Surface and Panel Q3 Digital Edition

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U N I T I N G M AT E R I A L S , T E C H N O L O G Y A N D D E S I G N

Better Design+ at the show continuous laminate revolution Always Modern in All Ways What's new in HPL The edge of Technology special Section :

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Finishing matters

9/24/13 11:14 AM

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The m house project is taking shape. The architectural work on the shell and core is complete and construction will begin shortly. Our goal is to the have the structure enclosed before the snow starts flying here in Wisconsin. Then the fun starts.

The theme of the m house is to demonstrate “what’s possible” in creative applications of materials. The design of the house is decidedly contemporary; the perfect platform for showcasing the best our industry has to offer. The interior of the m house is like a blank canvas on which architect John Vetter and interior designer Amy Carman will create art.

They’ve been asked to stretch their imagination to utilize surface and panel materials in non traditional applications. There will be a great deal of “what if”questions asked…and that’s exactly what we want. Every room and every surface is fair game. From floors, walls and ceilings to furniture, cabinets, storage and everything in between, the creative use of these materials will inspire. And it does not just include the interior. The exterior of the m house will be clad in compact laminate rain screen. Creative applications in the m house today may become the norm in the construction industry tomorrow. And that’s exactly what our industry needs to continually expand.

Revealing the unique application of materials in the m house certainly shows “what’s possible,” but the latest in sophisticated processing technology is what makes it possible. In collaboration with our exclusive m house technology sponsor, we’ll show the world precisely how it was done.

You’ve got to love this business. It has pace, style and endless creative opportunities. Panel processing is the universal language that we all speak. It doesn’t matter in which segment you reside. Whether you make kitchens, store fixtures, furniture, commercial cabinetry, office furniture or architectural woodwork, materials, technology and design are critical to each. It is no coincidence that the tag line of Surface & Panel magazine is uniting materials, technology and design.

As William Woodsworth wrote; “What we have loved…others will love, and we will teach them how.”

Uniting materials technology and design in the m house project is our way of “teaching them how.”

To find out what architect John Vetter, principal of Vetter/Denk architects and interior designer Amy Carman have in mind for the m house, join us at the Decorative Surfaces Conference in New Orleans on November 4-6. To register, see the details on the cover wrap on this issue of Surface & Panel or go to www.surfaces-conference.com

As William Woodsworth wrote; “What we have loved others will love, and we will teach them how.” Uniting materials, technology and design in the m house project is our way of “teaching them how.”

With Kind Regards,

John Aufderhaar, Publisher | Surface & Panel | jaufderhaar@surfaceandpanel.com | 920-206-1766

hnologies, Inc.

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8 Better Design+ Chuck Saylor’s idea of design goes beyond a pleasing aesthetic to a far more strategic approach that connects disciplines and technologies to make relevant products. This is evident in the conception and operation of the relatively small but prominent izzy+ brand. [

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3 From the Publisher 34 Architect Spec rem koolhaus / Benjamin Pardo 56 Regenerate 72 Advertiser Index 74 From the Editor

12 At the Show Highlighting a few examples of design trends that were in evidence at 2013 design fairs in Milan and Cologne, as well as New York City and Chicago.

16 Continuous Laminate Revolution Revolution is happening across the board, and it is beginning to change the way that designers create and fabricators produce. Like most significant shifts, the continuous laminate revolution is the result of a perfect storm of many indirectly related factors.

24 WMIA Educator of the Year Dean Mattson's speech, given at the Wood Industry Conference, when he accepted the WMIA Wooden Globe Award as Educator of the Year.

publisher

John Aufderhaar/Surface & Panel Magazine 1617 Country Club Lane, Watertown, WI 53098 Ph: 920-206-1766 fax: 920-206-1767 jaufderhaar@surfaceandpanel.com www.surfaceandpanel.com

30 Educating the Industry This program at North Salem High School is the embodiment of what an effective, modern technical education program looks like.

advertising

32 Always Modern In All Ways As part of its 75th anniversary, the iconic furniture company Knoll launched a new collection that embodies its “Always Modern” ethos.

Ryan Wagner, Vice President, Sales & Marketing Surface & Panel Magazine 1617 Country Club Lane, Watertown, WI 53098 Ph: 920-262-2080 fax: 920-206-1767 rwagner@surfaceandpanel.com Jake Gawel, Marketing Director www.materialicious.com/www.surfaceandpanel.com Ph: 920-728-0369 fax: 920-206-1767 jake@materialicious.com

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On the cover: Bold colors and 48 The Edge of Technology stripes were prevalent at design T.C.M. (technology, creativity, manufacturing) makes a shows worldwide in 2013. Image lot of innovative products, including retail store fixtures, courtesy of Interprint's design team. but it does it differently than most of the competition.

Circulation

Jennifer Schroedl/Surface & Panel Magazine 1617 Country Club Lane, Watertown, WI 53098 fax: 920 206-1767 jsstudio123@yahoo.com

52 Lighting the Way to Increased Sales Solid-state lighting technology continues to grow exponentially, and it brings new methods for integrating light along with it.

Editorial Director

Suzanne VanGilder/Surface & Panel Magazine 1617 Country Club Lane, Watertown, WI 53098 Ph: 608-698-0375 fax: 920-206-1767 svangilder@surfaceandpanel.com Art Director / Graphic Design

Karen Leno/KML Design, Inc. 923 Forest Edge Circle, Coralville, IA 52241 Ph: 319-430-5108 kmldesign@mchsi.com Composite Panel Association Main Office

19465 Deerfield Avenue, Suite 306 Leesburg, VA 20176 Ph: 703-724-1128 fax: 703-724-1588 Toll Free 1-866-4COMPOSITES www.CompositePanel.org

40 What's New in HPL The original plastic laminate celebrates 100 years in 2013. Since then, companies have constantly found new ways to make a great product even better.

On the FM cover:

Mock Woodworking's fine finish at the Smithsonian's Treasures of the World retail space.

59 Finishing Matters A special section highlighting the finishing industry.

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60 Always Functional Eficiency 64 UV LED Curing – A Cool New Technology 66 Reducing Finishing Costs 72 Fixtures Crafted Through Technology 76 This is Where Hope Thrives Human centered design in the Seattle Children's Hospital's new expansion.

Canadian Office

Post Office Box 747, Station B Ottawa, Ontario CANADA K1P 5P8 Ph: 613-232-6782 fax: 703-724-1588 International Testing and Certification Center

73 Lawson Road, Leesburg, VA 20175 Ph: 703-724-1128 fax: 703-724-1588 www.itcclab.org

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Surface & Panel is published quarterly by Bedford Falls Communications, Inc., 1617 Country Club Lane, Watertown, Wisconsin 53098, telephone 920-206-1766, fax 920-206-1767. John Aufderhaar, President, Christine Aufderhaar, CFO. All rights reserved. No part of this publication may be reproduced or transmitted in any form, electronic or mechanical without written permission from the publisher.

Subscription policy: Individual subscriptions are available, without charge, to manufacturers who engage in panel processing, qualified service providers and suppliers. Publisher reserves the right to reject non-qualified subscribers. One year subscription to non-qualified individuals: U.S. $50, Canada/Mexico $75, all other countries $100, payable in U.S. funds. Single issues are $15, and must be prepaid.

Bedford Falls Communications, Inc., does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. Printed in the U.S.A. Postmaster: Send address changes to Surface & Panel, 1617 Country Club Lane, Watertown, WI 53098. Please direct all subscription questions and mail to: Surface & Panel, 1617 Country Club Lane, Watertown, WI 53098 ph: 920-206-1766

8/26/13 3:16 PM

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Decorative Surfaces Conference Coming to New Orleans

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ex www.surfaces-conference.com TCM Americas presents the fourth annual Decorative Surfaces Conference to be held at the Loews New Orleans Hotel on November 4-6, 2013. presented by

PA The continuing theme of the DSC is to explore the latest advances in surface materials, technology and design. with media sponsors

Prominent industry leaders will present at this year's conference including architect John Vetter, principal of Vetter Denk, on the progress of the exciting m house project (see page 3 in this issue for more details).

www.surfaceandpanel.com www.materialicious.com

If you are interested in becoming a DSC sponsor, please call Ryan Wagner at 920-262-2080 or John Aufderhaar at 920-206-1766.

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If you manufacture, specify or use decorative surfaces in any residential or commercial environment, this conference is for you.

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Decorative surface materials and surfaced composites have rapidly become the products of choice in retail, healthcare, education, hospitality, residential and commercial environments.

At the DSC you’ll witness the best this global industry has to offer.

Make the decision now to attend the DSC in New Orleans. Go to www.surfaces-conference.com to register for the conference and to secure your hotel reservation at the Loews New Orleans Hotel.

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Better Design+ b y

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nce upon a time in the not too distant past, the North American office furniture industry enjoyed a robust economy that traded, by and large, in paneled cubes. It was a model that thrived on isolation, and in a sense, it mirrored the insular North American market. According to Chuck Saylor, founder and president of izzy+, “We as an industry rode the cubicle wagon for a very long time, and it was a successful growth engine. Because the economy was so overwhelmingly positive, we lost sight of the importance of design and innovation, and their roles in creating success. The economies of the last decade have brought America back to the reality that we are in fact going to have to differentiate ourselves. We know today, on a global basis, that there are a lot of lower cost ‘me too’ products coming in from Asia. Authenticity really does matter, and design is the key driver to bring that value back.” This shift in the market place created an environment where outlying companies can share space with the big players, provided they deliver on design.

Saylor’s idea of design goes beyond a pleasing aesthetic to a far more strategic approach that connects disciplines and technologies to make relevant products. This is evident in the conception and operation of the relatively small but prominent izzy+ brand.

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“I have always believed that no one thing should do only one thing.

So we have tried to embed this idea into our design philosophy, that when we create a new product, if it can do multiple things, live in multiple places, then it becomes more culturally relevant.”

Chuck Saylor, founder and president of izzy+

“When I started thinking about the company I was pretty significantly impacted by Jim Collins and his book “Good to Great” about the importance of a company having meaning and purpose other than just making money. That got me thinking. The world certainly didn’t need someone else to just look and act like everyone else,” says Saylor, a self-described “furniture brat” with decades of experience in the industry. “I chose a path that said we would always look at our children and grandchildren and use them as a reference point for developing products. We’re creating, innovating, bringing new ideas for the future, the continuum of change.”

The izzy+ motto, “Better Together” runs through the company’s development process and material philosophy all the way to how the company works with the end user.

Connected Development for the Connected Age

Looking forward, coming generations will work in significantly different ways. Already there is an emphasis on leveraging technology, leveraging space and leveraging relationships. All of this leans toward a culture of connection and stacked functionality. “I have always believed that no one thing should do only one thing,” says Saylor, “So we have tried to embed this idea into our design philosophy, that when we create a new product, if it can do multiple things, live in multiple places. Then it becomes more culturally relevant.”

As a brand, izzy+ embodies this belief. Though initially conceived to be a contract furniture company, izzy+ developed a product portfolio that fits educational environments as well as contemporary offices. “Chuck has a great vision for growth, both organically and inorganically,” says Allison Roon, an independent design consultant who has worked with izzy+ for years. “He acquired brands, including HÅG, Fixtures Furniture, Harter and ABCO, that align very strongly with the company’s ethos. They all have great attention to design and reach the markets that izzy is already reaching.”

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Material Flavors

Headquartered in Spring Lake, MI, izzy+ operates two manufacturing facilities and employs roughly 400 people. A 400,000 square-foot operation in Florence, AL does all the panel processing, furniture manufacturing and metal powdercoating for the company. Another facility in Middlebury, IN is dedicated to seating and upholstery. Despite the geographical distance, izzy+ utilizes technology to stay connected, allowing for agile production across the umbrella of brands, as well as customization. “It used to be that the elements of a business could work in vertical silos by themselves. Manufacturing, design, development, marketing, each could do their own thing. And that did not necessarily translate to agility or enhanced design,” says Saylor. “But what we know today, supported by ubiquitous access to information through technology, is that different entities can collaborate in real time and bring broader and more exciting thinking to a particular idea. To me, connection is a big part of agility. It shortens the cycle time of development and enhances design both domestically and on a global basis.”

Each product within each line in the izzy+ portfolio can work together in different configurations, or layers, to optimize the functionality of the system. In order to do this, izzy+ developed a comprehensive materials palette. “Prior to introducing the Flavors program last year each brand had their own material finishes, so it was very difficult for specifiers to try to use different product lines together,” says Roon, who collaborated with color and material specialist Kerry Rowe to develop the program.

Drawing inspiration from the izzy+ brand, which is very energetic, confident, modern and material centric, the Flavors program itself is set up with three different layers of finishes selected to meet the needs of future generations. “Our core palette includes long lasting neutral colors. The classic palette is made up of timeless favorites that have a 10-year life cycle. And the evolving palette is all about emerging trends with a three-to-five-year life cycle,” says Roon. “We wanted to focus on bold chromatic colors and we wanted the platform to be constantly evolving and changing,” The team started by developing 15 colors of polypropylene for thermoplastic seating, and then looked to laminate, veneer, glass and resin suppliers to help with the development of other finishes. “Before this program izzy+ had not worked with Formica, but we found that Formica was very forward thinking in terms of their research into global trends, things like matte finishes and textured woodgrains that mimic real wood veneers. So we added them to our line as our evolving collection,” says Roon. “We also partner with Wilsonart for our classic palette. Their products are wonderful and they have a great reputation in the marketplace.” Stevens Industries, which offers exact matching for nearly all the HPL designs in the Flavors palette, is the TFL partner.

Other exciting partners include textile manufacturers- Momentum, Maharam, Knoll, Camira, Ultrafabrics and Greenhides Leather.

“At some point in the design process you begin to realize that the bigger differentiation won’t necessarily be function or style or even a particular design philosophy as much as it will be the use and application of materials,” says Saylor. “I can create a much more realistic looking product because of current technology. For example, printing technology and processing makes laminates that have the look and feel of real wood, so it is a layering of my senses around engineered products.” izzy+ is constantly looking at materials innovations, from powdercoating to the switch over to ABS edging on all lines, as a means of conceptualizing for the future. “It is really culturally

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Connecting on the Surface

relevant all the time, and constantly changing on its own continuum. We know that technology is influencing materials in incredible ways so that today we have more options, and more exciting things happening with materials than ever in our lifetime.

