It’s important to make the tile inline, especially because PVC is heat sensitive, KraussMaffei Berstorff officials said.

Downstream from the second smoothing calen der, the three-layer core material is provided with the decorative film and the wear protection layer. The entire composite then passes through an embossing station and a temperature control section, before it’s cut to size.

“Experts forecast unparalleled growth rates for LVTs in Europe and North America in the years to come,” said Hilmar Heithorst, division manager for sheet and foam extrusion lines at KraussMaffei Berstorff. “The growing demand is based on the specific benefits of LVTs in terms of unlimited and appealing design options that range from natural wood to stone optics of any color.”

In other news from the Hannover, Germany-based Berstorff extrusion company, KraussMaffei Berstroff ran a demonstration of weatherproof sheets using ground rice husks and PVC, at March 12 open house in Munich. About 60 international customers watched production of Resysta sheets on a twin-screw extruder. The sheets, which look like wood, are mainly used for outdoor applications, such as facades, outdoor furniture and the decks of ships.

The manufacture is Resysta International GmbH in Taufkirchen, Germany, near Munich.

KraussMaffei Berstorff’s U.S. operation, KraussMaffei Corp. is in Florence, Ky.

Tel. 859-283-0200, email sbaker@kraussmaffeicorp.com.


Comments

New process makes multilayer PVC floor coverings

By Bill Bregar
Senior Staff Reporter

Published: April 23, 2014 10:32 am ET
Updated: April 23, 2014 10:34 am ET

Post Your Comments


Back to story


More stories

Image

PC used in academy roof retrofit

January 28, 2015 8:55 am ET

Polycarbonate sheet meets the demands of a “living roof” in a retrofit at the California Academy of Sciences in San Francisco.    More

Lehvoss nylons stand up to auto uses

January 28, 2015 8:49 am ET

Lehvoss North America has upped performance of polymers in automotive gears. Plastics replace metal in many auto gears because of design freedom,...    More

Molder develops multi-shot process for liquid silicone elastomers

January 28, 2015 8:42 am ET

A liquid silicone injection molder has developed a multi-shot process in conjunction with Dow Corning's QP1 silicone elastomers.    More

Struktol additive to improve properties of recycled resins

January 28, 2015 8:44 am ET

Struktol Co. of America has extended its lineup of additives to improve processing and properties of recycled resins and will feature the technology...    More

Image

KraussMaffei to feature multicomponent molding at NPE

January 28, 2015 10:34 am ET

KraussMaffei Corp. will show multicomponent injection molding, the FiberForm and MuCell processes, and a new Adaptive Process Control system, at NPE 2...    More

Market Reports

Plastics in Automotive: Innovation & Emerging Trends

This special report newly released by PN and sponsored by The Conair Group examines current trends in the use of plastics in automotive, materials innovations and the changing landscape. It includes a review of legislative/regulatory activity impacting vehicle development and lightweighting, market opportunities & challenges for mold and toolmakers, innovative design strategies being implemented by major OEMs and suppliers, as well as a review of key indicators in Canada, Mexico, Brazil and China.

Learn more

Plastics Recycling Trends in North America

This report is a review and analysis of the North American Plastics Recycling Industry, including key trends and statistics based on 2013 performance. We examine market environment factors, regulatory issues, industry challenges, key drivers and emerging trends in post-consumer and post-industrial recycling.

Learn more

Injection Molding Market Analysis & Processor Rankings

Plastics News BUNDLED package contains our in-depth Market Analysis of the Injection Molding segment. You will gain keen insight on current trends and our economic outlook.

As a BONUS this includes PN's updated 2014 database of North American Injection Molders RANKED by sales volume. Sort, merge, mail & prospect by end market, materials processed, region, # of plants and more.

Learn more

Upcoming Plastics News Events

February 4, 2015 - February 6, 2015Plastics News Executive Forum 2015

June 2, 2015 - June 3, 2015Plastics Financial Summit - Chicago 2015

September 16, 2015 - September 18, 2015Plastics Caps & Closures - September 2015

More Events