1. Flush Door Production — 200 door leaves per shift
Product: 0.5 mm-veneered or HPL-laminated flush door
Construction: softwood frame + tubular core (or 4 mm plain MDF) + 0.5 mm veneer / HPL on both faces
Capacity: 200 door leaves per shift
Edging: up to 2 mm edge-banding tape in rolls, up to 12 mm in strips
Finishing: UV roller coater recommended for door-leaf top-coat
Validated process sequence
| # | Operation | Recommended Caple machine |
|---|---|---|
| 1 | Softwood framing — cross-cutting | Sliding-table cross-cut / panel saw |
| 2 | Multi-ripping the frame stock | Straight-line rip saw |
| 3 | Four-side planing of the frame stock | 4-side moulder / throughfeed planer |
| 4 | Final length cutting of frame members | Cross-cut saw |
| 5 | Sizing the tubular core | Panel saw / beam saw |
| 6 | Sizing the 4 mm plain MDF skin | Panel saw / beam saw |
| 7 | Frame assembly, gluing & cold pressing | Cold press / hot press / roller press |
| 8 | Calibration sanding of the assembled blank | Wide-belt calibration sander |
| 9 | 0.5 mm veneer preparation | Veneer & post-forming |
| 10 | HPL cutting to size | Panel saw / beam saw |
| 11 | Veneer / HPL pressing onto the door blank | Hot press / laminate press |
| 12 | Final sizing of the laminated door | CNC beam saw / sliding-table saw |
| 13 | Veneer or PVC edge-banding | Through-feed edge bander · High-speed auto edge bander |
| 14 | Lock and hinge cut-outs | CNC router / pin router · Multi-boring |
| 15 | Sanding & UV finishing | Wide-belt finish sander + UV roller coater (project-specific) |