And I personally see that continuing to accelerate,” Saylor adds.

Saylor built a brand by looking to the future, and when asked what he sees for the furniture segment in North America, he is enthusiastic about the potential. “We are now entering a period where I know for sure our industry has come to grips with the fact that design is incredibly important going forward, and we can never lose sight of it again,” he says. “It is what differentiates us and brings meaning and purpose to our businesses and lives. It is what pushes innovation forward and brings about new technology. I see this as positive for the furniture industry specifically and American businesses all around.” s&p

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deaPaint is a great example of how design influences technology and materials. izzy+ started working with the company, which originally specialized in liquid coatings (available in black, white and clear) that turn any surface into a dry-erase board, to add to the idea of furniture facilitating connections. “We like sharing ideas with one another,” says Chuck Saylor, founder of izzy+. “And one of the best ways to make that connection is to give people markers and space to write.” In fact, the concept for IdeaPaint was born when it was observed that brainstorming on a giant sheet of paper engaged participants and democratized the idea generation process.

The functionality of the material made it very popular in office and educational environments, which drove further development.

“For years IdeaPaint’s customers have been applying IdeaPaint to file cabinets, doors, desks and more,” says Jeff Avallon, vice president of business development for IdeaPaint. “Realizing this was not an ideal solution, we set out to figure out the best way that IdeaPaint could be integrated into the manufacturing process.” The result is IdeaPaint Powder, a specialty powdercoating that can turn any metal into a dry-erase writing surface.

“This is a perfect case where technology, need, sustainability and application all come together,” says Saylor. “And I think we will continue to see that type of development happen.” n

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images courtesy of Interprint

woven upholstery

guerilla crochet artist Yuki Matsuoka's d-torso creations utilize CNC and laser technology

woven string

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rend watchers are tossing around a new term, “glocal,” which refers to global inspiration translated into design for products that are made locally/domestically. It is an interesting concept for North America, one that balances the importance of having a strong design identity with the importance of staying internationally relevant.

In an industry that, at times, has suffered from design-deprivation driven by price fights; and in a market that is geographically distant from the broader world, there is something optimistic about the term “glocal.”

So what does it look like? Here are just a few examples of design trends that were in evidence at 2013 design fairs in Milan and Cologne, as well as New York City and Chicago.

In all venues, specific elements were often mixed, sometimes in experimental juxtaposition.

What follows is an overview of observed fashions. It is by no means comprehensive and it is not intended to be authoritative, merely an invitation to imagine. A more materials-specific Surface Design Guide will appear in the Q4 issue of Surface & Panel.

Early craft and primitive patterns were present, as was “guerilla crochet” a term used to describe many variations of weaving, string art and macramé.

These concepts were often mixed, both in terms of using multiple patterns in one piece and in terms of using unexpected media.

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tessellation

On the flip side, design paid homage to the modern with several trends made possible by technology. Perforation, geometric gradation, tessellation and forced perspective all make use of the capability to precisely shape and repeat patterns with CNC. Along the same lines, LED, and to an emerging degree OLED, was used widely in everything from traditional lighting applications to integration into images.

images courtesy of Interprint

forced perspective perforation

geometric gradation

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images courtesy of Interprint

stripes purposely threadbare

re-purposed propane tank created by eco artist Colin Selig Colors tended toward primary and stripes, with metals moving into bronze and brass. Materials were humble including reclaimed and purposely threadbare. Cardboard was also widely used, particularly amongst students, which asks the question, are designers becoming more open to the idea of lightweight materials? s&p

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Continuous Laminate

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evolution is happening across the board, and it is beginning to change the way that designers create and fabricators produce. Like most significant shifts, the continuous laminate revolution is the result of a perfect storm of many indirectly related factors. The growing popularity of continuous laminates (3DL/RTF films, 2DL films and low basis weight papers) is well documented in the store fixtures industry. Consider that, according to Dustin Smith, National Sales Manager for Omnova Solutions, Inc. “The reports from the ARE show that the retail segment, in general, remained stagnant from 2008-2011, yet in that time frame Omnova grew double digits every year. It is a shift in market share. Our products are displacing TFL and HPL sheet goods and paint.” Continuous laminates are also making quiet but steady gains in the office furniture segment. Looking ahead, the ARE is predicting 10 percent growth in store fixtures for 2013 and 2014. Add to that the expectations for the re-shoring of manufacturing and… is that revolution in the air?

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As further evidence, there is an uptick in components manufactures acquiring membrane-pressing capabilities (3DL). But the leading edge of the revolution goes well beyond that into profile wrapping, inventive applications of miter folding, and even flat panel laminating (2DL). Jeffrey Jappa, owner of JMC Wood Manufacturing, a laminator and fabricator of wood products located in Bridgeton, MO, is one of the visionaries leading the charge. “I lost a million in sales during the recession of 2008-2009,” says Jappa. “So I went out and invested. I bought a Wemhöner membrane press. The economy was so bad that Stiles provided discounted pricing and set up low interest financing.

It looked risky from the outside, but research and market insight told a different story. During a recessionary economy, I wasn’t going to do real risky stuff.” Although JMC is equipped for traditional 2DL panel processing, the company’s core competency began to shift. In fact, that membrane press did $3.2 million of business in 2012 alone.

More recently, Jappa made sizable investments in miter-folding capabilities. “Everything I am doing now is miter folding. It happened so

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fast, but it was not a blind endeavor. I saw it coming for a couple of years and prepared for it. Now it is a huge program and JMC has developed integrated, exact design matching product lines that no one else has. We’re tooled up, and getting trained up, to be truly a one stop shop. I just really believe in the possibilities with continuous laminates. And I have the optimism to shape the future.” (See Tech Spec page 20 for more about JMC’s equipment investments).

So what makes Jappa so sure? Design. Design. Design. There are three distinct ways to think about the design advantages of the continuous laminate revolution. Design in the sense that store fixture and furniture designers think about it. Applied design in terms of process engineering and what is possible. And the actual design of the materials as it relates to surface aesthetic and construction.

What do we want? Clean seamless edges! When do we want it? Now! Many retailers tasked with keeping fixtures fresh are turning to vinyl.

“Part of using the vinyl laminates, besides the obvious 3D applications, is that you can achieve covered edges,” says Rick Dalton, senior business analyst for J.C. Penney Company, Inc. Charged with sourcing for 1100 stores in North America and Puerto Rico, Dalton works closely with JC Penney’s fixture design team and pays careful attention to materials. “It is primarily aesthetic. Both HPL and vinyl perform well in a retail environment, and both are better than paint, in my opinion. But it is eliminating edge banding and the potential for seam lines on the edges of solid pieces, more than anything, that is the reason we are utilizing vinyl in some of our fixtures programs.” The continuing trend of white in general, and high-gloss in retail environments, amplifies the desire for a seamless look.

Proponents of vinyl will point out that there are indeed inherent quality differentials between sheet goods and 3DL. “Vinyl is not pressed into the board, so it won’t chip. And the impact resistance is much greater than sheet goods. Hit with a hammer, HPL/TFL will crack; 2DL and 3DL vinyl will indent,” says Smith. Another big advantage is eliminating seams all together. “Retailers don't like edge banding because it falls off. Plus, people pick at it. We have a large customer with a continuous laminate program now that was spending $2 million a year to replace edge banding and cracked HPL.” The Mighty Miter and Other Intriguing Processes

Most people get that 3DLs can be membrane pressed into profiles, which allows for contoured surfaces that just aren’t possible with HPL/ TFL. But the potential for applied design with continuous laminates moves into another dimension with miter folding. JMC recently did a very unique job for JC Penney utilizing Omnova’s Starlight White highgloss vinyl to make 3-inch thick parts. “Even with membrane pressing you get fiber pop on the edge because the faces of the MDF are hardened in the presses, but the middle is punkier, and that punkiness telegraphs,” says Jappa. “So we took a 1.5-inch board and miter cut it. Then, 1.5-inches up we made another miter. We glue the 1.5-inch board back on itself and it wraps over, making a front edge that is 3" thick and very clean looking.”

Part of the appeal of continuous laminate is that it offers opportunities for efficiencies. “With profile wrapping the machine runs 50-feet a minute inclusive, that is glue, vinyl on the board and out the door,” says Jappa. “compare that to the traditional: gluing sheets, putting them on the press shuttle table, running the press recipe that could be up to 4 minutes long, and then bringing the molding back out. Next the moldings have to be trimmed out. Or compare it traditional moldings that have to be sanded and stained multiple times. There is no comparison.” JMC also goes beyond conventional machining and laminating, utilizing a double end tenoner (DET) in place of a CNC to add edge profiles on flat MDF panels in preparation for 3DL processing. “The DET runs 60 feet a minute. We also have a feed through boring machine that can bore 300 parts an hour.

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Dean Mattson

WMIA Wooden Globe Award Educator of the Year

Editor’s note: The following is the complete text of the speech given at the Wood Industry Conference by Dean Mattson, director of the Wood Manufacturing/Cabinet Making Program at North Salem High School, Salem, Ore., when he accepted the WMIA Wooden Globe Award as Educator of the Year.

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t is so surreal to be standing before you today and for you to have recognized our educational program at North Salem High School in Salem, Ore. Last year three companies nominated us for this award and the winner was the Blum Corporation. For me it was like David and Goliath. When we were nominated again this year it was like, “Who is going to win this year? IKEA?” I was sitting at my desk counseling a student whose foster parents told him he wasn’t good enough to get one of our industry’s contracts when my iPad beeped and I looked at the screen and it said, “Congratulations! You are the winner of our Educator of the Year Award.” I said, “Holy $#&@! We won!” My student said, “Mr. Mattson, you just said a bad word!” I was shocked and speechless.

Last week at the Stiles Executive Briefing Conference (EBC) in Chicago, industry leaders were asking me, “What is the secret to attracting so many high school young people to enroll in your woods program and then upon graduation, place them into good paying jobs in our industry when so many programs are being closed?”

I would like to go back a few years ago and start there to answer this question.

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In 2007, my late wife, Ann, was stricken with cancer and passed away. Shortly after that trial came the financial crises of 2008, and my cabinet manufacturing company lost a great deal of work when the stock market crashed. I was forced to reinvent my life.

The reinvention started by meeting a remarkable lady named Rosemary. Rosemary lost her husband years ago to cancer, as well.

Rosemary allowed me to date her, fall in love with her and she graciously became my wife. Our families joined together to make one new family and we now have four new grandchildren. We feel extremely blessed. But my career still seemed to be empty.

Rosemary, a most gifted teacher began to heighten my passion for teaching. I thought about the eight years I had volunteered teaching at Oregon State Penitentiary, helping men re-enter society. I was beginning to think of pursuing some form of teaching. Then a call came that asked for my help in finding a replacement for the legendary woods teacher David Anderson who was retiring at NSHS after 30 years. Six months later I was awarded the job.

I had no clue what I was doing. I was surrounded by teenagers that were acting and talking in ways that were shocking to me. Back in the day, they would have been immediately expelled. I remember saying to myself all the time, “Lord, what am I going to do?”

Like many woods programs around the country, this one was shrinking. It had become for the most part a dumping ground by counselors and administrators for problem kids. I was extremely frustrated.

It was an uncomfortable environment with all the dangerous outdated equipment to manage. I had nightmares of cut-off hands.

As a former marketing professional and an owner of a cabinet manufacturing company, I needed to change the image and produce products that young people could embrace. I needed to react quickly, but that is not the norm for public education. In addition to this, NSHS is a Title I school with a poverty culture and over 20 percent of the students are homeless. I struggled to grasp the way to turn this program around until I had a conversation with one of my students.

During the first six weeks of my first semester sat a quiet Hispanic young lady whom we will call Mary. Progress grades were due and Mary had all D and F grades. I decided to sit down next to her and see if she would talk to me. She did not say much. I told her that I wanted to give her a C- but she had to turn in her work and would work with her to help her finish her basic cabinet project or she would fail. Mary said she would try. She began to respond immediately. At the end of the semester when we graded her cabinet, she received a B grade and Mary had tears running down her cheeks. Mary said it was the best grade she had ever received. I, too, was encouraged and I thought maybe I could become an acceptable teacher.

The next semester’s Cabinet Making 2 project was a solid stock, mortise-and-tenon table that measures 16x16x16 inches. At the end of the semester, Mary asked if I would assist her with dry fitting her table. I looked over at her, and she began to cry again. I asked her what was wrong. Was she disappointed in her table? She said, “Oh no, Mr. Mattson, it is perfect for my dining table.” As a father of girls, I said, “You mean for your dolls?” Mary’s answer changed my life as an educator. She said, “Mr. Mattson, I live in a car, and I take care of my little brothers and sisters. At night I work in the cannery to buy food for them. The car is cold and we have no lighting so that is why I was not able to do my homework in the past. My new little table will fit perfectly on the back seat of the car, and the four of us will be able to eat on it.”

I was stunned.

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Mary went on to ask Mrs. Mattson and me if we would be her Mom and Dad at graduation exercises. Two years later, this remarkable young lady returned to my classroom and told me she was a secretary, earned enough money to rent an apartment for her siblings and she would never have to work in the cannery again. She said, “Mr. Mattson, your woods class changed my life.�

Following this experience I became a driven and passionate proponent for youth. I developed a vision and implemented the vision with the help of many people. I wanted students of all colors, English language learners, first generation Americans, any student, to have the chance and the experience that Mary had. I ramped up the program using Lean Manufacturing principles. I contacted all the business partners in the industry that I have worked with and told this story. They opened up their check books, sent truckloads of supplies to grow our program into one of the largest woodworking programs in the country. To date, more than $600,000 has been raised for the program. This along with the support of Salem-Keizer School District has been enough.

