From Log to Layon
This section describes the processes involved in transforming a sawn log, from a tree into a layon that is ready to be pressed and made into a decorative panel or door.
Stage 1: Slicing
Once the tree is felled it is then transported to a veneer mill. Here it is debarked, sawn, cooked and then put on a slicer or lathe. This cuts the logs, using one of the different cutting methods discussed here, into the sheets that we know as veneer. These sheets are then clipped along their edges and bundled up into manageable parcels usually comprising of either 24 or 32 leaves. It is at this stage that they are ready for inspection. Once we have selected the logs that we want to buy they are transported to our London warehouse.
Stage 2: Grading/Sorting
When the veneer arrives at the warehouse it is carefully graded and sorted on the basis of quality and several other criteria such as colour, length and grain pattern. Once this process has been completed it is either put into stock ready to be sold as flitch veneer, or it is put into Jointed Veneers to be made into layons.
Stage 3: Trimming
The first process must be to create a straight jointable edge on the outside of each bundle of veneer. Each bundle is therefore parallel trimmed to give it a perfect edge.
Stage 4: Jointing / Stitching / Splicing
Once trimmed, the bundle is ready for jointing and will pass through one of two types of machine.
The animation illustrates the first method. The veneer is jointed using a thread applied to the back side of the veneer. Leaves are joined into a series of pairs, which are again jointed into larger pairs until the required width of layon is created.
The second method uses glue to bond the edges of the leaves together. The edges are firstly finely coated in glue allowed to dry then placed together, heated and pressed.
Stage 5: End Trimming / Stitching
We now have a layon that is jointed to the required width. All that is now left to do is trim the ends to make it the correct length and to apply a stitch to top and bottom to prevent splitting when it is handled being put on to a panel/door prior to pressing.
The layon is then given one final check and any repairs carried out, before being packaged up and sent out to the customer. They will then bond, sand and apply the final finish to it in order to create the finished door or panel that they require.