Flush Door Manufacturing Process Steps:

The Beginning

• The manufacturing process begins in saw mills, where logs without any natural defects are cut into
planks of different shapes and sizes.

• These planks are treated with concentrated and saturated chemical compositions of boron compounds.
This protects the wood from termite and borer infestations.

• Once they have been treated with chemicals, the planks are sent for drying by exposing them to
ambient air. This technique is called Air Seasoning.

Seasoning to Stiles

 The next step, Kiln Seasoning, is the most important step to match our set standards. The planks
are stacked inside a kiln to season the timber to the desired moisture content. The seasoning
starts at a lower temperature and higher humidity level. These conditions keep altering until the
timber dries, and the targeted moisture content is achieved. Kiln seasoning kills fungi and insects
and is suitable for proper drying.

 The planks are then cut into various thicknesses. This process is called Ripping and Plaining.
These cut planks are known as fillers and are used to fill up the inner cores of the doors. This
process also ensures the smooth surface of the fillers and the frame.

 The planks are then used to make vertical stiles of the frame. They are cut into smaller wooden
blocks with finger cuts. Each block is then affixed to one another at the finger joint, providing
more strength.

Fastening and Compressing

 Once the stile is made, the external frame is composed with special fasteners, which join the stile
and the rail. Batons are then placed on both sides for the lock area on the door.

 For the board assembly, wooden batons are placed end-to-end inside the frame. The end joints
are compressed to leave no space in between.

 Once the board is assembled, the core and face veneers are glued up. Our patented glueline
technology is applied on the veneers. The face veneer is then overlaid on either side, thus
assembling a five ply construction for unmatched strength and sturdiness.

Pressing and Finishing

 The bunch is then sent to a single opening hydraulic cold press under a certain pressure and
temperature. This helps in the distribution of GLP and moisture, ensuring that the panel is
microbial decay proof.

 Cold Pressing is followed by Hot Pressing. The pre-pressed panels are fed into a multiple
opening hydraulic hot press. This ensures that the layers are bound by glue, under a defined
pressing cycle, thus giving the doors a longer life.
 The assembled door goes through the finishing and branding process. It is processed through
edge trimming and sanding, after which preservative chemicals are added to it, as a protection
against borers and termites.

 Finally, the finished doors go through a stringent quality check before they are branded and
dispatched.