I continue to sell the vision to anyone who will listen. At a regional WoodLINKS seminar on a furlough day, I spoke about our program. Joe Wadsworth, an employer and owner of Custom Source Woodworking out of Olympia, Wash., started talking to me. He was so thrilled with students being taught integrity, finances, math, woodworking and what employers are expecting from the workforce. He and his partner, Jim Mammina, have hired all of our graduating seniors that have wanted to into the woods industry. It has changed his organization so much so they say it is their edge in a tough market. He said they went from a 98-percent failure rate with off-the-street hires to 50 percent with my students.

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“This award makes these underprivileged students national champions. They are beginning to feel like winners when all society and even sometimes their families have told them they are not.”

This year, more than 400 students will move through the Cabinet Manufacturing program, and there are hundreds on a waiting list.

Students suddenly want to be educated in math, reading and writing. Many students for the first time have the motivation to learn.

Because mathematics plays such a large role in educating our youth, we sought out a grant to bring a leading math teacher, Mr. Mark Atkinson, into our program this spring to write new math curriculum using woods as the core curriculum and math as the elective. Next

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year with the help of our far-sighted principal, Cynthia Richardson, and her staff of administrators, we will be able to handle more than 800 students and hopefully not have to turn any students away.

A Wall Street writer interviewed me and his article is titled “A New Model of Education for America.”

Many of our students for the first time believe they can go to college or directly into an industry that is screaming for quality young people to bring back manufacturing in America to its place of prominence. Last week at the EBC in Chicago, the number one need of industry companies large and small is trained youth. This is why in our opinion, Career Technical Education (CTE) is so important to the future of America’s workforce.

Here is a quote from Jonathon Adams, COO of the Adams Group from North Port, Fla. “Good evening, Dean. It was a pleasure meeting you at the Stiles EBC the last few days. I enjoyed learning about your program. I would like to continue to learn more and possibly become one of the companies who recruit your students for internships and eventually full-time employment. Please keep me posted on your progress and perhaps I’ll plan a trip to come see your program sometime later this year.” I read this email to all my current 240 students. They walked out of the classes with a sparkle in their eyes and a swagger I had not seen before.

This award makes these underprivileged students national champions. They are beginning to feel like winners when all society and even sometimes their families have told them they are not.

It is our goal to share this model of CTE education with any organization that believes that this is a key to the future of education in our country. It has been written in publications all the way to Wall Street that this is an important breakthrough. If you think it is, please pass this on to prominent people in education, industry and in Washington, D.C. You are the industry leaders of machinery. Programs like mine need state of the art equipment to train the future leaders of our industry.

You want to create a market edge. Place your machines in prominent educational programs and let them sell for you 24-7. It is the least costly marketing with the biggest ROI you can have. Your competitors will be wondering what happened. Join me on the cutting edge. It is where the action is. I sacrificed my company for youth. What can you do? A freshman in Cabinet Making 1 says after asking his class what makes this program special to them. He answered, “You’re not just teaching us how to make stuff out of wood; you’re also teaching us how to make something out of our lives.”

On behalf of the fabulous young people of North Salem High School, the teachers, the volunteers, the administrators, the industry partners, the investors and most of all those that pray for these children every day, and myself … thank you from the bottom of this man’s heart. s&p

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Educating the Industry b y

*If you have not read Dean Mattson’s acceptance speech for the WMIA Wooden Globe Award for the Educator of the Year (page 24), do that before reading this.

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ean Mattson’s program at North Salem High School is not the only successful woodworking program in schools today, but with its model of operating like a business, and the excellent work Mattson has done raising the funds and awareness necessary to outfit the shop, it is the embodiment of what an effective, modern technical education program looks like.

Ask any business owner the secret of success and that person will tell you, “good people.”

Advanced machinery, new materials and powerful software are all useless without people who know how to apply them. This is particularly true as manufacturing technology continually advances to meet the demands of a design- driven global market. And the need is only going to become more pronounced as manufacturing is re-shored to North America (more about this trend in the future).

Yet. Ask any business owner how skilled labor is recruited, and there is a lot of scowling and grumbling about the lack of trained people in the workforce. Some large companies have developed programs to “grow their own,” but for the most part, the increasingly sophisticated realm of manufacturing has a talent demand that far exceeds the supply. Conversely, there are countless young people in North America with clever minds who are not well suited to academia.

Even the most cold hearted CFO will admit that it pays to retain quality employees. All good companies know this. The difference between a good company and a great company, however, is purpose; a human element that cannot be added into the latest software package or calculated on the bottom line. All the above reasons underscore the absolute importance of industry getting involved with education.

When Dean Mattson took the job teaching woodworking, he was looking for something different. What he found was purpose. The principal that hired Mattson did so as an experiment. He wanted to see what would happen if someone with no educational background, but with strong business experience, ran the program. And the result was synergy of education and industry.

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This story is so compelling because Mattson is just a regular business guy. In fact, anyone reading this has the potential to be just as influential. What any endeavor requires for success is a narrative that supports the outcome. For Mattson, his student Mary changed the way he viewed his role. Suddenly he understood that he wasn’t selling woodworking, he was providing students that had been told their entire lives that they would never amount to anything with a new narrative. Along with technical skills each student receives life skills: business etiquette, accountability, respect; but most importantly Mattson acknowledges the innate purpose in his students. And when he sees it in them, they see it too. This transformation in perspective has benefits that reach far into the future. Potential thugs become responsible citizens, taxpayers, supportive parents, community members. At the same time it strengthens North America’s industry position.

Technical education, and our industry that depends on it, are also in need of new narratives.

This pivotal point in North American manufacturing requires a new model of education that includes the type of experiential learning and inspiration that only trained woodworkers can provide. And that shift is already happening. The AWI’s Adopt-A-Shop program has been aiding technical education for several years. And now, with the support of industry partners and an esteemed board of directors, Mattson’s program is growing into a non-profit operation tasked with developing transitional leadership and creating a replicable model that covers the most up-to-date processes and equipment. A perfect example is Stiles Machinery’s recent partnership with Mattson, which adds entry-level CNC skills to his curriculum. And that is just the beginning. Where this story goes depends on how the players do, or do not, participate in the narrative. It is a “choose your own adventure.” s&p

Mattson’s program at North Salem High School proves that it is possible to change the narrative of technical education for the benefit of industry as a whole. Now it is up to industry to get involved. Most people want to help, but don’t know how. Here are four things you can do today to get involved.

1. Join the LinkedIn group “North Salem High School Woodworking program”. Celebrate the student’s latest victories, as well as keep up to date with current initiatives to improve and enlarge this desperately needed resource. Be a part of the discussion driving the content and quality of the program. Participate in the placement of qualified woodworkers.

2. Contact the NSHS Woodworking Program directly for an updated list of graduating students ready to interview for your positions.

3. Support woodworking education.

Make a tax-deductible donation directly to the NSHS Woodworking program (one time or recurring monthly).

4. Contact the AWI via www.awinet.org to find out more about Adopt-A Shop.

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I m ag e s c o u r t e s y o f K n o l l I n c .

Always Modern in All Ways

T

his year marks Knoll’s 75th anniversary, and as part of the celebration, the iconic furniture company launched a new collection that embodies its “Always Modern” ethos. “We are dedicated to the idea of using modern design to connect people with their lives, their work and their world,” says David Bright, senior vice president of communications for Knoll. To do this, Knoll employs a creative process that keeps the company on the leading edge of thought. Rather than designing from within, Knoll works collaboratively with the foremost architects and designers of the time to develop products that are not always the norm, but are always relevant. Knoll’s strengths lie in the engineering and commercialization that bring these ideas to the market. In fact, many of the professional designers engaged by Knoll have no furniture experience, instead lending expertise from other areas, such as user interface. Backed by Knoll’s design engineering prowess, these partnerships regularly result in products that go far beyond the traditional concept of furniture. “We have had a great run pioneering work place models for commercial, healthcare, government and educational institutions, and as a result, have created a very comprehensive product portfolio which not only spans object furniture, but also open plan systems, private office furniture, textiles and accessories,” says Bright. “And based on the precepts of our founders, there is huge crossover into residential.” Regardless of the category, each product combines artistic invention with functional efficiency.

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Always Artistic Invention

A look at Knoll’s latest collection gives some insight into the company’s creative process. “Tools for Life” includes 11 easily adaptable pieces of furniture designed by eclectic Dutch architect and provocateur Rem Koolhaas of OMA (see Architect Spec page 34). The design brief was based on the concept that today people work everywhere, and to that end, many of the pieces in the collection move, taking different and sometimes unpredictable shapes based on what the user needs. “In the case of ‘Tools for life’, Koolhaas had a certain vision for each piece,” says Khalid Masoud, Knoll’s lead product design engineer for the collection. “They wanted a certain aesthetic. They wanted pieces to rotate, or move specific distances. So my team’s task was to figure out exactly how to make that vision happen.”

As the pieces were conceptualized, Masoud’s team went to work.

“When we first saw the designs we were a little unsure. Engineers tend to be a bit conservative,” says Masuod. “But the Knoll leadership team basically told us that we didn’t have to think about the project conventionally. We had open space to play in and were encouraged to use any technology necessary.”

www.surfaceandpanel.com

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This sort of product development re-imagined through the lens of modern design continually brings new technologies into Knoll’s product lines. “Some of the componentry that we used for the collection was pulled from an industrial robot,” says Masoud. “From an engineering perspective that is really exciting.” According to Bright, materials innovations have always been an important part of the Knoll story, and that holds true for this collection. Koolhaas deliberately specified a wide range of materials for the pieces, from the archetypical, such as leather, to engineered products. “Some of the materials specified were new to Knoll, so it was a good opportunity. And others, like the Formica laminate used for the 04 Counter, were the right solution for the technological look of the piece,” said Masoud.

The newest collection will be available through Knoll’s direct sales force and dealers throughout North America, as well as through showrooms in major cities. In its 75th year Knoll also introduced a new method for bringing certain products to market, an e-commerce portal launched in April of this year. Of course, nothing less would be expected of a company with a global viewpoint and a dedication to being always modern. As Bright says, “What has distinguished Knoll over time is not only the materials we use, but this whole idea of advancing craftsmanship and technology through the use of design.” To learn more about Knoll’s processes, finishing technology and commitment to sustainability, read “Always Functional Efficiency” page 60. s&p

Reach out and touch an exclusive line of textured surfaces. With the natural look and feel of real wood, our designer finishes are the fraction of the cost. And, with 100% recovered wood material, you can help preserve habitats for our wild friends.

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(888) 358 · 5075

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Rem Koolhaas Partner, OMA Benjamin Pardo Executive Vice President, Design Director, Knoll

Im a g e s c o u r t e s y o f O M A

Tools for Life “Tools for Life” is an 11-piece collection of furniture designed by Rem Koolhaas and his studio, OMA. Overall, it’s a frank and, at times, frisky expression of the idea that furniture is, ultimately, equipment for living and so has an obligation to perform at a high level.

Architect, author, curator, professor, self-made sociologist, and full-time provocateur, Koolhaas has produced a wide range of projects, though it’s the large, such as the Rothschild Bank in London, the extra large, such as the CCTV tower in Beijing, or the super-sized, such as a master plan for a city of 200,000 people in Doha, that have dominated his office in recent years.

For this, his first official foray into product design, Koolhaas had to rethink his own preconceptions about practicing at such a small scale. Tapped by Knoll to help mark its 75th anniversary, he joins an august group of architects who have shaped the company’s history, including Mies van der Rohe, Marcel Breuer, Eero Saarinen, Robert Venturi and Frank Gehry. What follows is a condensed and edited series of interviews outlining the principles behind “Tools for Life.”

WHY DID KNOLL WANT TO WORK WITH OMA? BP:

Because of the way Rem Koolhaas thinks about architecture. In general,

I’m drawn to his thinking—not always to exactly what it is that he’s saying, but to the frankness with which he says it and his ability to dismiss extraneous stuff. And we wanted to see a contemporary figure interpret Modernist ideas. Some of the pieces are, in their static state, very much like Florence Knoll pieces: They are the background pieces that create subarchitecture in an architectural space. Yet there’s a kinesthetic quality to this collection—many of the pieces adjust, move, or transform. Certain pieces undergo a metamorphosis. It’s the first time since the Frank Gehry collection where we’ve done something that says: “Here’s an architect of today who is challenging us to think about furniture and ideas related to both business and domestic environments.” And it’s not just about wonderful objects but also about how people interact with space and architecture.

WHY FURNITURE? WHY NOW? RK: I had always felt that designing furniture was kind of redundant. But due to some experiences in my private life, at home, I was designing at that scale. I had thought that it would be almost impossible, but actually I enjoyed it. It unlocked energy. So I decided that our so-called principle of not being involved in design needed to be thrown overboard.

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HOW DOES THE FURNITURE COLLECTION RELATE TO OMA’S ARCHITECTURE? RK: The pieces all perform different tasks. The furniture is, in a way, mutable and changeable and so for that reason it corresponds very closely to my interest in things that perform rather than things that have particular shapes. So in that sense there is a kind of seamless incorporation of the same logic, but at a totally different scale.

HOW DID THE COLLECTION DEVELOP? BP: From the start, what was important to me in terms of talking to Rem about this project was that I wanted to be able to talk about office space planning concepts in the most neutral possible fashion and to tie them back to residential ideas as well. In the initial discussions, I was trying to avoid any kind of aesthetic imposition or any question of geometry or any kind of influential materiality.

Strangely enough though, that neutrality is very much part of what the furniture has actually become. So, the real conversation at the start was about height, adjacency, and visual division. I said that I wanted to focus on work, not the office. And the distinction is that people work everywhere. And one of the reasons why height, boundary, and spatial relationships are so important is because you find yourself working in very different kinds of circumstances.

So, what was critical in terms of the overall concept is being able to work in any position from sitting on the floor to standing up, and that requires height adjustments of tables more than anything else. The next question was really one associated with partitioning: how can we have some kind of architectural form that physically divides space? So, we talked through all of those different kinds of abstract ideas that might apply equally to the office as to the home.

RK: Knoll presented a series of interconnected typologies they wanted us to do and those turned out to be in themselves very, very interesting almost to the point that we decided to translate the typologies into a kind of apparatus—to be very literal about them. We thought we ought to make the pieces perform but we ought not to mask them in terms of adding “design.”

