1. place doors and tray on table.
2. Temp Run is 200-230 degrees.
3. Temp preheat = 150 seconds (their machine reads seconds)
4. press for = 120 seconds
5. cool down time = 150 seconds.
Re: Vacuump press, vacuclamp, vacuumclamp, press settings
Wrinkles on components can be improved or fixed completely by a series of trouble shooting steps.
If your part has a shadow were a wrinkle was but has been pulled out then it means that a wrinkle has formed and was stretched out during the press cycle. There may be different steps to solve this but this article will primarily focus on wrinkles that remain after pressing.
Typically wrinkles are caused by the material becoming too soft and "gaining" inside the press. When film is calendered it is pulled through the machines. This means that when you reheat the material it will grow length wise and shrink a bit width wise. So there is some movement to the film as its getting reintroduced to heat. And typically wrinkles are caused by excessive exposure to heat via high temp or preheat so if you adjust settings it should be a reduction of heat in some manner.
The first thing to always try is to put a dummy part on the size of the part. Items such as large doors or table tops are prone to wrinkles as the vinyl slides across the table then wrinkles up on the part. By putting a dummy part beside the large component it will capture excessive vinyl and stop it from sliding onto your large component. You can play with the distance and height of the dummy part but in general this should solve most problems with wrinkles.
If your component is too large to put a dummy part or if a dummy part didn't solve the issue you can finally go to settings. The vast majority of issues can be solved by reducing the heat by a few degrees. Normally you will notice that wrinkles will occur later in the shift and only on large parts. This is due to excessive heat build up. By lowering the temp you should solve the issue but if you are not getting the definition needed you may need to then increase the preheat. Longer preheat slowly soaks the vinyl so that it will still stretch but not so soft that it expands in the press and causes excessive growth of material.
Above we have discussed not only the settings but also the characteristics of WHY wrinkles are occurring... We've discussed the nature of expansion length wise and contraction width wise showing movement as well as the growth (increase) in material that is now trapped between the gaskets. I hope that the above has solved your problems however if it has not you can contact us for more assistance.
When membrane pressing or vacuum forming components using 3D Laminates dog ears are a symptom that can sometimes occur. This post is to address or assist that that issue.
Dog-ears are the bunching of the laminate on the corner which is also called webbing. This occurs when the material appears to be a wrinkle on the side of the component/door.
Solutions to repair doors:
1. Minor wrinkles such as 1/8", can be pushed out with a piece of wood and possibly colored. This is a rare fix on already pressed doors
2. Trim out. You can trim out the door with more vinyl then take a heat gun softening the vinyl and then use the extra trim out to tug the vinyl before trimming.
Solutions to prevent:
1. Experiment with a jig that is closer or further so as to capture the vinyl and pull away from the components. If your jig is small you may want to make it tall like a dummy part or wider so that it commands more vinyl and pulls it away.
2. Solution two is if using pedestals to leave more of a gap so as to create a under pressure and it pulls down and slightly inward the vinyl.
3. Experiment with pre-heat and heat. If material is over stretching you could have over pull as material could be too soft. Or it may be that the material is not soft enough and has not fully pulled away from the component and been commanded by the jig to the outside.
If you have read the above and have any questions, please contact us to clarify.
Here are Youtube links to popular videos on installing Peelstix
Vertical Doors and Walls
To place an order simply email it to firstname.lastname@example.org or call 407-654-5013
Some helpful forms:
What is the minimum quantity to color match?
How long does color matching take?
Melamine board matches & Leathers: 600 yards
HPL, High Gloss & Pantone Matches: 1200 yards
Wrap deck: 300 yard minimum on items in this deck
First call us at (407) 654-5013 to confirm we are able to effectively make your match based upon color or lead time needed. Our specialized account executives will work closely with you on the details for your project.
Mail us a letter sized sample of the design target and we will lead the matching process from there! Once lab samples are produced we will send them to you for review. Typically, the matching lead time is 4 to 6 weeks. We require a deposit of $500 which is fully refunded upon order.
