Particle Core Fabricator

During production we take a flat sheet of particle board and with our fully automated core fabricator, we cut it, glue it and shape it to the required specifications (e.g. profile, width). Laminate sheets are then coordinated with the ‘shaped’ particle board and stacked on a pallet for further production.

• Particle Board specifications – at present Horizon uses 5/8” particle board in 30” x 96”, 30” x 120”, 30” x 144”. 48” x 96” and 60” x 144” sizes

Glue Sprayer

With the automatic spray system, the sheet of laminate is sprayed with a neoprene contact adhesive and then is followed immediately by the particle board core. The sprayer reciprocates to ensure adequate surface coverage of the adhesive to ensure proper bonding. The laminate sheets and core are taken through a drying tunnel to make sure the glue is dried to the required level prior to bonding.

Indexing Table

Both the laminate and the core board go onto an index table where the operator places the laminate on the core with the required amount of overhang on the front and back. This overhang portion is the part that will be post formed onto the ‘shaped’ particle board edge and ‘rolled’ underneath.

Post Former

The laminated board will now travel through the post former which will heat the overhanging laminate to 360 degrees Fahrenheit. Within three to five seconds of heat application, the forming begins with rollers directing the laminate around the pre-shaped particle board. Excess laminate is trimmed and a groove is cut for the backsplash while on this post forming machine. The top then goes into the final forming step which is to for the backsplash. The fully automated backsplash coving machine will clamp the tops in place, apply 360 degrees of heat along the newly cut groove, bend the backsplash into place, apply several beads of hot melt glue to a particle board back strip, and with pressure, insert the strip into the opened groove. This strip holds the backsplash in place at 90 degrees. The entire process of bending a backsplash into place takes about 30 seconds. The product is immediately ready for market when it is taken out of the coving machine. It is generally placed on a pallet to be shipped or transferred to the cut shop for further custom work to be performed.

Size Capabilities

• Minimum depth - 12" for post formed edge(6" for #100 profile)
• Maximum depth - 39 " for post formed edge (59" for #100 profile)
• Popular sizes and uses ( Click here to view )
  • Standard Kitchen - 25" depth
  • Standard Vanity - 22" depth
  • Standard Bar Top
    • Profile #100: 27 1/8 " depth
    • Profile #200: 27 1/8 " depth
    • Profile #300: 26 3/8 " depth
    • Profile #400: 26 3/8 " depth

Packaging & Shipping

Please note that packaging charges apply to the package length, not necessarily the footage of the countertops contained within the package. The shipping department at Horizon Laminates uses experience and professional judgement to determine the size of a package and when a pallet is to be used.

• Cardboard
• Shrink Wrap and Foam
• Pallets