DOORS MANUFACTURING
PROCESS
MASONITE DOORS PVT LTD
INDEX
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Masonite Incorporate –Introduction
Masonite Innovation center -Global
Masonite India- Journey so far
Masonite India –Manufacturing Facilities In India
Doors & Door components-Introduction
Timber & Timber technology
Adhesives & Resin chemistry(Basics)
Masonite Skins –Manufaturing Process
Masonite Skins –Sailent features & Properties
Moulded Doors – Introduction
Components of Moulded Doors
Variants In Moulded Panel doors
Moulded doors- Manufacturing Process
Moulded doors –Indian standards & Specifications
Advantages of Masonite Molded doors
Molded doors quality – Parameters & In process checks
(Continued …..)
INDEX
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Flush doors – Introduction
Flush door –manufacturing Process
Components & Specifications in Flush doors
Variants in Flush doors
Veneer doors – and various designs
Flush door – In Parameters & In process checks
Door Frames – introduction
Doors handling - Procedures
Finishing Recommendations -Molded doors
Customer complaints –How to resolve- Escalation procedure
Warranty –Guidelines
Measurements Units & Conversion Factors.
Masonite Incorporate –Introduction
1924
William H Mason Invented High density fiber board
1925
On sept 1 Masonite Fiber company was formed
1928
Company name was changed to Masonite Corporation
1960
Masonite Innovation center was built as R&D center
1972
Masonite enters the door business as a supplier of interior
facings and other components to the door industry
1990
Premdor expands its global footprints by acquiring or
building door manufacturing facilities in US, Ireland,
Canada, Mexico, UK, France and Israel.
2002
Masonite sells Craftmaster Manufacturing Inc. (as required
under a 2001 U.S. government voluntary consent decree
related to Premdor’s purchase of Masonite).
2010
2011
2014
Tuck In Acquisition - Masonite buys assets of two premier
interior flush door manufacturers in the United States, and
enters the door market in India by acquiring select assets of
three leading door manufacturers
Masonite acquires Marshfield DoorSystems, Inc., a leading
provider of doors and door components for commercial and
architectural use.
Masonite Incorporate –Introduction
1898
Waste paper pressed into Product Reassembling Hard board was
made first In England – called Masonite.
1924
Patented in 1924 in Laurel ,Mississippi, by William H. Mason.
1925
1928
1929
1960
On sept 1st 1925 Masonite Fiber company was formed
Company name was changed to Masonite Corporation
First mass production started
Masonite Innovation center was built as R&D center
Masonite Incorporate –Introduction
1972
2001
Entered the door business as a supplier of facings in 1972
Masonite Facings (SKINS) was purchased in 2001 by Premdor
Corporation
2010
Tuck in Acquisition - Masonite buys assets of two premier interior
flush door manufacturers in the United States
2010
Stepped Into Indian Door Market by acquiring select assets of three
leading door manufacturers
2011
Masonite acquires Marshfield Door Systems, Inc., a leading provider
of doors and door components for commercial and architectural use.
Masonite International
5 CONTINENTS 12 COUNTRIES -60
Manufacturing Facilities
60 Manufacturing Locations – 12 countries
Capacity : 1,50,000 doors /day
Masonite Global - IC
Masonite India – Journey sofar
DOORS & DOOR
COMPONENTS -Introduction
Door : A movable structure used to close off an entrance, typically consisting of
a panel that swings on hinges or that slides or rotates is called Door.
Doors In Ancient History:
Stone door,Hampi,India
A decorated door from the
Montiserry southern India
Door in rural Punjab
Old double French doors (6 lites
each), with hinges on the exterior
they must open outward;
Doors Introduction
 Doors perform several functions.
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They shield an opening from the elements.
Add decoration and expand visibility.
Emphasize the overall design.
Provide light and ventilation.
 Planning is necessary to provide maximum
design and function.
Doors Classification
 Several door classification systems are used
to identify types of doors.
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Two broad classes are interior and exterior
doors.
Doors also may be grouped according to
method of construction, uses, function, or
location.
 Doors are typically 6'-8" high and available in
various widths.
Interior Doors
 Common types of interior doors include:
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Flush, panel, bi-fold, sliding, pocket, doubleaction, accordion, Dutch, and French.
 Interior doors should be at least 32" wide for
wheelchair passage.
 Lever or pull-handles may be easier for a
handicapped person.
Exterior Doors
 Residential exterior and interior doors are
similar in many ways, but have decided
differences.
 Exterior doors are generally solid core and
thicker than interior doors.
 Exterior doors may have one or more glass
panels to provide visibility.
 Exterior door styles include flush, panel, and
swinging or sliding glass doors.
Exterior Doors
Flush door with Decorative Lighting
A traditional exterior panel door.
Door Components
Jamb
Top Rail
Rail
Lock Rail
Bottom Rail
Frame
Hinge Stile
Door
Stile
Face
Filler &
Lock set
Panels
Lock Stile
Door Components-Nomenclature
Door Components - Nomenclature
Door Jamb
 Most interior and exterior doors are placed
in a door jamb.