PRODUCTION: Once we receive approval for the sample it will take us 10 to 12 weeks to produce and have available from Orlando, FL, USA
RUSH: The other option would be to rush production / air one or more rolls at a cost of approximately $6 per linear yard. This will shorten the lead time to 4 to 6 weeks.
In most cases, we will produce a greater amount than the minimum order quantity. This allows us to grow our inventory while ensuring the color you need is always available.
Many people think of sales calls in the Decorative Surfacing industry as something of pressure or of convincing people to buy product however that is a very short sighted way to think of Sales Calls.
In the Consultative Sales Call approach a person calls their clients in the following manner:
1. QUALIFY: Are you speaking with the right person? Simply asking the reception or the contact you have on file who the correct person is to speak with. People are eager to help to make sure that you get to the right person. In doing this it shows an eagerness to clean up your database, make sure they have adequate samples and know that you are a call away should they need anything. This is the first step to establishing a relationship with that company. In addition, when speaking with the correct person you are able to learn more deeply if they just handle purchasing or if they specify colors for their company or their clients. Simply ask during the conversation to get a better understanding if that person is truly the decision maker or if you are able to assist each other.
2. LEARN: In selling any product or service, knowledge is very important. Companies do provide training however learning never stops. When you call a company ask questions that enable you to get to know their company. This is a key step in understanding their needs and simultaneously learning about their abilities, types of machinery , etc. If much of your day is spent speaking with clients about their businesses the learning is multiplied and you become more and more knowledgeable.
3. DIG DEEPER : In learning about your client's business you will be listening and taking notes by pen or by typing in quietly into your Salesforce or other CRM. By asking "What ifs" you get to know more depth of what they are saying. For example, "What if we stocked that would a different texture, would that solve your problem?" That doesn't mean that you will however it will give you a better understanding. Often the client will say "No , they really are expecting the product to perform more than this type of product can". This type of response will enable both you AND the person you are speaking with to better understand the depth of the issue. Another key is to repeat their comment in another way "So what you're saying is .... ". The client may then confirm what you are saying and then you know you are in completely understanding.
4. SAMPLING: As you are talking to your client you will see opportunities to sample and the samples are something that will be shown to their clients. This is a key point in servicing their needs and providing value. For a company to accept a production sample and then utilize it is a key to showing the actual product in action.
5. FOLLOW UP: Follow up of quotes, samples and maintaining an ongoing relationship is key to building sales. By following up with your clients sales growth is guaranteed.
6. ACTIVITY: For a person to be successful in the material business they need to be active and constantly making calls or visits. Administration is something that people need to streamline or squeeze in however most successful sales people do admin after hours when their clients are not available. Notice from the steps above that you are always growing, making connections, sampling and following up again and again.
CONCLUSION: Imagine a snowball rolling down a mountain and all the snow is knowledge, clients, good-will, experience, and good habits. Such a snowball will thrive and become large and full of snow. On the other hand, imagine a snowball moving down a mountain and knowledge not sticking to it because of a lack of questions and lack of digging deeper or follow up..... will the snow ball pick up clients, good will and a lot of experience? Absolutely not. Good habits not only better serve clients but they are undeniable. If you learn to have good fundamentals your success is guaranteed.
This article is to explain the Dackor color matching policies on how we develop prints and colors. As most people know, we offer 600 yard minimums on board matches that are in distribution as well as leathers however we require 1200 yard minimums at the time of this post for non board matches, pantone solid colors and most other items. We typically produce 2,000 yards our first production and then stock the remaining quantity thereafter. When we work with board producers we often stock with very little to zero requirement from our membrane pressing customers.
How do you match woodgrain designs?: There are two ways we match woodgrain designs, the first is via proprietary prints that we develop or that the paper company develop. The vast majority of Dackor woodgrains are items developed by paper companies such as Schattdecor, as an example. The second type of woodgrain is one in which we own the cylinder for that is similar enough the target match and have had for many years. We can determine within 48 hours if we have a print cylinder close enough or we need to seek the original design from the paper company.
