Caple Industrial Solutions
Furniture & Door Manufacturing Process Charts
Production sequences and machine selection — validated for Indian factory floors.
Caple Industrial Solutions publishes this page as a working reference for furniture and door manufacturers planning a new line, expanding capacity, or auditing an existing factory. Each chart below maps a real product — a flush door, a solid wood panel door, a jamb or an architrave — to the exact sequence of operations and the woodworking machine that performs each one. Capacities are stated per shift so you can size your line before you buy a single machine.
The process flows on this page were prepared by Subash Gopalan, S4S Manufacturing Solutions, Bengaluru, and are used by Caple’s application engineers when scoping projects across India, Bangladesh, Nepal, Sri Lanka, the Maldives, Bhutan, the UAE and Africa. To request a customised layout, project sheet and ROI calculation, contact Caple — return turnaround is 72 hours.
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) |
Download Door Leaf Production Chart (PDF)
2. Door Jamb & Architrave Production — 200 sets per shift
Products: door jamb (frame) and architrave (face moulding)
Door frame finished section: 100 × 45 mm
Architrave finished section: front 60 × 18 mm, back 25 × 18 mm
Capacity: 200 sets per shift
Material options: solid wood OR finger-jointed board / LVL / HDF
Door Jamb — process sequence
| # | Operation | Solid wood | FJ / LVL / HDF | Recommended Caple machine |
|---|---|---|---|---|
| 1 | Cross-cutting | Y | — | Cross-cut saw |
| 2 | Multi-ripping | Y | — | Straight-line rip saw |
| 3 | Pre-planing | Y | — | Surface & thickness planer |
| 4 | Sizing the substrate | — | Y | Panel saw / beam saw |
| 5 | Throughfeed planing, rebating, grooving | Y | Y | 4-side moulder |
| 6 | Profile sanding, staining & sealer | Y | — | Wide-belt sander · Edge sander |
| 7 | Flexi veneer wrapping | — | Y | Profile wrapping / post-forming |
| 8 | PVC / paper foil wrapping | — | Y | Profile wrapping / post-forming |
| 9 | Mitre & final cutting | Y | Y | Cross-cut / mitre saw |
| 10 | Hinge & lock-plate cut-out | Y | Y | Pin router / CNC router |
| 11 | Lacquer sanding & top-coat | Y | — | Wide-belt finish sander + UV / PU finishing line |
| 12 | Assembly | Y | Y | Manual / Tenon mortiser |
Architrave — process sequence
The architrave route is identical in spirit to the jamb but adds Planing & Thicknessing between cross-cut and multi-rip on the solid-wood line, and Shaping instead of rebating on both routes — performed on a spindle moulder or 4-side moulder fitted with profile cutters.
Download Door Jamb, Architrave & Panel Door Chart (PDF)
3. Solid-Wood Panel Door Production — 25 doors per shift
Product: solid-wood panel door
Door size: 2075 × 915 × 40 mm
Capacity: 25 doors per shift
Construction: solid-wood stiles + solid-wood rails (curved or straight profile) + MDF centre panel
Solid-wood rail — curved profile
Cross-cutting → shape cutting → planing & thicknessing → curved profiling → manual sanding. Machines: cross-cut saw, bandsaw, surface & thickness planer, spindle moulder.
Solid-wood rail — straight profile
Cross-cut → multi-rip → pre-plane → throughfeed plane & profile → profile sand → cross-profile & tenon. Machines: cross-cut saw → straight-line rip saw → surface planer → 4-side moulder → edge sander → tenon mortiser.
Solid-wood stile
Cross-cut → multi-rip → pre-plane → throughfeed plane & profile → profile sand → final length cut. Same chain as the straight-profile rail, ending at a precision cross-cut saw.
MDF centre panel
Sizing → shape routing → panel-raise shaping → flexi veneer membrane pressing → final trimming → manual sanding → staining, sealer, top-coat. Machines: panel saw → pin router / CNC router → spindle moulder → vacuum membrane press / thermoforming press → edge sander.
Final assembly is a press-and-clamp operation performed on a cold press.
