Press release
High temperature, high pressure, high quality
From the raw material to delivery: How successful rubber floor coverings are created
at nora systems
At nora systems, it all comes down to the right mixture. So what is needed to make rubber
floor coverings of such high quality? Not every flooring can withstand extreme stress. Also,
not every flooring has such a dense surface that it does not have to be sealed with an
additional coating, unlike other resilient makes. The crucial steps towards a successful end
product involve the perfect combination of the materials and the production process.
Valuable natural and industrial rubbers provide the foundation for these floorings made in
Germany. They can be found, for instance, in hospitals, old people’s homes, nursery
schools, universities, and buses. They are processed on ultra modern production plant to
technical standards that are the highest in the world. At the same time, all production steps
fulfil strict ecological requirements. For example, the whole process is geared towards
minimising the use of resources. This includes reduced cooling water consumption in closed
circulation systems and the most environmentally friendly generation of electricity and
process steam in a cogeneration power plant, including efficient air filtration systems.
From the raw materials warehouse to the mixing chamber to shaping
It is a long way from the raw rubber to the floor covering, starting at the raw materials
warehouse. From there, the diverse constituents have to go through several stages of
treatment. Afterwards, all materials enter the large mixing chamber. Here, up to 30 raw
materials are mixed together, including minerals from natural sources as well as light and
ageing stabilisers. The whole process can be compared to baking a cake. Now the decision
is made as to which of the 300 colours from the nora standard range the flooring is to take.
The corresponding pigments are then added to the mixture. After the following treatment in
the mill, the compound passes through the so called batch stores where the blanks are
stacked on top of each other before they enter interim storage. After two days of maturing,
the primary product again passes through the large mill. Now the rubber mixture passes over
the calendar, a set of rollers arranged over one another, that compresses them under heat
into sheets. This is the first step towards shaping.
Rolled and stacked – vulcanised and finished
For the noraplan product line, later available as sheets in a standard length of 15 metres, the
interim product is now rolled up. For the norament product line, on the other hand, the square
metre tiles are stacked. noraplan is now vulcanised, so to speak “baked”, at a high
temperature and under a huge pressure in a continuous process that lends it its deformation
resistant, yet permanently resilient properties. On the other hand, its sister product norament
Press release
is subjected to the identical process, but under heavy presses. Now both product lines are
ready for “finishing”: The backing is ground, and the surface treated with nora cleanguard
that makes it even more resistant to wear and scratches. Thanks to this technology, installed
nora floor coverings can later be cleaned economically and easily with the mop care method.
The edges are now trimmed on the sheetware noraplan, and the product cut to its final
length. The norament tiles are punched accordingly. Finally, the two rubber floor coverings
are ready for packaging and putting into storage.
Sustainable and environmentally friendly life cycle
The sheetware is rolled on spindles of recycled cardboard, and also the outer packaging is
made of recyclable paper. The rolls are then prepared for delivery in a standing position on
wooden pallets, and are then shrink-wrapped using environmentally compatible and
recyclable sheeting. Just as the customer wishes, the norament tiles are delivered either
loosely or in cardboard boxes on wooden pallets that are reclaimed and reused by nora
systems within the framework of a European recycling programme. Just how sustainable the
life cycle of this product is, is underscored by an additional fact: The production residue – like
grinding dust and punch chips – again serve as an important constituent of the raw materials
used in various nora products. They are used as decorative granules for design decorations,
for example.
Today, more than one in every three orders received by the nora systems experts are for a
special design. Whether a specific colour that matches exactly a corporate design or inlays
arranged in individual motifs, we can realise our customers’ ideas without long delivery times.
And combining the technical properties of noraplan sheetware with a particular design of
norament tiles? Possible at all times, in virtually any colour you want.*
*This text can be copied free of charge. Please send us a specimen copy.
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Press release
About nora systems
nora systems develops, manufactures and markets high-quality resilient floor coverings and
shoe components under the nora® brand name. The Weinheim-based company was formed
from Freudenberg Bausysteme KG in 2007, and as a global market leader has been shaping
the development of rubber floor coverings for many years. In 2013, more than 1100
employees generated a turnover of 206.5 million euros.
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