PVC decorative film is a widely used material in the furniture, cabinetry, and interior design industries due to its versatility, durability, and aesthetic appeal. The production of PVC decorative film involves several stages, each of which ensures that the material maintains high quality and meets the specific needs of various applications. Below is an overview of the key stages in the production process of PVC decorative film, using the calendaring method, which differs from extrusion.

1. Raw Material Preparation

The process begins with the selection and preparation of high-quality raw materials. PVC resin, along with various additives such as stabilizers, plasticizers, pigments, and other chemicals, is mixed to create a consistent and stable formulation. The precise formulation is important to ensure the film’s desired properties, such as flexibility, color consistency, and durability.

2. Calendaring Process

Unlike extrusion, where the material is melted and forced through a mold, the calendaring process involves passing the prepared PVC mixture through a series of rollers at high temperatures and pressures. This method flattens the PVC into thin sheets of the desired thickness. The sheet is carefully calibrated to ensure a smooth surface and uniform thickness, essential for high-quality decorative films.

3. Printing Process

Once the PVC sheet is formed, it is ready for the printing process. The film is passed through a printing machine where designs, patterns, and colors are applied. We use high-quality printing techniques, such as gravure printing or flexographic printing, to transfer precise and vibrant patterns onto the film surface. This process allows for the creation of complex textures, wood grains, leather-like finishes, or any custom design that meets the client’s requirements.

4. Embossing

After printing, the PVC film undergoes the embossing process. This step is crucial in adding texture and depth to the surface of the film. Engraved rollers press the desired pattern into the film, which could include wood grain textures, geometric patterns, or other custom designs. The depth of the embossing can be adjusted according to the customer’s requirements, adding both visual appeal and tactile qualities to the material.

5. Coating (Optional)

To enhance the performance and appearance of the PVC decorative film, coatings can be applied. Common coatings include:

• PU Coating: Provides a super matte finish with a soft-touch feel.
• UV Coating: Offers improved scratch resistance and a matte finish, enhancing the durability of the film.

6. Cooling and Solidifying

Once the embossing and coating processes are complete, the PVC film is cooled and solidified. The cooling process is essential to ensure the film retains its shape, texture, and finish without any distortion. This is done in a controlled environment to preserve the integrity of the film.

7. Cutting and Packaging

After the film has been cooled, it is cut into rolls or sheets of the required size. The film is then carefully packaged to protect it during shipping and handling. We ensure that the film is packaged securely to avoid any damage during transportation.

8. Quality Control

Throughout the production process, quality control is a critical component to ensure that every roll of PVC decorative film meets our stringent standards. This includes testing for color consistency, checking the embossing quality, and verifying that the film passes durability tests, such as the LG (LX) test. We inspect the film at each stage of production to ensure it meets the required specifications and is ready for its intended use.

Conclusion

The production of PVC decorative film using the calendaring method is a multi-step process that involves careful preparation, printing, embossing, coating, and quality control. By using advanced techniques and maintaining strict quality standards, we can create a high-quality, durable product that meets the aesthetic and functional needs of our clients.

At TLBS New Material Technology Co., Ltd., we are committed to delivering top-quality PVC decorative films that offer both beauty and durability. If you are interested in learning more about our products or would like to request samples, please feel free to contact us.