German tech helps Belgians create faux wood flooring
An endless stream of what looks like hardwood cascades over a metal cliff before gently undulating through a series of rollers.The wooden river looks and feels like a flexible hardwood floor, but it’s actually the newest type of vinyl flooring that’s realistic enough to pass for stone, tile or wood.This special type of vinyl is so popular that IVC US sold $100 million of the material last year, capturing double-digit percentages of the North American market, according to Xavier Steyaert, CEO of the Belgium-based company that set up shop here in 2011.”You will not see this technology anywhere else,” Steyaert told a group of visiting diplomats. “This is not off-the-shelf, this is very unique.”
The optical illusion of flexible wood owes its appearance to heat, pressure and a convincing paint job, Steyaert explained. That, and a very expensive chemistry set.Globs of liquid PVC are spread evenly onto a sheet of flexible fiberglass, which then is painted, heated, re-coated and cooled into 1,000 rolls per day.IVC’s plant has the capacity to produce 5,000 miles of vinyl flooring per year in its 250,000-square-foot plant, and store 25,000 rolls in its 270,000-square-foot distribution center.The company in February expanded to a third shift and added 30 positions to the existing workforce of 150.
The CEO already is talking about another expansion. The 44-acre site has room for IVC to nearly double the plant’s size, and he wants to add two more shifts. The extra shifts will enable IVC US to run the plant 24 hours per day, eliminating costly restarts, he said.Steyaert’s advantages over competitors are twofold. He has the world’s longest vinyl production line in the world, served by the longest heating oven in the industry, which allows him to run his production line faster. As an added bonus, the plant contains enough printing presses to keep the line going 24 hours per day, he said.