4. Six video case studies
- Panel Processing | Cabinet Making | Modular Furniture Manufacturing Process — sliding-table panel saw → CNC beam saw → through-feed edge bander → multi-boring → CNC router. Standard process for kitchens, wardrobes and modular office furniture.
- Solid Wood Joinery | Solid Wood Furniture Manufacturing Process — cross-cut → straight-line rip → 4-side moulder → spindle moulder → tenon mortiser → wide-belt sander. Classical European joinery sequence.
- Surface Finishing with Lacquer, Polyester, PU and UV Process — spray booth, roller coater, UV curing line. Covers PU, polyester, NC lacquer and UV systems.
- Drywall Construction & Wall Sanding Process — gypsum board cutting, finishing and dust-controlled wall sanding for the interior fit-out trade.
- ACP Fabrication Process — aluminium composite panel routing, grooving, bending and fastening for façades and signage.
- Solid Surface Fabrication Process — Corian-style solid surface cutting, thermoforming and seamless bonding for kitchens, vanities and reception counters.
5. Frequently asked questions
What machines do I need to manufacture 200 flush doors per shift?
A complete 200-door-per-shift line requires: cross-cut saw, straight-line rip saw, 4-side moulder, panel/beam saw, cold press for frame assembly, wide-belt calibration sander, hot press for veneer/HPL pressing, through-feed edge bander, multi-boring or CNC router for lock and hinge cut-outs, and a UV finishing line. Caple supplies all of these as a single turnkey package — see Packages for woodworking.
What is the difference between a door leaf, a door jamb and an architrave?
The door leaf is the moving panel of the door. The door jamb is the fixed frame inside the wall opening that the leaf hinges from — finished section 100 × 45 mm. The architrave is the decorative moulding that covers the joint between the jamb and the wall — finished section 60 × 18 mm at the front and 25 × 18 mm at the back. The jamb and architrave can be made from solid wood OR from finger-jointed board, LVL or HDF wrapped with veneer or PVC foil.
Can the same factory make both flush doors and solid-wood panel doors?
Yes — most Indian door factories do. The two processes share the panel saw, wide-belt sander, edge bander and finishing line. They diverge at the core: a flush door uses a cold-pressed softwood frame with a tubular or MDF core; a solid-wood panel door uses moulded stiles and rails with an MDF centre panel. Typical same-floor capacity: 200 flush doors against 25 solid-wood panel doors per shift.
What edge-banding thickness should I plan for?
Up to 2 mm in rolls and up to 12 mm in strips. A high-speed auto edge bander handles both. Add a curvilinear edge bander for curved or arched panels.
Why is UV recommended for door-leaf finishing?
UV roller coating cures in seconds under UV lamps, gives a harder and more scratch-resistant film than PU or NC lacquer, and lets you finish 200 leaves a shift without curing-rack space. For decorative profile parts (jambs, architraves, panel-door rails) PU or polyester remains the norm because UV cannot wrap around complex profiles.
Who prepared these process charts?
Subash Gopalan, S4S Manufacturing Solutions, Bengaluru. They are published by Caple Industrial Solutions for use in customer projects, factory audits and machine-selection workshops.
How do I get a customised line proposal for my factory?
Contact Caple with your target capacity, product mix and floor area. Our application team returns a machine list, a CAD factory layout, an ROI calculation and a finance/leasing option within 72 hours. Mumbai +91 99300 69909 · Bengaluru +91 91487 88500 · Delhi +91 95994 87490 · Kolkata +91 98314 73500 · Centre of Excellence Pelhar +91 99300 69908.
6. Related reading on caple.in
Panel Processing | Cabinet Making | Modular Furniture Manufacturing Process
Solid Wood Joinery | Solid Wood Furniture Manufacturing Process
Surface Finishing with Laquer, Polyester, PU and UV Process
Drywall Construction & Wall Sanding Process
ACP Fabrication Process
Solid Surface Fabrication Process
Door Leaf Production Chart
DOOR JAMB, ARCHITRAVE & SOLIDWOOD PANEL DOOR
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