WHY IS IT IMPORTANT THAT THE BEAMS OF THE 04 COUNTER ROTATE AS MUCH AS THEY DO? BP: 04 Counter is a wall. Also, it’s a piazza of sorts, as it brings people together. Once people discover that the object moves, they want to engage with it, gather around it. When all the beams are aligned, it’s a wall. When the top two beams start to rotate, the wall begins to dematerialize and people are able to walk through a space that was, seconds ago, occupied by a massive solid. Now you are suddenly using the different beams in different ways, even sitting on them. And then when you’re finished with whatever it is you’re doing, you align the beams and it’s an architectural partition once again.

RK: The piece that cantilevers in all directions is an amazing piece—an amazing engineering feat—because you simply do not understand how it’s done. That is particularly rewarding.

WHAT DOES THE COLLECTION SAY ABOUT KNOLL AT 75?

RK: They had wanted to work with us for a very long time, so the first thing that I would say is that Knoll has stamina. The second is ambition.

BP: One of the things that is great from my perspective is that this project gives our product development team exposure to work and to an architectural studio that they’re not going to get every afternoon. s&p

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Success doesn’t come by chance Success A home run is not a matter of luck, but the result of hardwork and dedication.

We make decors successful.

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What is ECC? ECC stands for Eco-Certified CompositeTM, as defined in a ground-breaking new Sustainability Standard and Certification Program for composite panel products – specifically particleboard, MDF, hardboard and engineered wood siding and trim, and products made with them.

What makes a composite panel Eco-Certified?

The requirements for ECC Certification are tough and specific, and require annual audits.

Composite panels must first comply with the stringent California Air Resources Board (CARB) formaldehyde emissions regulation.

In addition, the panel manufacturing facility must meet at least 3 of the following requirements: • Carbon Footprint – Demonstrate that the panel’s carbon store offsets its cradle-togate carbon footprint as determined in kg-CO2 equivalents of greenhouse gas (GHG) emissions.

• Local and Renewable Resource – At least 85% of wood fiber sourced within 250 miles.

• Recycled/Recovered – At least 75% recycled or recovered wood fiber; or at least 50% recycled/recovered wood fiber plus a minimum of 5% post-consumer fiber.

• Sustainability – At least 97% of the wood fiber furnish used in the manufacturing process is either converted into panels or other non-waste products.

• Wood Sourcing – Hold a valid assessment and certificate from a certifying agency recognized by CPA such as FSC or SFI.

The Composite Panel Association is committed to advancing and certifying the sustainability of industry products for residential, commercial and industrial uses.

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ECC Wood Products are among the greenest on earth.

What products carry the ECC logo?

Products carrying the ECC-certified logo include furniture, cabinets, closet systems, flooring, doors, mouldings and more.

Who can be ECC certified?

ECC certification is available to composite panel plants and facilities that manufacture laminated panels, components and finished products. Certification provides independent third party verification and an audited chain of custody.

What about LEED? ECC certification may help products achieve LEED credit for Recycled Content MR Credit 4, Regional Materials MR Credit 5, Certified Wood MR Credit 7, and/or Low Emitting Material EQ Credit 4.4.

ECC certification may also help earn credit for Low Emitting Materials EQ Credit 4.5 (LEED–CI) and others.

Who sponsors ECC? The Composite Panel Association (CPA) developed the ECC Standard, including its pioneering Carbon Calculator. CPA administers the ECC Certification Program as a third party certification agency accredited to ISO/IEC Guide 65by the American National Standards Institute (ANSI).

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Û

What’s New In HPL The original plastic laminate celebrates 100 years in 2013.

Since the material’s initial application as a decorative surface, it has reached many developmental milestones in performance, construction and aesthetics. And still, the innovation continues, with companies constantly finding new ways to make a great product even better.

The following pages showcase some of the latest from HPL.

Ü

Û Arborite Ink www.arborite.com/us

New Series Features Custom Patterns from Leading Designers Arborite, a Montreal-based leader in the laminate industry, is taking high-pressure laminates to the next level with Arborite INK, its new designer series. This color-forward collection features three patterns from designers at the forefront of their fields: Gonzalo Bustamante of GBDW (hospitality); Peggy Leung of Peggy Leung Designs (retail); and Giona Maiarelli of Maiarelli Studio (graphics). Each designer set out to create something completely fresh and colorful that would fill a market need and appeal to contract specifiers across North America.

According to Arborite President, Salvatore Rivera, “By partnering with outside designers with deep experience in specific market segments, we are identifying opportunities to bring our 60+ years of product development expertise to a wider range of customers. The designers used laminate as a canvas to create innovative and contemporary patterns that are unique to Arborite and unlike any other available on the market.”

Rivera continues, “At Arborite, we are committed to innovation and collaboration. This collection gave us the opportunity to do both. We are excited to launch new patterns, designed by designers for designers, which are ideally suited to the market segments that are important to Arborite’s growth.” n 40

www.surfaceandpanel.com

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Laminati Ü

www.laminati-usa.com

The surfacing of interior elements has evolved dramatically in the last few years in response to the worldwide tendency to try to incorporate high design into utility products without losing their practical function.

As a result there has been a diversification in the design of HPL, TFL, edge banding, flooring, wall cladding and 3DL PVC films. This overwhelming diversification has made it exceedingly difficult to find exact matches since the different designs from different trades come from different manufacturers who have no relation to each other.

A Florida team with European products is making it easy for architects and designers by matching all indoor elements in order to save time and effort. Laminati has concentrated its efforts on those interior elements that are exposed to high traffic, requiring maximum protection as well as design. From furniture to floors, walls and doors, all the elements can now match perfectly.

The Miami “deco center” offers HPL in exclusives designs with 350 different patterns in stock as well as the exact matching flooring, wall cladding, and 3DL films. n

Û Advanced Technology advtechnology.com

Advanced Technology, Inc. introduces two new HPL designs to the NuMetal line.

NuMetal HPL is comprised of a thin metal surface with phenolic paper backing.

Known for high quality design solutions NuMetal is suitable for both vertical and light duty horizontal applications, such as wall coverings, wall panels and ceilings.

The new designs add an element of interest to an otherwise utilitarian setting.

Embossing, hand painting techniques, etching and other innovative techniques enhance the look of the metals. n

Take a closer Look...

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Providing quality products since 1932

Dover, Ohio • 800-377-1221 www.marlite.com • info@marlite.com

Stocked product: White LPM Maple LPM Paint-ready Panel size & Groove Configuration: 4’ x 8’ x 3/4”, 3” on-center

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Û Abet Laminati www.abetlaminati.com

ABET Shines with SWAROVSKI ELEMENTS ABET LAMINATI has teamed up with designer Konstantin Grcic, in collaboration with SWAROVSKI ELEMENTS, to produce the Crystaline Collection – three shining patterns, on black and white backdrops. Simplicity and elegance characterize the pure lines of “Ray”, the geometry of “Peak” and the sparkling lights of “Bling.”

A revolutionary manufacturing technology developed by ABET allows insertion of the SWAROVSKI ELEMENTS onto the surface of the laminate without damaging them. Dazzling with design, the Crystaline Collection will add the WOW factor to any space.

Inclusion of the crystals inside the ABET LAMINATI laminates has been possible thanks to a new technology developed by the company. The challenge was to include the crystals in the laminates without crushing them, especially during the pressing phase of laminate manufacturing. Another big issue was to organize the small SWAROVSKI elements following the décor created by Konstantin Grcic, who shaped the design in order to meet the requirements of the company.

ABET LAMINATI’s marketing director Alessandro Peisino comments, “we have been able to create a totally new material. Laminate is paper impregnated with resin and compressed with 90kg of pressure per square centimeter. We had to create a special compression system in order to integrate, and not crush, the crystal. But technology is not enough, it was the willingness of Konstantin Grcic to help that lead to the success. That is the mind of a true industrial designer at work.” n

Þ Wilsonart www.wilsonart.com

Industry leadership and educational efforts underlie Wilsonart’s operations. For more than 50 years, Wilsonart has led the decorative surfaces industry with best-in-class service, strong distribution networks, dedication to new technologies and manufacturing, innovations in design and product development, and a commitment to sustainability.

Five years ago, Wilsonart took the lead to reshape the entire supply chain for its paper source, which makes up 70% of its HPL product lines. Wilsonart’s technical department worked with suppliers to ensure all source materials such as kraft, pulp and decorative paper suppliers for more 513 patterns and 1,600 SKUs met stringent FSC certification requirements. At the onset of the project no company in the industry had undertaken this endeavor. Wilsonart was the first North American laminate manufacturer to achieve Forest Stewardship Council® Chain of Custody Certification, providing thousands of SKUs of FSC® Mix Credit Certified HPL. This example fits the company’s sustainability journey they characterize as ZERO: Zero Waste, Zero Impact and Zero Barriers. The philosophy is embedded in the company’s DNA as every function is measured against metrics. n

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FEEL NATURAL, FEEL GRAND, FEEL ILLAMINATED.

2013

COLLECTION

Santo branco 3125

Go real. Go for our New BIG SCALE Granites, with no pattern repetition used on traditional laminates.

Get real scale looks for unique and spectacular spaces.

2013 COLLECTION We are inspired by natural creativity.

R

Phone: (57-1) 644 9898 Fax: (57-1) 644 9897 R

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Ý Arpa HPL

www.arpaindustriale.com

Silverlam is the innovative Arpa HPL able to inhibit the growth of bacteria across its whole surface. It is microbiologically tested and boasts an antibacterial protection system (Bacteria Blocker) that actively kills bacteria, even the worst of them such as MRSA (Methicillin-Resistant Staphylococcus Aureus) and E-Coli (Escherichia Coli) responsible for several difficult-to-treat infections. Laboratory testing has proven the prevention of bacterial growth reducing within 24 hours the quantity of bacteria by 99%.

Why an antibacterial surface?

Over the last few decades there has been a progressive increase in antibiotic resistant bacteria with the elderly and young children being the most vulnerable. Hospitals, schools and high traffic areas crowded with people such as public buildings, stations, gyms, and swimming pools are at greater risk… but also homes: in kitchens, bathrooms, children's playrooms, on floors, in the whole house or apartment!

Silverlam panels incorporate in their surface an antimicrobial compound based on glass-encapsulated Silverions. This extra protection in suppressing and actively destroying harmful bacteria is evenly distributed across the whole surface, ensuring safety even in hard-to-reach areas. Being encompassed during the production process, silver ions have a long-lasting antibacterial function and cannot be removed, eliminated or washed away. n

Greenlam Ý

www.greenlam.com/us

Greenlam Laminates offers eco-friendly laminates from India’s largest interior infrastructure company, the world renowned Greenply Industries. With a strong presence across the globe, Greenlam is present in over 70 countries and offers laminates in mesmerizing colors, textures and patterns created with cutting-edge technology to enhance the overall ambience of the interior of a building.

Greenlam proudly presents its Veneer Laminate collection - an array of innovative and super flexible veneers on kraft paper i.e. a thin base with more flexibility that allows a range of applications and enhances the scope of creative use to beautify interior spaces. Among the species available are American Maple, White Oak, American Red Oak and more. These species of wood are sourced from across the globe and are made available in different cuts like quarter crown, rotary and many more. n

Û Lamitech www.lamitech.com.co

Lamitech Big Scale Granites Lamitech takes it to the limit with Big Scale Granites. The big, bold patterns make dramatic statements showcasing the natural, varied colors like the veins of a real slab.

These designs don’t have any pattern or repetition found in traditional laminates. Big Scale Granites are available in three stone like hues; Lapidus with its exquisite and infinite gold tones, Santo Cinza with its vibrant grey and neutral color scheme, Santo Branco with a color swirl of cool and warm greys and whites. All are available in sheet sizes of 5 feet x 8 feet, 5 feet x 12 feet, 4 feet x 8 feet and offered in gloss and matte finishes and special finishes Splendor and Pietra. Lamitech’s paper suppliers use raw material made of renewal forest and they are FSC certified. All laminates offer low VOC emissions and are Greenguard certified. n 44

www.surfaceandpanel.com

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Ý Formica

www.formica.com/en-US

North America’s only source for soy-fiber particle board.

Now CARB Exempt No Formaldehyde!

Third Party Certified at 0.00 ppm (Parts Per Million)

Rapidly renewable, abundantly available soy fiber Regionally sourced from Minnesota/Iowa LEED contributing

Phone: 507-388-2472 | Toll-free: 888-250-5625 Email: info@agristrand.com

CPA MEMBER

www.Agristrand.com 46

Laminate’s Storied History Continues to Be Written Formica Group, the inventor of laminate, continues to push the limits of its tried-and-true surfacing material to ensure it remains on trend, relevant and in demand … a spirit of invention that has been a constant throughout its 100-year history. Early industry firsts laid the foundation for today’s investments in breakthrough manufacturing processes, print technology and design capabilities.

Formica Group’s 2013 product introductions continue to reimagine the possibilities of laminate.

The colorful and graphic Anniversary Collection, a fresh take on its iconic laminate, pushes the boundaries of print technology.

The collection’s Endless™ and Ellipse™ patterns are created by independent layers of pattern randomly interacting in the course of printing, resulting in the fluidity of overlapping elements that have no repeat for 500 to 700 sheets, or approximately 1.3 miles.

Formica Envision™ is the latest product to capitalize on laminate’s limitless design potential by turning high-resolution images into captivating wall panels, doors, countertops or any surface on which a designer would use Formica® high pressure laminate or Formica® Compact™. A technology employed by other regions of Formica Group around the globe, the July 2013 product introduction by Formica North America harnesses this technology to bring photography, graphics and artwork to life with amazing clarity. Whether using this customized surface to extend a brand or bring a designer’s unique vision to a project, Formica Envision™ pairs a “blank canvas” with a durable, affordable surfacing material.

At its core, Formica Group is a company based on invention. Read about its history and the origins and evolution of laminate – one of the most prevalent surfacing options on the market – in the new commemorative book Formica Forever, available at better bookstores, online booksellers and at www.artbook.com. n

www.surfaceandpanel.com

AGRI-0813-01 c.indd 1

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Û Chemetal ialaminates.com

Interior Arts InteriorArts introduces 4 new HPL design laminates to its collection. These new designs exemplify what makes InteriorArts unique – it’s a collection of textured and high gloss wood looks and exceptional designs.