What would constitute a cylinder being close enough to match? For prints such as oaks, maples, cherries as well as linear woodgrain prints we have an extremely large availability to choose from. It is very common that if the design is not unique that we already have a cylinder close enough to match. Sometimes we can even remove one of the cylinders from a three cylinder set to make it work or add a new cylinder to combine with the series.
Are there woodgrains you will not match? Yes. There are woodgrains we will not match. For example, if your woodgrain target has very specific sap marks or knots that are proprietary to the design we would need to reach out to the original paper producer to see if the PVC rights were available. If the rights are not available we then direct our clients to the competitor.
Are woodgrains patentable? In most of the world, woodgrains designs are protectable however this has been extremely difficult in the US. We encourage our customers to purchase only original designs from us or our competitors however we recognize that alternative cylinders that give a close match in a Hard Rock Maple or basic Oak design, are completely acceptable.
Why are edgebanding companies able to match all? The reason edgebanding producers are able to match most items is because so little of the print is revealed.
How do you analyze if a print cylinder is close enough? We can look at a design and determine if the 3 cylinder set will work or can be complimented with an emboss that will help that color match. Through experience we know quickly if we are able to make a match for a project or specific client who is looking for better stock, more scratch resistance or whatever the reason. However, typically, we have a budget available to purchase rights and develop tooling with the original design, especially if the match is being done in cooperation with the board producer.
Do you do custom embosses? Yes , we will do custom embosses to match the board company's emboss but in a PVC emboss using emboss cylinders, not press plates.
I'm a board company, why should I partner with Dackor? Dackor has one of the largest inventories in the world of 3D forming laminate. Over 95% of our sales are done through warehouse and shipped within 3 days of the Purchase Order. In addition, we sample aggressively, market the designs to the market place and we do not sell paper which competes with the board companies.
I hope that the above was helpful and informative, please inquire with Dackor at 407-654-5013 for further questions.
We all want to grow business and sales management is one of the difficult tasks we all face. How do you communicate to your sales team how to reach their goals?
Although there are many aspects to success in sales , one of the most important is in organized activity. Many sales people spend a lot of time preparing, on their computers or in meetings yet fail to make enough touches with customers. I'd like to propose you administrate a point system.
If we are talking about outside sales, imagine that you have a point system such as:
1 visit=10 points
1 successful call= 1 point
1 email= 0.25 points
The above point system means that just to maintain a basic, average day a person would need 30 points. To be above average they'd need 40 points, to be a sales winner they'd need 50 points and to be a sales whale they'd need 60 points per day. Below are some examples of successful sales days:
Monday: paperwork, planning week, 10 calls, 8 emails: 12 points
Tuesday: 4 visits, 24 emails, 10 calls= 56 points
Wednesday: in office: 50 calls, 96 form emails, 12 personalized emails =78
Thursday: at tradeshow: 4 visits, 24 emails, 10 calls= 56 points
Friday: 3 visits, 12 emails, 10 calls = 45 points
As you see from the above example, the person averages 49 points which makes them just shy of being a sales winner. Does this mean that the person cannot create success? No... But what it means is that they are active and digging for sales.
As sales professionals our goal is to combine quality with quantity the best we can. If you are only averaging 20 points to 30 points a week what are your changes to become a sales winner? However if you are averaging 60 points a week and working nights to organize your next day and weekends to catch up on emails imagine how much further ahead you can get. This doesn't mean that you must work so many hours but it does mean that if you go home at the end of the day and you look at a call volume of 10 calls and 12 email that you simply are not creating overwhelming action that will create success.
I hope that this post helps to motivate you and keep in mind that the points aren't exact, they are just representative of a bigger point.
(THIS ARTICLE WAS PUBLISHED by SURFACE & PANEL magazine Q2, 2008; www.surfaceandpanel.com)
Whether you refer to it as thermofoil, foil, PVC Veneer, 3D Laminate or Vinyl, one thing can be certain: there is an identity crisis regarding our product here in North America. As with marketing any product, it is not only important that people know what your product does, but that they also have a positive impression about it and the product segment that it resides in; as a result, the quality and reputation of your product segment as a whole is ever bit as important as your company and brand.
