Formica Group Maintains Product Consistency with a Sustainable Approach to a Key Manufacturing Component

The creation of Formica® Laminate is an interesting process in and of itself. But one key manufacturing component — the large steel press plates that deliver the brand’s signature textures — have a unique quality and sustainability story. The plates can be refurbished, not only to maintain texture integrity and consistency, but also to move the company toward its sustainability goals.

A Quick Refresher on How Laminate Is Made

High pressure laminate, or HPL, is made by treating several layers of brown kraft paper with a phenolic resin. A layer of melamine-infused decorative paper is added to the top to give the laminate its overall design, color and durability.

The layers are fused together at high temperatures between large steel plates. Depending on which of our signature textures is to be applied, the appropriate plate is used to create the final laminate sheet.

Old Press Plates Are New Again

Formica Group’s stainless steel press plates are produced in its plant in Quillan, France, and shipped to the company’s European and North American manufacturing facilities. Over time, the plates need to be replaced or refinished to maintain our high standards of product quality and texture.

Fortunately, the team in Evendale, Ohio, developed an innovative process to refurbish the plates in a way that ensures consistent décor texture and promotes sustainability. This involves polishing and reworking the surface of the plates to bring them back to their former glory, thus re-using existing materials rather than commissioning tons of new steel.

Plates refurbished in Ohio feature the same level of quality as the originals from France because they’re refurbished to the same gloss and texture levels as new plates. The result is laminate sheets that are consistent in terms of surface features and quality, and a reduced need to manufacture brand-new plates from scratch. This noteworthy capability is a testament to Formica Group’s culture of innovation and resourcefulness in manufacturing.

The Bottom Line: Sustainability and Quality Go Hand in Hand

Formica Group is the only laminate manufacturer in the world that operates its own plate-making facility. This gives us full control over the process and ensures top-quality products that promote sustainability. By giving new life to old plates, we're able to reduce waste and maximize the use of valuable materials.

Formica Group’s Commitment to Sustainability

Formica Group is proud to be evolving its business practices and looking at everyday processes in new ways to help protect the planet. We will continue to share updates on our progress via our website and annual position paper as we work toward reducing our carbon footprint. Learn more about our approach to sustainability and other initiatives, including our sample recycling program and renewable energy practices.