Most unusual is #2005 Cracked Cement, a textured design that looks like it’s name, a worn cement wall or floor, only now in a lightweight 4 x 8 foot laminate.

Another aged or weathered look is 3025 Grey Oak Cross Curve, a textured, wood veneer pattern with the deeper, richer appearance of flooring material.

“Design professionals gravitate to the aged looks in Chemetal,” says Chemetal, InteriorArts and Treefrog Veneer creative director Geoff Schaefer, referencing Chemetal designs like 380, 381, 349 and 350 Factory patterns, and the new for 2013 Alu, Light, Medium and Dark looks.

“We took the opportunity to offer something similar in HPL. We’re excited about these new additions to InteriorArts, and we’re happy with how the whole line is gaining traction, and specifications, in the design community.”

InteriorArts was launched just over a year ago at NeoCon to complement the Chemetal’s metal designs and Treefrog’s wood veneer laminates. The collection featured 15 different textures, contains no added urea-formaldehyde and is available in 4 x 8 foot sheets. s&p

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The Edge of Technology b y

A

dapting groundbreaking technologies to make unique manufactured goods cuts two ways, like a v-groove. On one side, it results in products that look and perform unlike anything else available in the marketplace, often at lower cost. On the other, a significant effort is required to educate customers about what is possible. “It doesn’t take a lot of effort to understand HPL and TFL. People are pretty familiar with the products,” says Layne Cardellini, account manager for T.C. Millwork, Inc. “A lot of times it is easier to talk to individuals directly about what we do, but a challenge to tell the story to a company that has done things one way for its entire existence. It is hard for them to change their paradigm.” Yet, between the two edges of innovation and education is the fold, a sweet spot that has more possibilities than most specifiers ever consider.

T.C.M. (technology, creativity, manufacturing) is comprised of three inter-related, complementary business models. T.C. Millwork produces millwork, casework and lighting products, while SpecTrim is focused on building products and TRICON construction does planning, general contracting and installation. “We’re pretty much full service.

We make a lot of innovative products. Retail store fixtures are one of the main things. And we do it a little differently than many of our competitors. This tends to help us and hurt us at the same time,” says company owner Art Kubach, a trained cabinetmaker, technology junkie and visionary. “Technology interests me a lot, and I have a pretty good feel for markets,” says Kubach. “I think the biggest advantage that we have is that I

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S u z a n n e

V a n

G i l d e r

don’t look at my marketplace with blinders.

We go to every industry and say, ‘okay, how do we integrate that into my product? Or how do I create a new product with it?’ That is all I do, really. That is the trick. You have to take the blinders off. It is a race to keep obsolescence away from our door. That’s the way we look at it.”

For all the actual production that happens in manufacturing, not a lot is said about creativity. Maybe the connotation is more foofoo and artistic than the average woodworker or engineer is likely to embrace.

Mechanism and systems are alluring in their logic and predictability, but from a design perspective, predictable products are both passé and vulnerable to imitation. And in many ways, the design community relies on fabricators to know what is possible.

“From an architectural perspective, everybody is squeezed for time and money,” says Kubach. “But don’t be lazy. Don’t cut and paste the same old tired stuff over and over again and change the finishes.”

Creativity: Materials

T.C. Millwork introduced films for surfacing into the retail arena in 1982. “We now have three hot melt reactive PUR laminating lines that we have been running for eight or nine years now. We adopted it right from the automotive industry when they started using it,” says Kubach. “And we’ve been through them all. As an early adopter I’ve gone through all the pain and suffering. Now we use a reliable adhesive company that not only supplies our glue, but also brings the application engineering, which is so important as it relates

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to PUR adhesives. It is 100% solid and zero VOC’s. It’s great to work with and gives me the ability to laminate virtually any film to any surface, be it laminate, steel, aluminum, MDF, it doesn’t matter. We do laminations we could never do before.” The advantage of the PUR is that it allows T.C. Millwork to introduce hybrid composites for the fixtures industry.

This gives customers unprecedented options for value engineering, while at the same time improving performance and enhancing the look of the product.

One of the hybrids goes by the name Ven4ma. The construction goes like this: a highly decorative pre-finished top film (PVC, PET, OPP) is laminated to a very impact-resistant thick PVC or ABS substrate of the same base color to create an extremely durable, 50mil thick material. Think vinyl HPL that requires no edgebanding. That enhanced film is then laid up on MDF. “What that does for my customers is it gives them the option of having a very high-performance, high-end look without the cost associated with it,” says Kubach.

Creativity: Processes

Part of the benefit of the hybrid material is a superior end product, but it also allows for extraordinary innovations and efficiencies in processing, material handling and assembly, all of which improves accuracy and reduces cost. “Take a set of nesting tables a retailer would typically use, for example,” says Kubach. “My competitor builds that table out of 25 parts. We build it out of five.” To accom-

plish this, T.C. Millwork starts by laying up the decorative sheet on one side of a substrate.

From there it goes to the CNC routers, which are all equipped with c-axis aggregates that allow for efficient v-grooving. “I am able to v-groove right down to the back of that sheet, so all my parts are together, they are never detached. We don’t have piles of skids with different items that need to be sorted.” From the mill, the still-hinged parts go to assembly where they are quickly folded into seamless finished products.

A modified version of this approach is used to make extremely strong shelves.

“Some companies had a major problem. With the weight of their products, their shelves would constantly sag. They tried steel and reinforcement, but nothing worked,” says Kubach. “Another advantage of the hybrid is that it is very lightweight. So we built what is basically a torsion box, like an airplane wing, that has very little deflection over the span.

We have it down to such a science that it is nearly the same cost of a regular shelf.” For this product, a film composite is miter-folded to wrap around a hollowed out MDF core.

The resulting shelf is strong and seamless, requiring no edge banding. “It takes me less than 30 seconds to fold the shelf, and there is no edgebanding, so it has a nice front edge,” says Kubach. “I would literally have to sheer the entire glue line on both sides of that shelf for it to fail. We’ve tested it with 450 pounds of bricks, and the shelf never failed, the metal brackets did.”

Creativity: Technology

T.C. Millwork’s facility is outfitted with equipment from many different manufacturers, Biesse, Onsrud, Weeke, Holzma, Koch. “We buy machines specific to what we do,” says Kubach. “Every one of our routers is equipped with C-axis aggregates so that we can do v-grooving.” An in-house programmer writes code that can relate the geometry necessary for intricate folding into programs that run on any machine, regardless of platform, without additional conversion. “If one of my bigger machines goes down and we already have stuff loaded, with the press of a button I can load it onto another machine,” says Kubach.

The programmer, who incidentally wrote the code for the Palm Pilot, has also made the operation truly screen to machine. The initial 3D drawings are done in AutoCAD Inventor, then with a couple of clicks the program optimizes and generates G code, cut lists, and bill of materials, all of which are transferred directly into T.C. Millwork’s ERP system.

Another somewhat unique in-house capability is plasma treating related to the heavy use of the PUR reactive hot melt for laminating. The process requires an optimal dyne level. “If you are below a certain surface energy on the product then the adhesive is going to have a hard time grabbing, which can result in delamination,” says Kubach.

“PET, OPP, and PVC all have very low surface energies, so they are pre-treated. We have extremely high quality standards, and with the plasma treating we have 98-99 percent success.”

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T.C. Millwork at a Glance n Incorporated 1993 n Privately owned and operated n Located in Bensalem, PA n 400,000 square foot facility n 110 employees

TCM Family of Companies Includes: n T.C. Millwork, Inc. n TRICON Construction

(construction, general contracting and installation) n SpecTrim Building Products

Markets Served: n Retail: Big box, Shop in shop, specialty, brand identity n Gaming: Casino slot machine bases and interior millwork n Hospitality: Hotels, resorts, restaurants n Institutional: Banks, offices, lobbies n Healthcare: hospitals, long-term care facilities

RIKEN USA CORPORATION

Creativity: Sales and Solutions

“I tell my salespeople, ‘Don’t go sit in front of a customer and be a “me too” company. Anybody can be a “me too” company. You need to be more than that,” says Kubach. “And pay attention to the little details.

If you do that, the big things will take care of themselves.” Of course, sometimes T.C. Millwork has to simply bid to spec, which is the downside to new products; people don’t know to ask for them. But the sales team works tirelessly to get the word out. And Kubach keeps them on their toes by constantly developing new products, processes and solutions. The next big thing in the works is a product with an enhanced topcoat that is beyond a level-five floor finish. “It will really blow the lid off the vinyl industry,” says Kubach. “The Europeans are using it like crazy.”

The topcoat is extremely scratch-resistant, made from PUR intermixed with UV coatings. After a lot of experimentation, Kubach is looking at investing $2 million in equipment to bring the capability in-house.

“We’ve almost figured out how to fold it up,” says Kubach. “At the end of the day this product is super durable, but if I can’t make it seamless, I s&p still have the same issue as plastic laminate.”

Riken USA Corporation produces foils for 3D laminate for seamless cabinet doors, office furniture and store fixtures using Japanese printing technology.

Vacuum and membrane press the most complex dimensional profiles on routed substrates in solid colors, patterns and wood grains with satin, matte, desktop and contemporary high-gloss finishes.

New items items –– Almic Graphit, Terra Grau, Champagne Metallic, Circle Line High Gloss 1D & 2D

Graphit Almic Amber

Terra Circle AlmicGrau Blue Champagne Almic Red AlmicLine Silver

Metallic 1702 Beverly Road | Burlington, NJ 08016 | p: 609.387.2011 info@riken-usa.com | www.riken-usa.com

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Performance through-and-through. ™

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1.877.689.9145 www.arclin.com/tfl

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Lighting the Way to Increased Sales

S

olid-state lighting technology continues to grow exponentially, and it brings new methods for integrating light along with it. With the ability to specify light more precisely than ever before, the effects of lighting on people’s behavior is becoming better understood; and the methods for calculating energy efficiency have become both more complicated and more accurate.

Like most segments, retail stands to gain a lot from these advances in terms of energy efficiency and buying behavior. With his keen eye trained to the market and a natural proclivity to adapt technologies, Art Kubach, owner of T.C. Millwork (see page 48) developed a plug and play lighting fixture for retail called SMARTWALL®.

“SMARTWALL® is the biggest growth item we’ve got going on here right now,” says Kubach. “It is a product that literally brings the light directly to the merchandise.”

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surface comprised of a decorative film (PVC, PET, OPP) that is overlaid atop a thick PVC or ABS substrate. The process results in seamless corners and edges. “This thing has evolved like you can’t believe,” says Kubach. “We actually have the finest lighting engine in the market, bar none. The photometrics are amazing. Our color rendition is 93.5 right on the black body curve. We’re using three watts of power to get around 1000 lux at 16-20 inches. It’s remarkable.” The proprietary driver technology and wiring integrator used in SMARTWALL® can power 48-lineal feet of wall with one duplex outlet. And because the entire product is UL listed, the installer simply takes the pre-fabricated

Integrated Light

The idea came to Kubach about eight years ago, while he was assembling straight stretches of track for his son's toy train set. “I thought, ‘Why couldn’t that be a couple of wall standards in retail?’ So I figured out how to power the wall standards with a low voltage power,” says Kubach. “Then it all started to come together and I was able to make a hybrid composite shelf that could house LED light engines and power them virtually wirelessly to the end user.” One of T.C. Millwork’s specialties is miter-folding MDF boards that are laminated with a hybrid 52

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The Next Big Thing

SMARTWALL® has been in development for the better part of a decade, and while the LED product is an effective and easy to use lighting solution, Kubach is already working on an OLED version.

LED solid-state lighting uses the energy differential within a diode of semi-conductor materials to release electromagnetic radiation as a discreet point of light. Organic LEDs typically employ either small molecule or polymer organic compounds to make self-emissive electroluminescent film. “OLED is going to be the absolute next revolution in lighting,” says Kubach, who follows the technology closely. “Our current LED strip lights or pucks have those annoying points of light.

Despite the amazing light engine and color rendition, they are still single points of light, which is driving me crazy. I want a self-emissive light that just washes down.” By replacing LEDs with OLEDs, the entire surface of the panel will be the lamp. Kubach is currently working with manufacturers in the lighting field, and expects to integrate OLEDs made on glass substrates into the SMARTWALL® systems by the third quarter of 2013. Researchers worldwide are making progress toward applying OLED technology to flexible films, as well. s&p Imagine the possibilities. and pre-wired shelves, attaches them to the SMARTWALL® brackets, and plugs the power supply into a standard outlet. The lamps, which can be either strip lights or pucks, are built into the shelf. “The lamps were developed so that if there is ever a problem, or a desire to change the color temperature, the puck or the strip just pops out and we send a new one,” says Kubach. “And if a store wants to do a re-set on their wall, they simply remove the shelf, the lights go out, they move the brackets wherever they want, put the shelf back in the brackets, and the lights go on. It’s that simple.”

The Psychology of Light

A study done by Merchant Mechanics entitled, “Effects of White Light POP Display Illumination On Consumer Behavior” looked at the way adult mall shoppers interacted with endcaps that were lit versus endcaps that were unlit. The research found significant increases in glancing behavior, entering behavior, eye contact, browsing, product handling and purchasing behavior when the fixture was lit. Retailers using SMARTWALL® report similar phenomenon. “We just finished a second full year with one company using SMARTWALL® in their stores, and their same store sales have taken a dramatic turn for the good,” says Kubach. “Everybody that uses the product has an increase in same store sales. It’s just amazing.” Another anecdote about the effectiveness of lighting to drive sales is a women’s clothing retailer.

The company was reluctant to try the new technology at first, so T.C. Millwork did one section of women’s shoes with SMARTWALL®. “They weren’t selling many shoes. Then after installing SMARTWALL® they couldn’t keep them on the shelves,” says Kubach. “Sometimes retailers are reluctant to change, but evidence shows that if you lower the overall ambient lighting and light the product where it is displayed, you create a dramatic effect because there isn’t harsh light coming at the customer from all directions. Plus, it lowers the over all energy costs, both for lighting and cooling.”