 The door jamb fits inside the rough
opening.
 Jambs may be wood or metal.
 A jamb consists of two side jambs and a
head jamb.
Door – Locking System
AL Drop Lock
Door Stopper
Knob Lock
Tower Bolt
Door Handle
Glass Handle
Hasp & Staple
Hinges
Door Eye
watch
Anatomy Of a Door
Raw Materials of
Wooden Panel Door
Timber
Particle board
Glue
Masonite Skin
Timber & Timber Technology
Timber & Timber Technology
Timber & Timber Technology
Timber & Timber Technology
There are around 150 species of Timber which are produced In India
Some common trees used for supplying Timber in India like..
Babul
Banyan
Bamboo
Deodar
Elm
Coconut
Mahogany
Mango
Mulberry
Palm
Pine
Cedar
Rose wood
Sal
Sandal wood
Teak…etc
46 Big Companies
1000+ small
companies In India
Timber & Timber Technology
Classification Of Timber:
Hardwoods
- Broad leafs
-Generally Higher Densities
-Often Dark In color
Soft wood
-Needle like leaves
-generally lower densities
-Often light in color
Timber & Timber Technology
Timber Classification (Water Absorption)
Timber
Green
Timber
15 % Absorption
Rate
Recently Harvest
Cracking easily
Air Dry
Timber
12-15 %
Absorption Rate
Resists splitting
Oven Dry
Timber
12 % Absorption
Rate
Recently Harvest
Splitting easily
No cracks
Timber & Timber Technology
Timber & Timber Technology
Timber & Timber Technology
Timber & Timber Technology
Timber & Timber Technology
Air Seasoning
Timber & Timber Technology
Timber & Timber Technology
In process Checks & In process Parameter :
Moisture
Density – weight/Unit Volume
Specific Gravity
Strength & Stiffness
Toughness
Compression Strength
Tension Strength
MOR
MOE- Modules of Elasticity
Electrical Conductivity
Thermal Conductivity
Timber & Timber Technology
Properties Of Hemlock
Light in weight,
uniformly textured.
It machines well and has low resistance to decay and no resinous.
 Used for construction lumber, planks, doors, boards, paneling, sub
flooring and crates.
Average Dried weight density 450kg/m3
Properties Of Pine
Pine is a softwood which grows in most areas of the Northern
Hemisphere.
Properties:
Pine is a soft, white or pale yellow wood
light weight, straight grained and lacks figure.
It resists shrinking and swelling.
Knotty pine is often used for decorative effect.
Timber & Timber Technology
Mango wood:
 Mango is a hardwood
 Appears light brown and deeper brown in
color
 Average dried weight : 675 kg/m3
 Used for furniture and Door making
Adhesive & Resin Chemistry
Resin is a sticky flammable organic substance, insoluble in water
Generally in door industry for making doors we use
Ploy Vinyl Acetate (PVA)
Melamine Urea Formaldehyde(MUF)
Phenol Formaldehyde(PF)
Adhesive & Resin Chemistry
MUF :
 Belongs to Amino Resin group
Advantages :
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Low cost
Easy to use in different curing conditions
Hardness
Excellent thermal features
Low energy consumption during the production with low curing temperature
Disadvantages :
 Resistant against humidity is low especially in High temperatures
 Products have been produced with MUF is suitable for use in closed
conditions
 Formaldehyde gas emission is more
Adhesive & Resin Chemistry
Phenol Formaldehyde (PF):
 Poly-condensation product of phenol and formaldehyde
Advantages :
 Non-conductive, heat resistant, water resistance, moderately
inexpensive
Disadvantages :
 Formaldehyde, brittle, distinctive redish-brown color, much more
expensive than UF, need a higher temperature and longer cure
time than UF or MUF
Adhesive & Resin Chemistry
Adhesive durability :
Masonite Skins
Masonite Ireland
The Masonite state of the art production
facility in Southern Ireland is the result of a
138 million dollar investment. Production of
door facings from this plant is exclusively
dedicated to Europe, guaranteeing volume
supply to satisfy increasing demand.
Masonite, in conjunction with leading door
manufacturers, operate in all the major
markets of Europe, North Africa and the
Middle East. With its full back up team of
sales, technical, marketing, shipping and
customer services support.
Door facing facility at Carrick On Shannon -Ireland
Masonite Skins
Why choose Masonite Door Facings?
Doors made with Masonite facings are made of tough moulded
engineered wood, so you can be sure they will resist splitting, warping,
cracking and damage even in centrally heated rooms and homes with
lively children. With a wide range of both smooth and grained designs,
there is a door to suit any decor.
Masonite Skins
Manufacturing Process:
Moulded door facings are made from locally grown wood, using a process developed by
Masonite.
Raw wood chips are refined into fibers, the fibers are then mixed with resins, dried and then
formed into a continuous mat.
