1 Material preparation
From autumn to spring, we store beech trunks and logs in outside pools that are constantly moistened with water when the air temperature is higher than 15 °C. Before they enter the manufacturing process, the logs remain in small vats where they undergo the controlled steam plasticisation process. After removal, the bark is removed and they are cut into specific lengths.
The wood is then peeled into 1.15 mm thick layers. Afterwards, the veneer is dried at 160 °C and then sorted according to size and quality. We differentiate these into three quality types - A, B, C. Only the A type, the highest-quality veneer, can be found in TON products, in the visible parts of chairs. Its appearance is absolutely flawless, so it only needs finishing with a coat of varnish.
3 Layering of the veneers
Our veneers are laid down in layers ranging from three up to twenty-five layers. This depends on the quality and width demanded - each veneer sheet is one millimetre thick after pressing. If a customer so desires, it is possible to add a veneer made from decorative woody plants, laminates, or ALPI veneers on the top surface. Every single sheet is interspersed with glue. This is composed of gluing and stiffening constituents, mixed mechanically in specific proportions. Currently, we use a very ecologic veneer-gluing procedure, where special paper is used.
243 types of wooden and metal moulds can be used for pressing purposes. In case of external customers´ serious interest, a custom-made mould can be produced for their own shape. The pressing process can be divided into two technological procedures - high frequency stiffening, or by using steam. High-frequency Presses can hold larger forms - and the final appearance resembles grown wood due to the way the veneers are layered. This technology works on the principle of a microwave oven – the vibration of a material´s molecules heat it up and cause the condensation of the glue, thereby stiffening the pressing. Steam Presses are usually used for smaller types of plywood, like seats or rests. Metal moulds are used in these cases.
The final products, seats, rests, and laminated pressings are used in a wide range of interiors ranging from household furniture, to school and catering premises´ furniture and stadium or hall facilities. These are not only in a range of TON products but can also be sold to other companies. If interested, do not hesitate to contact us.
Plywood can be ordered from a minimum quantity of 10 pieces.
Josef Cigánek, mobil: +420 603 872 339, e-mail: josef.ciganek@ton