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PUT YOUR PRODUCTS IN THE BEST LIGHT POSSIBLE. Häfele’s LOOX LED lighting system is the ideal solution for retail fixture lighting. We offer a broad selection of surface and recess mounted 350mA lights and drivers that can allow you to create the precise lighting effects needed to make a product stand out in a display environment. LOOX carries many international certifications, so you can be confident it will meet your discriminating requirements.

For all the illuminating details, call 1.800.423.3531 or visit www.hafele.com/loox.

Request our new LOOX lighting catalog.

Visit www.hafele.com.

Showrooms: New York, Chicago

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www.Roseburg.com

Delivering a World of Panel Options

The Enemy of the Good

Green Decorative Wood Panels Third party certified “GREEN” Decorative Panels that are FSC, ECC and CARB Phase II compliant include: • Duramine TFL Panels • Roseburg Hardwood Plywood – CARB exempt for Ultra Low Emitting Formaldehyde resins (ULEF) • UltraFinish - Vinyl, paper & painted overlaid • RediShelf – Cut to size shelving • UltraBlend & SkyBlend – Particleboard

For more information visit our NEW website at Roseburg.com

TF 800-245-1115 www.Roseburg.com

Decorative | Construction | Industrial W O O D P R O D U C T S

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“…the best is the enemy of the good.”

— Voltaire, La Bégueule (1772) b y

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dozen years ago, the California Air Resources Board (CARB) embarked on a regulatory process that resulted in groundbreaking limits on formaldehyde emissions from composite wood products. California’s Airborne Toxic Control Measure (ATCM) went into effect in January 2009 and has altered the way industry does business around the world. Product emissions have dropped to historic lows, the development of new adhesive formulations has accelerated, and a global Third Party Testing and Certification (TPC) system has emerged to manage CARB’s regulation and support its credibility in the marketplace. It is without question the toughest production standard in the world for composite wood panels and the products made with them, and gives unprecedented assurance to architects, designers and fabricators.

The US Environmental Protection Agency (EPA) gazed on CARB’s rules and decided four years ago to likewise assert its authority and develop a national standard for formaldehyde emissions from industry products. EPA began its process without any preconditions as to whether the federal rule should resemble CARB’s, which gave all interested parties much concern. The Composite Panel Association, in partnership with the Sierra Club, intervened to assert that Congress ought to dictate to EPA that its rules must be consistent with CARB’s insofar as the scope of products affected, emissions ceilings, and economic impact, and that the national standard should be enforceable for products sold in the US regardless of where in the world they were manufactured. In short order we were joined by an unprecedented coalition of business, environmental, labor and health care groups that shared this perspective. While motivations differed, all of us agreed that permitting EPA unsupervised latitude to develop a rule was a recipe for trouble.

We went to Congress and successfully lobbied for bipartisan legislation that specifically directed EPA’s approach and scope, leaving the agency with modest discretion to implement the Congressional directive. The Formaldehyde Standards for Composite Wood Products Act was signed into law by President

www.surfaceandpanel.com

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www.Roseburg.com

Single Source Producer

The New Roseburg.com Here at Roseburg, we are excited to unveil our new, redesigned, customer friendly website. The website is packed with information about our products and company. These updates will help you make correct and informed decisions about using our wood products.

Obama in 2010, and EPA restarted its work on a regulation that Congress directed be completed by January 2013.

In May of this year, the EPA finally released its proposed rule for public comment. The rule is divided into two parts, one titled Third-Party Certification Framework for the Formaldehyde Emissions Standards for Composite Wood Products (the TPC rule) and the other titled Formaldehyde Emissions Standards for Composite Wood Products (the implementation rule). The comment period closes on September 25, 2013 for the former and October 9, 2013 for the latter.

And there is much to comment about.

In its proposals the EPA has addressed many of the issues as instructed by Congress. Unfortunately, EPA has also substantially overreached insofar as how implementation of a national standard will impact the entire supply chain – particularly for fabricators of wood components and finished products, and for retailers who sell them. The agency’s eagerness to so perfectly stamp out even the remotest possibility of noncompliance by expanding the scope of the rules will cause dire collateral damage.

In CPA’s view it should be enough to replicate CARB’s successful approach, with some refinements that both the EPA and CARB can support. The EPA’s striving for a “perfect” regulatory scheme proposes to turn thousands of small businesses in the United States (and around the world) into de facto composite panel producers with corresponding burdens for product testing and certification, bringing massive new manufacturing costs. Might such an approach result in a more complete regulation? Perhaps theoretically, but in reality it may cripple fragile domestic manufacturing that is just now emerging from years of recession. It may also result in product de-selection, and the unintended consequence of driving more domestic manufacturing jobs overseas where enforcement and oversight of environmental laws are less rigorous. Compounding the situation, even the most optimistic view of this unwarranted expansion would bring negligible public benefit. continued on page 58

We are excited to introduce you to these new features: • Easier than ever to order samples and literature through the new Samples and Literature Library plus fast checkout • View detailed sample information and green specifications for each product in the Roseburg catalog • Download technical documents and product catalogs through the Library • Download software tools when you need them • Gain access to Roseburg featured CEUs and education videos Take a quick tour of the new site through our 3-minute video at: www.roseburg.com/introduction-to-the-newroseburg-com

TF 800-245-1115 www.Roseburg.com

Decorative | Construction | Industrial W O O D P R O D U C T S ›

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“Without substantial changes, the proposed EPA emission rules could dismantle many good companies and derail what could otherwise be a reasonable and effective approach to national regulation.”

By the time this column appears, the reader may have little or no time to express concerns to the EPA within the official public comment period unless it is extended. That should not deter you from reminding the EPA of the limited Congressional mandate, and that a highly effective national standard on product emissions, consistent with CARB’s approach, should be the agency’s chief goal. The EPA’s new rules cannot be permitted to stand as proposed. Without substantial changes, the proposed EPA emission rules could dismantle many good companies and derail what could otherwise be a reasonable and effective approach to national regulation. s&p Please consider sending your comments to the EPA through the Federal Register.

Implementation Rule

https://federalregister.gov/a/2013-13258 TPC Rule

https://federalregister.gov/a/2013-13254 Tom Julia is President of the Composite Panel Association.

The Composite Panel Association (CPA), founded in 1960, represents the North American composite panel industry on technical standards, industry regulation, and product acceptance. CPA also operates a world-renowned testing and certification program for industry products. For a list of companies and products represented

by CPA see DecorativeSurfaces.org and CompositePanel.org.

www.asia-surfaces.com

The Asia Surfaces Conference 2013 is organized by

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TCM-Asia (Malaysian Office) c/o Bridge's for Concepts SDN No. 45, Plaza Damansara Block A, 2nd Floor , Medan Setia 1 Damansara Heights 50490 Kuala Lumpur, Malaysia Phone: +60 3 2094 2880 Email: TCM-Asia@bridges.com.my

TCM-Asia (European Office) c/o Technical Conference Management Fasangasse 1B A-2103 Langenzersdorf, Austria Phone: +43 (0)2244 33870-11 Email: kurt.fischer@tcman.at Website: www.tcman.at

www.surfaceandpanel.com

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September 2013

Matters

always functional efficiency UV LED Curing – A cool new technology Reducing Finishing Costs Fixtures Crafted Through Technology

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Always Functional

Efficiency b y

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noll’s “Always Modern” philosophy is as present in the company’s finishing technology, sustainability practices and constantly evolving manufacturing processes as it is in design development. (See Always Modern in All Ways page 32). “To address a multitude of customer needs, you have to have manufacturing facilities that are inherently different than what they have been in the past.” says Fraser Houghton, marketing director for Knoll’s wood products division. Seventy-five years ago Knoll offered a handful of wood finishes and a relatively narrow set of SKUs. Today a price list for a single product line is 800 pages long. “We now have 36 standard colors, plus 30 percent of what we do is non-standard and goes through custom product development,” says Houghton. “So the plant is constantly reinventing itself. It is still a wood plant, but the products being made are very different.”

Images courtesy of Knoll Inc .

Sustainable Materials

A fundamental aspect of being modern and forward thinking is to continuously evolve best practices for a sustainable operation. “The thing that we are most proud of in manufacturing is our commitment to clean technologies,” says David Bright, senior vice president of communications for Knoll. “Over time we have really pioneered in three unique areas relating to climate change, third party certification and environmentally friendly processes and materials.”

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Knoll manufactures in four locations in North America, East Greenville, PA, Grand Rapids, MI, Muskegon, MI and Toronto, Ontario, plus there are two plants in Italy. All of the facilities are ISO 14001 certified. According to Houghton, the Toronto plant is one of the largest wood production facilities in North America, measuring over 500,000 square feet. The plant’s 1000 employees produce 40,000 finished pieces weekly for Knoll’s three primary flat panel wood product lines, as well as the accent pieces for other collections.

At such a large scale, materials efficiencies play a big role in Knoll’s commitment to best practices for manufacturing. Throughout the company’s history, Knoll has become renown for the quality and attention to detail that goes into its wood products. Today that also means utilizing materials that have a responsible supply chain, including FSCcertified veneers, engineered veneers and EPP-certified composites. “In the plant we make wood products, and also a lot of laminate products, including both HPL and TFL. The industry is moving to use TFL on a more regular basis because the product has improved,� says Houghton. “So the plant is somewhat unique in that we can make a laminate product one minute, and a wood product the next. It doesn’t matter to the machines.� Knoll uses a component-based approach for manufacturing rather than a casegoods-based approach, which makes for a very flexible production line.

“Representatives come in and are on our site virtually everyday working with us and helping us to fine tune the chemical compositions to work with our colors and machines�

Fraser Houghton Marketing Director for Knoll's wood products division

Functional Finishing

In the case of wood products, all components are finished with Knoll’s proprietary flat line process prior to assembly. “Our finishing is very different than most of our competitors,� says Houghton. “The line is dramatically larger, and we use a specially developed material that is both exceptionally durable and environmentally impeccable.� An extremely high-quality of finish is a sweet spot for Knoll. In fact, the materials and process behind it were at one point so secret that no visitors were allowed into the area. As with all great processes, over time this one has been emulated, though it requires an operation to have the scale to justify it and the capital to make big investments. “Most of our product is finished with a series of roll coaters,� says Houghton. “So the components go in one end of the line and receive stain coats, topcoats and sealer coats, with sanding between some of those applications. 250 feet later the components come out of the line fully finished.� This line is very fast, a necessity considering the scale of Knoll’s production.

Knoll’s water-based PUR derivative finishing material ties into the company’s commitment to environmentally sound processes. “It is 100 percent solids, so the material that goes on the board stays on the board� says Houghton. “The material is UV cured, so there is no heat or circulated air and no need to worry about VOC’s. The process is energy efficient and the end product is extraordinarily durable.� The sheer volume and variety of standard and non-standard finishes that Knoll is able to produce is in part due to great working relationships with materials suppliers, including AkzoNobel and Becker Acroma. “Representatives come in and are on our site virtually everyday working with us and helping us to fine tune the chemical compositions to work with our colors and machines,� says Houghton.

Flexibility Into the Future

One of the concepts behind modernism is simplicity in design reconciled with technology for functionality. For Knoll the ability to engineer and manufacture relevant, and often custom, products is the

It’s Time to Shine!

Solvent and VOC free, UV-cured powder coating is Fast, Clean & Green!™

Request a sample at www.dvuv.com/samples

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company’s strength. But even after 75 years, the process of innovation carries on. “The whole idea of continuous improvement is something that Florence Knoll, our founder, felt very strongly about from the inception of the company,” says Bright. “Particularly around employee engagement and involvement.” Knoll has always produced JIT, and has continually invested in technology that allows for greater flexibility in order to provide custom solutions. “Each of our plants has been tasked with getting better, becoming more functional and efficient,” says Houghton. “The term that gets tossed around is ‘batch size one,’ with the goal to be able to produce one item as efficiently as producing 500 items.”

Moving forward, Knoll is planning for many innovations that will keep its production on the leading edge of modern. “One of the cornerstones that our engineering team has been speaking about is automated material handling, from safety, efficiency and cost management perspectives,” says Houghton. 40,000 parts weekly is a lot, and production is batched for efficiency rather than assembly sequence.

To keep account of it all, Knoll is implementing an RFID system, which will allow for three-dimensional computerized racking and tracking of components within the facility. Additionally, RFID simplifies inventory control within warehousing as product moves into the market place.

On the customer end, there is also the potential to streamline customer service with the system. If a specific part is broken, the RFID tag contains all the necessary information to make a replacement.

For Knoll, “Always modern in all ways” captures the spirit of the organization, which is as dedicated to the artistic invention and functional efficiency of its operations as it is to the iconic designs the s&p company develops and brings to market.

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MLC4017

CLEAN CURE™ TECHNOLOGY

FORMALDEHYDE-FREE

SOLVENT BORNE

LOW ODOR

HAPs FREE

Innovation is in the air.

Formaldehyde-free Finishes from M.L. Campbell

Our breakthrough solvent borne Clean Cure™ technology platform provides acid cure formaldehyde-free amino-alkyd post-catalyzed and pre-catalyzed finishing systems that are both low odor and HAPs free, helping to create a safer work environment.

Our solvent borne, formaldehyde-free products include:

ENVIROVAR™ CONVERSION VARNISH ENVIROMAX™ PRE-CAT See your nearest M.L. Campbell distributor for recommendations on which Clean Cure™ Technology products best suit your shop’s needs.

Visit us at Booth #4623

*

®

Smart People. Brilliant Finishes.

Expertise is the key ingredient in all we do at M.L. Campbell. Not only in formulating our products, but also in providing invaluable technical answers. Our expert distributors are the best in the business. And they’re at your disposal with unmatched product knowledge and training programs. Along with our easy-to-apply products and industry-leading marketing support, M.L. Campbell gives you the wood finishing results you demand.

* M.L. Campbell EnviroVar™ conversion varnish earned a Sequoia New Product Award for Green/Environmental Leadership in Wood Coatings at the AWFS® Fair 2011.