 The mat is cut to length and fed into a large multi-opening press, containing dies.
The mat is then pressed at high temperature and pressure to consolidate the fibers into a high
density 3.2mm moulded door facing.
The door facings can be made with either a smooth or grained surface.
After pressing, the door facings are primed with a water based primer and an anti-metal mark
coating.
The anti-metal mark coating helps keep the surface clean during door manufacture.
They are then cut to size, packed and are ready for dispatch to door manufacturers.
Independent door manufacturers then make interior moulded doors from the door facings.
Ongoing technical support and help with production start up is available for all Masonite
customers.
 Door facings are made of engineered wood.
Masonite Skins
Advantage of Masonite Skins
Masonite has skin Manufacture Facilities in Malaysia,Chile,USA and
Ireland –world leader in SKIN Manufacturing
Masonite Skins have higher density – Better Strength & Surface
Appearance
Masonite skins have higher MOR - Higher strength will improve door
structural performance
Masonite skins have higher IB –Higher performance against de-lamination
of skins
Linear expansion (LE) of Masonite facings is lower than others. A lower LE
leads to less door distortion
with environmental changes.
The equilibrium moisture content (EMC) at 50% relative humidity (RH) of
Masonite facings is lower. In
a dry environment, Masonite facings will exhibit less shrinkage and
therefore less door distortion
tendency.
Boiling water resistant no disintegration even after 4 hours of Boiling –
Strong enough to face drastic Indian weather changes
Advantage of Masonite Skins
 Masonite SKINS have less formaldehyde gas emission –ECO Friendly
 Masonite facings have a better surface aesthetic appearance when
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considering primer coverage, hide mud cracks, and blocking/fiber
transfer. Primer adhesion is best in class.
Better water resistance – Again unlike others who publish a wide range
for certain properties, (i.e. EMC 5-11%) Masonite skins don’t exceed
6%.
Masonite facings have strong edges & corners thus face day to day
usage and natural wear and tear better. This is due to the fact that we
are the only player in Asia that has complete in house design &
development of dies.
Availability of Smooth flush facings + Complete range of facings,
designs and textures.
Highest capacity plant in Asia/Pacific with best capacity utilization.
Masonite Skins – Fact Sheet
Masonite SKIN (Facings) -Specification
Parameter
Density
Value
Moulded Densified Wood Fibre
plates having 1000 kg/m3 denisty
Thickness
3 MM
EMC(Equllibrium Moisture
Content)
6%
Boiling Water Proof
YES
Solid Particle Board
Is made from wood particles, which are often the residue from other wood
processing operations, combined under heat and pressure with a water resistant
binder.
Moulded Panel Door
Moulded Panel Door - Variants
Moulded Panel Door - Variants
Moulded Panel Door - Variants
Moulded Panel Door - Variants
Seven Panel - Mumbayia
Masonite - Gold
Moulded Panel Door –
Process Flow Chart
start
Framing
Assembli
ng/SKIN
Pasting
Filling
Hot Press
Stop
NO
Packing/
Shipment
Trimming
YES
Cooling
Tempera
ture &
Bonding
check
Moulded Panel Door –
Indian Standards
Moulded Panel Door –
Indian Standards
Timber:
Minimum density – 450 Kg/m3
Moisture should be Maximum -12 %
Rails & Stiles
Width Minimum : 45 mm
Maximum : 75 mm
Stiles & Rails is made of one species only without joint(For heavy duty doors)
The joints may be permitted on the rails and stiles but only vertically so far as the
Extreme member is of minimum width 40 mm and is in a single piece.
Moulded Panel Door –
Indian Standards
Moulded Panel Door –
Indian Standards
Glue :
 Adhesive used for bonding the face skins and
core shall be phenol formaldehyde synthetic
resin adhesive
 conforming to BWP grade of IS 848.
Moulded Panel Door –
Specifications
S.No
1
Test
2
Dimensions and squareness Test
Width
Length
Thickness
General Flatness test
3
4
5
6
7
Local Planess test
End Immersion Test
Glue Adhesion Test
Slamming Test
Impact Indentation Test
8
9
10
Flexure Test
Edge Loading
Buckling Test
11
12
13
14
Shock Resistance Test
Misuse test
Screw withdrawl Test
Varying Humidity Test
IS-15380 Requirement
+/- 5 mm
+/- 5 mm
+/- 1 mm
Warp/Cupping/Twist should not exceed 6mm
Depth of deviation at any point should be less than
0.5mm
No delamination
No delamination
No visible damage after the test
Depth of Indentation should not exceed 0.2 mm
The deflection at the maximum load shall not more than
1/30 of length
<5 mm
Initial deflection <50 mm
Residual deflection <5 mm
No visible damage after the test
No deferomation after test
>1000 N
No visble warping ,twisting or de-lamination
Moulded Panel Door –
Specifications
Moulded Panel Door –
Specifications
Moulded Panel Door –
Specifications