This categorization allows joined, molded pieces to match in shade and grain type. The sorted and indexed wood is then stacked by category. The wood then moves to a multisequence molding operation which shapes the planks into intricate molding designs. The company found that manipulating the molding cuts and planing angles in the molding process reduced grain rise and stain variation in the coating process, which is performed in a subsequent operation. The stain is applied with automated equipment which feeds the wood moldings to a three-head spray unit.
Excess coating is removed from the molding's grooves and channels via air knives.
The moldings are then fed back through the head of the spray coating process, where the topcoat is applied, using the same four-head HVLP spray gun process as employed in applying the sealer. The moldings are then fed back through the oven for an identical 2.5-minute dwell time. The finished moldings are then stacked as finished goods for shipment or are sent to the foiling shop for application of optional design treatment. The equipment changes entailed improved heat capacity and air flow in drying ovens, automated stain and sealer topcoat application equipment, automatic scuff disk sanding machines, and router tooling improvements. The conversion was not easy and not without risk.