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UV LED Curing A Cool New Technology

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Save energy and expense

UV LED curing technology makes it possible to save big on power usage. While a conventional arc lamp has a connected load of about 40 kilowatts, an LED unit has only about 5 kilowatts. Add the 2-kilowatt UVC emitter and the combined connected load remains a low 7 kilowatts. That’s a 33 kilowatt power savings with an 83% energy reduction! Through energy savings alone, the expected return on investment in this technology is two to five years, depending on cost per kilowatt in the region.

Extend bulb life

A

n award-winning technology for curing both pigmented and clear UV coatings can save energy and floor space, with added benefits for processing sensitive materials and protecting the environment. UV LED curing is quickly becoming the preferred method for curing finishes in Europe. As an advocate for the latest proven manufacturing technologies, Stiles encourages our customers in the U.S. to consider putting this technology to work at home.

Here’s how it works: UV coatings applied to a wide range of material types and dimensions are cured when exposed to cool, radiant emission from LED bulbs mounted in an industrial focused array. Coatings specifically formulated for LED curing are available at a nominally higher price (2% to 3%).

First introduced in 2011 by Bürkle GmbH for curing flat panel finishes, UV LED curing technology advanced again this year, when Venjakob made it available for threedimensional surfaces. The Venjakob UV LED oven received an award at the Innovation Conference held during the 2013 LIGNA Tradeshow in Hannover, Germany. This innovation combines UVB and UVC emitters, which work at different wavelengths to cure finishes very deeply and consistently across a surface within the same oven.

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LED bulbs deliver more than 10,000 hours of service, compared to the 2,000 hours associated with arc lamp bulbs. This long lifespan is further extended by setting LED lamps to activate instantly when parts are present and shut off when they are not.

Protect sensitive materials

Because they do not emit infrared light in the UVB wavelength, LED curing units can cure

UV finishes applied to thin, delicate materials and materials containing sap without damage. The addition of a UVC emitter adds a small amount of infrared heat; however, the board surface will rise by only about 10 degrees Fahrenheit.

Eliminate exhaust requirements

With both the LED unit and the UVC emitter mounted within the same enclosure this cool curing process doesn’t generate ozone— eliminating the need for an exhaust to atmosphere. An attached chilling unit mounted close to the oven cools the LED unit, which itself is mounted on a belted transport conveyor, assuring easy transport of parts.

At Stiles, we’re passionate about advances in equipment that bring manufacturing forward. As an innovation that delivers economic, efficiency and environmental benefits, UV LED curing technology is a great example. With it, finishing processes improve, manufacturers across industries do more with less, and together, we redefine s&p what’s possible.

Don Leblanc is the Director, Finishing and Technologies for Stiles Machinery.

He manages the company’s finishing division with over 30 years of industry experience.

www.surfaceandpanel.com

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I didn’t know...

Stiles offers a comprehensive range of finishing equipment.

Whether you make cabinets, architectural millwork, or flooring, Stiles can help you improve your quality and efficiency. We offer a broad selection of premium, cost-effective finishing solutions for roll coat, vacuum coat, spray applications, curing, digital printing and more. Let us put our expertise to work for you.

For more information, contact Stephan Waltman at 616.698.7500 or swaltman@stilesmachinery.com.

Or visit us at www.stilesmachinery.com.

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Reducing Finishing Costs b y

P h i l

S t e v e n s o n

F

or several consecutive years woodworking companies have experienced shrinking profit margins at an alarming rate. Overseas competition and high labor compensation costs, along with shortages of qualified woodworkers, have caused many company owners to rethink a strategy for survival and how to return profit margins to normal. One important, but often overlooked, opportunity is in the finishing dept. In many wood manufacturing organizations, the true cost of finishing is not known because of the lack of standards for the finishing department, or methods of tracking internal reworks which affect bottom line profitability. Often when the true cost of the finishing operations is determined, it is surprising how

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much time and materials are used, and to what extent the extra labor cost in reworks is affecting the bottom line profits. However it has been proven that by using lean manufacturing and finishing procedures, as well as operating at peak performance, finishing will often become the most profitable part of the organization. To many finishing personnel this may seem unrealistic or unattainable, considering the amount of neglect shown by top management and business owners of the finishing department. However, if given the appropriate tools and knowledge, with an abundance of patience, the finishing department can become a powerful revenue source that will exceed most expectations. This article will outline several areas for profitability improvement that will be detailed in further articles.

In performing an assessment of a finishing operation, the first area of critique is the incoming lumber material quality. In many organizations, the purchasing department does not have a clear understanding of what lumber requirements are necessary for the type of finish to be applied to the product or what the customers’ true aesthetic expectations are in relation to the price of the product.

Before the product is priced, visual and performance expectations should be established by a team of decision making personnel from purchasing, marketing, manufacturing, and finishing who collectively agree upon the raw lumber quality and price of the finish product.

Considering the wood grain pattern, color of wood variations, natural defects etc. will help avoid purchasing too high quality of wood in relationship to hiding properties of finish, or purchasing inferior wood quality that may require extra finishing steps and fail to meet customers’ expectations, thus requiring costly reworks. Careful attention should also be paid to moisture content and how moisture affects finish durability. Excessive moisture can cause reduced adhesive properties of the finish, uneven, and poor stain penetration, and stressing and cracking of the finish as the wood ages and moisture content decreases. Too low of moisture content causes finish to stress, buckle, and delaminate if introduced into highly humid environments.

www.surfaceandpanel.com

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A Great Finish is Only the Beginning

Roger Powell Branch Manager Alpine Sales, Inc.

David Stasiukaitis Vice President

Paul Stasiukaitis Plant Manager

Mike Steck President Alpine Sales, Inc.

Mr. Joe Stasiukaitis Senior Mill Shop Consultant

Joe Taschner Paint Specialist Alpine Sales, Inc.

“We rely on our Chemcraft distributor for fast product delivery, technical support and even education for our employees.

We know that if we need them, all we have to do is pick up the phone and they’re here for us. It’s much more than professional - it’s a personal relationship.”

Paul Stasiukaitis, Plant Manager Low Country Case and Millwork, Ladson, SC Founded in 1990, Low Country Case and Millwork is an AWI Premium Certified manufacturer of commercial cabinetry and architectural millwork.

Their Chemcraft distributor is Alpine Sales, Inc., and are shown here with three generations of the Low Country family.

Visit www.chemcraft.com to locate your nearest distributor. © 2013 AkzoNobel

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Chemcraft® is a registered trademark of Akzo Nobel Coatings Inc.

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image courtesy Burke Gibson

The next area to assess in the evaluation to improve profitability is the manufacturing and fabrication of the unfinished product. It is critical to the finishing department’s success to have well machined parts prior to final whitewood sanding. Attention should be paid to tooling and machining operations to assure minimal tear out of wood fiber, knife marks and acceptable quality in profiles. Joints should be tight and even, which insures sound construction and minimizes stress on the final finish film. The pre-sanding of the unassembled product is a critical factor in the finishing process as poor machining and insufficient sanding will produce poor quality finished product or cause excessive labor in the finishing steps to correct this difficulty. Not only does the finished product decrease in quality but also increases in cost due to the extra steps taken.

Sanding and abrasive technologies continue to rapidly improve, offering opportunities to increase over-all profitability. The sanding abrasive choices that are offered are seemingly endless and sometimes confusing. As a rule, low cost abrasives usually end up costing the manufacture more because the poor quality provided drives up finishing labor cost. Another factor to consider is the short life cycle of low cost abrasive, which results in ultimately higher sanding costs. New abrasive minerals, such as ceramic mineral out perform other older technologies 4 to1 in the cutting life of the abrasive. Other considerations in high quality abrasive are the uniformity of mineral grade, high performance backers, and anti-static or other dust release coatings which will dramatically increase the life of the abrasive, again resulting in lower abrasive costs. Other benefits of high quality abrasives are the ability to skip grit steps to reduce labor, better surface quality to decrease stain blotchiness, and finer over-all finish quality, increasing customer satisfaction. i m a g e c o u r t e s y n at i o n a l O f f i c e

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Low Cost Sanding Abrasive versus High Quality Abrasives Typical savings by using high quality abrasive material

Low cost sanding belt

=

$50.00

High quality sanding belt

=

$75.00

4 Low cost sanding belts in life of belt

=

1 High quality

4 Low cost sanding belts 1 high quality sanding belt

= =

$200.00 $75.00

● ● ●

●

Net savings = $125.00 for high quality abrasive material In performing profitability evaluations, one of the top concerns is the excessive number of internal reworks and customer returns due to finishing defects. Internal rework is defined as “any step of the process that must be performed over again due to the failure to achieve quality expectations”. These may include re-staining or sanding to take out a defect etc., which is a major factor to decreased profitability. It is repeatedly asked how defects can be prevented before the next step of the finishing process takes place? Generally the workplace environment plays a major role in failure to identify and correct defects before proceeding to the next step. Finishers are frustrated by not being able to “see” what they are finishing because of poor lighting conditions.

Many of the finishing environments general purpose lighting is less than 50% of the standard lumens necessary to appropriately meet the needs of the finisher. Work stations with high intensity inspection lighting will allow the finisher to see defects and take corrective action in the beginning steps.

One of the most exciting arenas for profitability improvement centers around vastly improved coating technologies. High solid coatings, UV curable materials, and two-component urethanes represent just a few of the options that are available in the industry. As statistics suggest, numerous manufacturers are still using a coating under 35% in volume solids. Switching from currently used low solids finishing systems to higher solids coating will reduce the number of steps or coats necessary to achieve the desired film build, thus saving labor costs.

www.surfaceandpanel.com

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Vlspar_Su

Do more than you ever dreamed possible with your woodworking jobs.

Valspar offers innovative, easy-to-use and apply products and superior support that help bring your ideas to life. So dream it, create it, and enjoy the results.

View how-to videos and find a local distributor at Valsparwood.com

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i m a g e c o u r t e s y n at i o n a l O f f i c e

Gallon for gallon, high solids coatings will be substantially higher in price than their lower solids counterparts, however, when considering all factors of the cost of production, high solids coating will generally result in lower overall cost comparing mil thickness per square feet.

UV coatings have become one of the latest trends in increasing productivity and profitability. New formulations have greatly improved the ease of application and curing of UV coatings. Advances in coatings and equipment have reduced the initial capital investment necessary, allowing mid to smaller sized companies to take advantage of these tough durable coatings. Two-part high solids urethane coatings from European and domestic manufactures are becoming much more available. These allow the finisher to fill open-pored wood easily with a reduced number of steps to provide high performance finishes at a competitive price.

Low Solids Material versus High Solids Finish To achieve the same build of finish:

20% solids material required 2 steps to = 1 step of 40% solids material.

This reduces labor by 50%

Reducing Finishing Steps Finishing with high solids materials reduces the number of steps to achieve high quality finish which, in turn, reduces the cost of labor and material.

Perhaps one of the most significant steps to profitability improvement is investing in the knowledge and skills of the finisher. Without exception, the wood finishing industry is experiencing a scarcity of knowledgeable finishing technicians. The position of the finisher must no longer be looked down upon, but elevated to that of a highly regarded profession. To accomplish this change will require significant investment in knowledge and skills of the finishing room personnel, to elevate the position to a competitive level in employee compensation with other industries. According to the American Society for Training and Development, US manufactures spend 2% of revenues for employee training compared to Asian companies who spend 3.8% of revenues for training. American companies which do spend more than the average on personnel training have a 24% higher gross profit margin and publicly held companies that invest in training have a 50% better stock performance. Spray operator laser gun training technology has resulted in up to 22% material savings due to more uniform material application and has substantially reduced defects and reworks.

In bringing attention to these areas of finishing it may seem like each point is insignificant, but when taken together and in-depth the increase in bottom line profits is amazing. Stay focused for future s&p articles where these topics will be discussed in more detail.

Low Solids Material versus High Solids Finish To achieve the same mill thickness of finish

20% solids requires 2 times the amount of material of 40% solids material.

LS material @ $16.00 per unit = $32.00 HS material @ $24.00 per unit = $24.00

image courtesy artopex

$32.00 – $24.00 = $8.00 savings per same mil thickness on same square footage.

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Phil Stevenson is President of American Wood Finishing Institute www.awfi.org

www.surfaceandpanel.com

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M12CLA-3

Highest quality HDF and MDF made in an unmatched facility located in the heart of Pennsylvania.

Contact Clarion Industries today at 1-800-373-4383 www.clarionindustries.com/boards M12CLA-39/S+P Print Ad.indd 1 SandP_Q3-2013.indd 71

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Through Fixtures Crafted Technology

C b y

s u z a n n e

V a n

G i l d e r

raftsmanship and relationships define the culture of Mock Woodworking, an architectural woodwork and store fixtures manufacturer that has been in business for nearly 60 years.

Located in Zanesville, OH, the company grew from a one-person cabinet making shop, to a 40-person operation that builds specialty fixtures for some of the world’s most recognized brands.

“Most of what we do is higher end specialty work. Our customers expect high quality and we give it to them,” says Doug Mock, president of Mock Woodworking. “The company is relatively small, which helps us to build relationships. We pay attention to project details, but are substantial enough to produce large scale projects.”

tafisa

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alto by tafisa

Introducing ALTO, a brand new texture and stunningly tactile surface for decorative panels. Available in 10 new

colors, the Alto texture is yet another exciting innovation from Tafisa—the company who leads the way in fashionforward interiors, touching off world-class trends right here in North America. And raising industry standards too.

Tafisa’s wood-fiber panels are manufactured using 100% recycled and recovered wood materials, saving over 2 million trees every year. Now that’s making a statement.

Find out about Tafisa’s green mission and see the new Alto colors at tafisa.ca Customer Service: 1-888-882-3472

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What’s in a name?

A promise.

SPECIFY “Sounds like a pitch, but it’s true. Collins Pine FreeForm ® Collins Pine Particleboard NAF, CARB Exempt, available moisture resistant

Particleboard is the best NAF out there. Good board. Good tolerance. Flat.

Collins Pine FreeForm

Machines well. Cuts well.

NAF, CARB Exempt, Declare Product, FSC-certified, and available moisture resistant; MR10, MR50

And you can lay up high

®

Collins Hardwood Lumber Millwork and dimension, veneer logs

pressure panels on it.