Since there are numerous names for our product segment, it is very difficult to explain to outsiders what our product is. I’ve even met cabinet makers and specifiers, much less people in typical social settings, who didn’t know what product I meant when I said “thermofoil”. I’d have to explain that it’s the same material used for “white vinyl wrapped doors”; even at that, though, they didn’t know that those same 3D laminates were available in wood grains! If I said that I sell granite, they would all clearly identify and usually have a positive reaction about that product segment; however if you take a look at our product segment, we lack all of that. When you think about it, though, how could a product segment that lacks a single, clearly identifiable name build awareness as an industry?
I have long thought that there should be one clear name to identify our product segment. In 1998, I started using the phrase “3D Laminate”. I can’t be certain that I was the first to use it, but I certainly had never seen it used previously. The year prior I had noticed at the NeoCon office furniture show that people would ask how our product was used. In response, knowing that most people clearly understood what an HPL chip looked like, I created a professional board that was backlit and spread chips out in front that were cut to represent the size and look of HPL chips. I used the term “3D Laminates” on top of the board. At that show I received many comments that, “Wow, they have 3D laminates now?” I realized then that the more descriptive name of “3D Laminate” helped to identify our product segment while also adding value over a traditional laminate.
Aside from a more descriptive name, our product segment lacks a positive image. Cabinetmakers and consumers alike do not recognize the quality and high end application potential that 3D laminates can offer. In Europe, 3D laminates are viewed as a durable, hygienic and a fashionable surface. It is not only more economical than wood, but it is also more consistent and offers a great deal more color and design options. If a project called for an exotic West African wood, the cabinet door could cost as much as $50 per square foot; however, a 3D laminate door in that same design and application would cost only a fraction of the price. In addition, a quality 3D laminate would be more consistent in design, and no “Old Growth” forest would need to be touched. Although 3D laminate doors are typically produced using PVC as an overlay, the bulk of the finished product is made by MDF. MDF is composed of blended raw wood material utilizing low priority wood composites of branches, small diameter trees, mill waste and forestry chips. It could be argued that our product segment even deserves recognition in the revitalized green movement.
In Europe, why are 3D laminates perceived as fashionable and modern surfaces to be used in mainstream and high end applications, but not here in North America? In North America, we typically see 3D Laminates as a lower end product used only in the bathroom, for apartments or in the closet. One problem is that, unlike their larger European counterparts, the extremely large kitchen producers here do not promote 3D laminates as a consumer friendly product and product of desire. At the opposite end of the scale, the small custom shop, which got its start as a custom wood craftsman, is pro natural wood, especially since “real wood” has a tendency to be viewed as a product that a cabinet shop without an automated CNC can roll up their sleeves and work with by hand.
So without the large kitchen producers and small cabinet shops pushing 3D laminates, what remains is only a small niche of kitchen and component producers who specify and utilize the product segment. The exact numbers are hard to pinpoint, but it has been reported that over 55% of kitchens in Europe use 3D laminates, whereas in North America that number is less than 10%. Typically, when you do see 3D laminates in North America, they are marketed as a type of counterfeit wood door. Mostly, though, they are promoted as multi-pass raised panel doors which require more CNC time than a slab door, thus warranting a higher price than a single pass routered door.
It’s also interesting to note that the perceived value of a kitchen in Europe is created by the color or design, whereas in North America the perceived value is more closely associated with how long it takes to produce. We have all heard the adage, “You sell what you show.” Well, in North America, the marketing efforts of 3D laminate door producers have collectively leaned towards selling their product as counterfeit, raised panel wood doors, which by their very nature is lower end on the pricing scale; as a result, thermofoil has become synonymous with low end.
As an Industry, shouldn’t we be promoting our 3D Laminate components to the High End design market? I feel that we should. The reason that 3D Laminates are not being offered to the high end clientele currently is a direct result of a category identity problem, which derives from a lack of information and education about our product segment as a whole.
