Questions frequently asked about the manufacture of Formica® high pressure laminate
Question
How is Formica high pressure laminate made?
Answer
Formica high pressure laminate consists of layers of specially selected kraft and printed decorative papers impregnated with thermosetting synthetic resins. These are fused together under heat and high pressure in a controlled environment so that the component parts consolidate to form a single high density sheet of laminate.
(For more detail, see 'The Manufacturing Process' under 'Product Design and Development' in the ‘Company’ section.)
Question
What gives Formica high pressure laminates their special decorative qualities?
Answer
The decorative surface of Formica high pressure laminate is created by encapsulating a printed or plain colour décor paper within hard wearing melamine resin. Alternatively, real wood veneer or real metal surfaces are offered, as with Veneer Laminate and Metallic Laminate materials. Through our Digital Service your own individual design can be encapsulated in Formica high pressure laminate.
Question
Are the manufacturing processes and finished products environmentally friendly?
Answer
Yes. Formica Limited, like all the component companies of Formica Corporation, recognises the importance of safeguarding the Earth’s natural resources. We have a solid commitment to protecting the environment both in sourcing the materials for, and in manufacturing, our products.
Formica high pressure laminates consist of paper and thermosetting synthetic resins, with paper comprising more than 60% of the product. The pulp for manufacturing this paper uses timber from managed sustainable softwood forests and from recycled paper products.
Formica laminate waste can be burned in modern, officially approved industrial incinerators, or can be disposed of in official landfill sites. Thermo-recycling, which recovers 18 - 20 MJ/kg, is the best option for disposing of waste HPL.
Phenol formaldehyde resin is used in the core layers of Formica high pressure laminate, while melamine formaldehyde resin is used in the surface layers. These resins are irreversibly inter-reacted, with cross linked chemical bonds being formed; this results in a stable, non-reactive material whose characteristics are totally different from those of the constituent parts. The laminate formulation does not include asbestos, cadmium, polychlorinated biphenyls, chlorofluorocarbons (CFCs), bromine / chlorine compounds or heavy metals.
The decorative surfaces resist all common household solvents and detergents and, in normal use, do not release any gases or other substances. They are, therefore, approved for food contact.
Formica high pressure laminate is difficult to ignite and has properties which retard the spread of flame. Decorative laminates, like all organic materials, will emit CO and CO2, depending on burning conditions; they burn much like other wood-based products.
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