I know because in addition to our 40 years as one of the

Collins Pacific Albus

leading lumber and plywood

Plantation hardwood lumber

distributors, we also operate

TruWood Siding & Trim Engineered wood

our own custom milling

®

®

facility for architectural millwork. So from our point of view, when it comes to FSC-certified Collins Pine FreeForm ® Particleboard,

In order to outfit museum stores, high-end commercial spaces and such well-heeled entities as Limited Brands, Vineyard Vines, American Eagle and Abercrombie & Fitch (often on national and international levels), Mock blends current technology with skilled craftsmanship.

“Our volume is high for the number of employees we have, due to technology,” says Mock. “We use virtually any material that is specified, plastic laminates, specialty resin panels, but our real strength, the place where we add value, is solid wood and veneer.” To enhance this area of expertise and better meet the needs of discerning customers, Mock recently invested in a Superfici flat-line finishing system. The new equipment improves the quality of Mock’s finishes and speed to market, both important aspects of the customer service.

what’s not to like?”

Chip Spellman, Owner, SpellmanHardwoods.com

Information and Sales: Mike Shuey 800.547.1793 mshuey@collinsco.com

FSC -C010859 www.fsc.org ®

Cindy Wigen 800.547.1793 cwigen@collinsco.com CollinsWood.com

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Building Custom Relationships

Although Mock’s work goes into projects throughout the world, the company has a definitively local client base. “We work with companies based in our market area only because we feel like we can serve them better,” says Mock. Many of the large store brands that rely on Mock for fixtures have headquarters and designers within driving distance.

“Retail is a fast paced environment with tight deadlines for store opening dates. We always have defined ship and arrival dates,” says Mock.

“Even if a project is going to be installed overseas, we can always get to the client’s corporate office and work with their folks to solve problems. That relationship is important.”

Textured surface with real depth

RENOLIT WOODSTOCK DESIGN OCEAN DRIVE Available in White, Paintable White and Black www.renolit.com www.laminatefinder.com 610-944-1413 74

That high level of customer service is supported externally by wellestablished distributor and fabricator partnerships, and internally by a committed team of associates. “We’re not all ready to retire, either, “says Mock. “We’ve been very fortunate to attract and retain some really talented craftspeople, it is the key to our success. One of the touchstones of our business is relationships: with our employees, suppliers and especially our customers. It is the best part of the old fashioned way, and we feel it is the best way to serve our clients.” Well over 50 percent of Mock’s current programs go into LEED projects, and over all, specifications for NAUF and FSC-certified materials are on the rise, further underscoring the importance of trusted partnerships all along the value chain.

Service and Technology

Although the company thrives on traditional values and craftsmanship, Mock’s facilities and processes are anything but behind the times.

Due to the volume of fine finishing required by store fixtures clients, Mock recently added a high tech Superfici flat line finishing system to its traditional spray and hand finishing operations. The 52-inch, fourhead reciprocating machine required Mock’s finishing department to learn, and thanks to Superfici and supplier partners like Sherwin Williams, it has also helped the business to grow. “The Superfici fit our needs because it has a relatively small footprint but has a 52-inch spray. We still do shorter runs and more complicated finishes by hand, but the finish is one of the most important steps in the process,” says Mock. “It is visible in the final product. Now we are able to offer a durable, furniture-grade finish, complete with computerized color matching.

And because of the automation, finishing is never a bottleneck, and that helps us to better meet our customers’ needs.”

The dedicated finishing environment is a part of Mock’s 46,000 square-foot facility, which includes offices for in-house engineering and document drafting. Master cabinetmakers, most of who have been with the company for 15 years, work out of a plant that is outfitted with both solid wood and panel processing equipment from SCM and Stiles.

“Blending current technology with craftsmanship is how we build long term relationships with our customers, associates and suppliers,” says Mock. “That stability helps to maintain our company culture and s&p to deliver consistent, high-quality products and services.”

www.surfaceandpanel.com

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CFP027_S

Photo shows Radius™ Bending Plywood... perfect for dimensional interior applications.

Innovating Responsibly.™

Get a free copy of our Grading Guide by visiting us online or scanning this QR code. columbiaforestproducts.com/CFPBranding

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This Is Where

b y

G o r d o n

C l o u g h

Hope Thrives Healthcare architecture can significantly affect the emotional well being of patients so it is important that health care providers seek to provide human centered design when planning new facilities or remodeling older ones. Nowhere was this a more important objective than when the Seattle Children’s Hospital was planning their new expansion. Not only did ZGF Architects design a beautiful, healing environment…they made the interior elements age-appropriate for their young clientele.

A new 330,000 sq/ft expansion building called: “Building Hope” provides a new home for the cancer center, emergency department and two critical care units. The objective of the hospital was to create a more welcoming and friendly environment for their young patients. Instead of being assigned to sequentially numbered floors, these children are now welcomed to zones such as Ocean, Forest, River or Mountain. During the young patient’s convalescent period, they make their way through hallways, elevators and lobbies adorned with brightly colored whimsical artwork depicting various natural themes. The hope is that, for a moment or two, they are cheered by their surroundings.

The colorful new facility has received rave reviews from staff, parents and most importantly the young patients.

The attractive, new and completely custom environment was made possible by fusing custom digital graphics (shown as decorative paper in the graphic on the right) into the 7 laminate layers in Panolam’s Fiber Reinforced Laminates (FRL).

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Cladding the hospitals walls was a straightforward procedure.

The hallways and elevators were covered with panels fastened with adhesive and then trimmed with aluminum moldings. Special color matched caulking was developed to ensure that the panorama of the art continued in an unbroken line. The tremendous physical attributes of FRL such as Class A fire rating, very high abrasion wear resistance (3500 cycles), high impact resistance, stain resistance and ease of cleaning all added to the benefits of using FRL. When custom prints are required for less demanding installations, the same digital art process can be used in a less expensive HPL configuration.

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The excellent physical properties of the FRL allowed designers to eliminate what can be expensive wall protection systems, including reinforced hand rails and impact protection from stainless steel wainscoting, allowing for broad unbroken vistas and continuous floor to ceiling imagery. This further enhances the environment by providing a look that is less institutional.

To produce the magnificent murals for the project, ZGF Architects assembled their own art team to create original artwork. The team worked together to develop story themes and provide color schemes that created a bright friendly environment. The FRL from Panolam Industries was a perfect platform to show-off the brilliant colors of the artists’ designs.

The project work started two and one-half years ago, with a team that included ZGF Architects, Sellen Construction, the creative group of artists, Seattle Sierra Forest Products and Panolam Industries, the manufacturer of these beautiful panels.

Building Hope provides improved patient care and comfort. It helps the hospital keep its promise to the community – providing compassionate, family-centered care to the children who need it most. It’s not s&p just about concrete and steel; it’s about Hope.

Gordon Clough is Director of Marketing at UCS Forest Group of Companies (Sierra Forest Products, Upper Canada Forest Products, UCS Global, and A&M Wood Specialty)

78

www.surfaceandpanel.com

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FUNCTION and BEAUTY

Salice, where function meets beauty Imagine doors opening effortlessly.

Sophistication made simple and quality guaranteed.

The Salice sliding door system offers the widest range of possibilities in the industry. A patented system allowing the doors to slide over one another while closing in the same plane ensures flawless structures and enables you to follow your cabinet lines smoothly.

Available for doors from 18� and up with a weight range of up to 240 lbs per door. The system can also be fitted with an electric motor for the perfect house centerpiece and offers a completely silent sliding mechanism with decelerated opening and closing devices, designed to fully support the door weight and rendering the motion seamless.

SALICE AMERICA INC. 2123 CROWN CENTRE DRIVE - CHARLOTTE, NC 28227 - info.salice@saliceamerica.com - www.saliceamerica.com SALICE CANADA INC. 4025 SLADEVIEW CRESCENT UNIT # 7-9 MISSISSAUGA, ONTARIO L5L 5Y1 - info.salice@salicecanada.com - www.salicecanada.com

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a d v e r t i s e r

i n d e x

Page

Page

Advanced Technology Inc. 15 800.849.1320 www.advtechnology.com

M.L. Campbell

63 800.364.1359 www.mlcampbell.com

Agristrand 46 888.250.5625 www.Agristrand.com

Northern Contours 14 866.344.8132 www.northerncontours.com

Omnova Solutions Arclin 23 866.332.5226 51 877.689.9145 www.omnova.com www.arclin.com

Panel Processing

Blum, Inc. 25 800.433.7142 83 704.827.1345 www.panel.com Perfecting motion www.blum.com Panolam

Boise Cascade 84 (BC) 203.925.1556 81 888.264.7372 www.panolam.com www.bc.com

Premiere Eurocase

Chemcraft, a brand of AkzoNobel 11/31 303.407.7214 67 336.841.5111 www.premiereurocase.com www.chemcraft.com Renolit

Clarion Boards 74 856-467-3800 71 800.373.4383 www.renolit.com www.clarionindustries.com

Riken USA Corporation Collins 50 609.387.2011 73 800.329.1219 www.riken-usa.com www.CollinsWood.com Roseburg

Columbia Forest Products 56/57 800.245.1115 75 800.808.9080 www.Roseburg.com www.columbiaforestproducts.com Salice

Composite Panel Association 79 800.222.9652 38-39 866.4Composites www.saliceamerica.com www.DecorativeSurfaces.org Schattdecor Decotone 37 314.400.6100 45 908.301.0600 www.schattdecor.com www.decotonesurfaces.com Sesa DVUV 29 +39.0331.631388 61 216.741.5511 www.sesaplates.com www.dvuv.com Flakeboard 7 800.430.4643 www.flakeboard.com

SierraPine Composite Solutions 19 800.676.3339 www.sierrapine.com

Forrest 20 800.733.7111 www.ForrestBlades.com

Stevens Industries 35 217.540.3100 www.stevensmelamine.com

Hafele 55 800.423.3531 www.hafele.com

Interprint, Inc. 2 (IFC) 413.443.4733 www.interprint.us

J.B. Cutting 18 586.468.4765 www.jbcutting.com

Kings Mountain International 13 704.739.4227 www.kmiinc.net Kleiberit 53 704.843.3339 www.kleiberit.com

Stiles Machinery, Inc. 21/65 616.698.7500 www.stilesmachinery.com

Surface Source International 28 973.598.0152 www.ssinorthamerica.com

Synergy Thermofoils 26 954.420.9553 www.SynergyThermofoils.com

Tafisa Canada 72 888.882.3472 www.tafisa.ca TCM 58 +43 (0)2244.33870.11 www.asia-surfaces.com

Thermwood 22 800.533.6901 www.thermwood.com

KML-Kustom Material Laminates 33 888.358.5075 Uniboard www.KMLcorp.com 27 800.263.5240 www.uniboard.com Laminati Valspar 47 877.863.7908 69 612.851.7000 www.laminati-usa.com www.valsparglobal.com

Lamitech S.A.

West Fraser Sales Ltd. 43 571.644.9898 77 780.413.8900 www.lamitech.com.co www.westfraser.com Marlite 41 800.377.1221 速 www.marlite.com 80

Wilsonart International 5 800.433.3222 www.wilsonarthd.com

www.surfaceandpanel.com

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ANCHOR

BOISE CASCADE FIXTURE GRADE

ANCHOR (Surface&Panel) 7-11-13 OUTLINE.indd 1 SandP_Q3-2013.indd 81

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f r o m

t h e

e d i t o r

Development Sometimes when I begin work on a story, the person I am interviewing asks, “What is the story going to be about?” And although I have a general idea (furniture, retail fixtures etc.), my answer is always that I cannot presume to know the real story until it has been told. In that sense, the final outcome of each issue of Surface & Panel is as much a surprise to me as it is to anyone.

My job is to research (typically excessively, but that’s my concern), deconstruct, distill and assemble information. Whatever creativity lies within the system is an input of the subject matter.

“At this moment, in this industry, design is a product differentiator and a technology driver as much as it is a philosophical process of mindfulness.”

And in part, that is what makes Surface & Panel meaningful. It’s not fiction; though sometimes the advances that grace its pages are so cool they seem like science fiction. It is more like a hospitable environment where big ideas alight. To that end, the publication provides a snapshot of what is happening in the moment.

On the production side of S&P, the intriguing thing is that the snapshot is akin to an old fashioned Polaroid. What you hold in your hand starts out blank; then the shapes become fuzzy, then clear. This issue has developed into a panorama of design. From aesthetic to philosophical to functional, the importance of design recurs in story after seemingly unrelated story.

“Design” is a pretty inclusive term, but in general, successful design solves multiple challenges.

As Chuck Saylor says in the story about izzy+ (page 8), “no one thing should do only one thing.” At this moment, in this industry, design is a product differentiator and a technology driver as much as it is a philosophical process of mindfulness. The companies featured in this issue (including North Salem High School, page 24) operate in line with these aspects of design. They exhibit a healthy self-awareness, and look outside of themselves and their markets to actively invent and improve.

Of course, that is also what I love about what I do. I get to peek into a variety of markets and business models. It keeps my work fresh and exciting, but it also continually refines the way that I think about the systems, big and little, in the world around me. It is also why I am looking forward to the Decorative Surfaces Conference November 4-6 of this year (page 6). I’ve seen the line-up of speakers, and it includes many different variations of people who are designing successful futures. It will be a big boost of inspiration and invention over two days. Also, it’s in New Orleans, so you know the, ahem, networking will be superb.

I hope you find value in this issue, and enjoy reading it as much I enjoyed working on it. Huge gratitude to everybody who helped to bring this project into being.

Laissez Les Bon Temps Rouler!

Suzanne VanGilder | Editorial Director | svangilder@surfaceandpanel.com

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blum-1443

Fine-tune your drawers.

Perfection at your fingertips with TANDEM plus BLUMOTION. Achieve precise tool-free depth, height, tilt, and side-to-side drawer gap adjustments with the industry’s leading soft-close concealed drawer runner system. It couldn’t be easier. It’s virtually silent. And who doesn’t like the sound of that? Visit us in booth 4200 at AWFS in Las Vegas, or ask your distributor about adjusting to life with TANDEM plus BLUMOTION. blum.com

Perfecting motion Perfecting motion

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