As I mentioned, 3D Laminates are more popular in Europe, but let’s further examine why. First of all, the European market has a greater concentration of large manufacturers whom value consistency in their production line. These larger manufacturers create brochures that rival the automotive industy’s in style and quality and they proudly promote Kitchens that utilize 3D Laminates. Wood is also more scarce in supply and comes at a higher cost, and the average labor rate is high in most European countries. As a result of all of this, the large manufacturers are compelled to better utilize their machinery and material, such as 3D laminates, to add the most value possible to their finished product. Consequently, the 3D laminate product segment is perceived as a high end, high quality product in the European kitchen market. (On a side note, the consumers in Europe also live in tighter spaces; therefore “Euro Style” or “Full Access” cabinetry lends itself to being more desirable since more of the cabinet is usable.)
Now let’s compare the European situation to that in North America. In North America, “real wood” cabinet doors are viewed to be higher quality than 3D laminates. It is interesting that some of these “real wood” kitchens use the low-end wood doors, cheap hardware, untreated paper on the cabinet sides, and low-grade particle board. Then these kitchens are sold as being a high quality kitchen simply because they utilize “real wood” doors. Compare that kitchen to a Euro Style kitchen produced here in the US using a CNC with an all melamine board construction and Blum hardware; I would contend that the US made Euro Style kitchen offers more quality and value than the former. That is not to say that 3D laminates are superior to wood, but at the same time they are not necessarily lower in quality either. Allow me to give some examples of where man made products can outperform or have a higher perceived value over the “real” surface:
“Real” but LOW END PRODUCTUses Natural Wood, Leather, Steel
“Man Made” but HIGH END Uses Graphite, Plastic or Fiber
Wooden Golf Clubs VS. Callaway Graphite Clubs
Leather Shoes at Wal mart VS. Nike Running Shoes
Leather Handbag from Mall VS. Gucci Designer Handbag
Butcher Block Island VS. Corian Solid Surface by Dupont
Steel Ford Pinto VS. Fiberglass Corvette
Steel Bike from Target VS. Carbon fiber Racing Bike
Low end Maple Cabinets VS. High End 3D Laminate Kitchen
The above examples show that a man made product with artificial surfacing can be of a higher quality or of a higher perceived quality when properly produced, designed and marketed. If you sell your product based upon the wood species or how many passes it takes on the router, then you are not branding your product to its full potential.
Let me give an example:
Two years ago I visited the showroom of an Italian kitchen producer here in Florida, and was very impressed by the size and appearance, as well as the beautiful kitchens on display in large, wide-open spaces... It was obviously a very upscale showroom. I was admiring one of the Kitchens when an attractive saleswoman walked over and asked how I liked the kitchen. I remarked that it was indeed beautiful, and asked whether it was thermofoil. She began to explain to me that it was a special lacquer dipped process they do in Italy, but after hearing this, the showroom manager quickly walked over and corrected the sales person. They did have a special lacquer line, but it was for special order only. As it turns out, the kitchen I was looking at was indeed thermofoil. When I asked how much it retailed for, I was surprised at the high price level. In general, the average retail for their kitchens was considerably higher than the average “real wood” kitchen, but it did have a lot more hardware, function, high quality melamine construction and most importantly style.The Sales Manager and I ended up speaking for hours about the Kitchen Industry, the US market and the perception of foils in the market. I then realized that some of these kitchens coming in from Europe were sold widely into condos, as well as high end homes. When I have mentioned to designers the names of some high end kitchen producers from Germany and Italy, they drool over the thought of specifying them into their next project. They are viewed as an ultra luxury product, yet they don’t know or don’t want to see that they are using products that can be sourced in North America as well. After leaving that showroom, and after multiple trips to Germany and Italy, I have realized my calling. Although I didn’t hear a trumpet sound, I knew that it was my job to bring design and profitability to producers of 3D laminate components and kitchens to North America. I hope that this article reaches those who are in a position in their daily activities to join me in spreading the awareness of 3D laminates for use in high end kitchens.
Color inspiration from around the world, backstories on design inspiration and informative articles about marketing, membrane pressing and personal development. Author Mark Viers delivers fresh content that will help you and your business grow and thrive.