PSC Dniprowood, Piontkovskogo str. 2-а, Berdichev, 13300, Ukraine

Factory Production Control and Technical file.

This Factory Production Control (FPC) covers the procedures which are put in place to allow us to maintain consistency in the characteristics of the product “Cathedral Brand engineered flooring”.

The manufacturing process ensures, Wood flooring and parquet – Characteristics, evaluation of conformity and marking to EN 14342:2013

Records will be kept for not less than ten years of non-conforming products, processes or materials, in order to make improvements and record compliance of the CPR.

This production control system documentation ensures a common understanding of conformity evaluation and enables the achievement of the required product characteristics and the effective operation of the production control system to be checked. Factory production control, therefore, brings together operational techniques and all measures allowing maintenance and control of the compliance of the product with this European standard.

Each batch of flooring manufactured will equate to one full load of 30 double pallets and take on average five days to complete.
This will be the frequency of all procedure checks and calibrations.
Profiling calibrations will be carried out intermittently during the production cycle.

Where any product fails to satisfy acceptance measures, the non-complying products shall be isolated and properly identified.
The necessary corrective action shall immediately be taken and the products or batches not complying disregarded for export.

 

 

Product description

Cathedral engineered flooring consists of an exterior grade plywood base with a hardwood wear layer.

It is manufactured in various thicknesses, lengths and widths as one product group.

This is a simplistic product in design and manufacturing with little room for deviance of characteristics as long as like for like materials are used.

The materials involved are Exterior Grade plywood in finished thicknesses of 12 mm or 15 mm (Birch, Alder or Poplar or a mix of). European Oak in finished thicknesses of 4 mm or 6 mm and Adhesives

Consistency of the characteristics is dependent more on the materials used than the production process.
Consistency of own grown Ukrainian Oak is static.
The Plywood we use must conform to Formaldehyde E1. Using Carbamide-Melamine-Formaldehyde Plywood ensures very low emissions well within E1.

Also
State of California AIR RESOURCES BOARD EXECUTIVE ORDER N-20-320

Relating to CARB approval for an Exemption from Third-Party Certification for Composite Wood Product Manufacturers that use Ultra-low-emitting Formaldehyde Resins under section 93120.3, title 17, California Code of Regulations. Carbamide-Melamine-Formaldehyde is within this category.
See certificate below.


Adhesive to bond the oak to the ply must be a D4 PVA

 

Intended uses

 

Interior use for overlay hardwood flooring

Brief Description of the manufacturing process

Round logs are collected from the forest and transported into our factory yard where they are checked for FSC and UTR compliance and stacked in area’s reserved for FSC timber.

The logs are cut into plank form and then stacked into kilns and kilned dried to a fair average of 8% +/- 1%

The kilned planks are taken into the main factory and cut to regulate parallel in length, checked for defects that are not permitted and defects cut out.

Planks are cut into veneers for use as top layers and transferred to the pressing area.

Plywood sheets are outsourced and delivered into the main factory and stacked in FSC defined area.

Plywood documents are checked for FSC and UTR compliance and then the plywood is cut to width into strips and transferred to the pressing area.

The adhesive is applied to the plywood strips on the glueing line and the hardwood wear layer placed by hand. The boards are stacked in the press and then pressed. 

After pressing the boards are transferred to the machining area into FSC defined stacking area’s.

The boards are profiles and regulated in thickness as one pass through the profiling machine.

They are then ends matched.

The boards are then transferred to the quality control area where they are examined for non permitted defects. Knots and shakes are filled and hand sanded.

The boards are transferred to the sanding machine and sanded.

The boards are transferred to the packing area where they are given a final examination for quality control, labelled and packed ready for export.

Factory production control and processing

EN 14342:2013 declares that the manufacturer shall establish, document and maintain an FPC system to ensure that the products placed on the market comply with the declared performance of the characteristics.

  • Stage 1.     Quality control of delivered logs and unedged lumber in accordance with waybills. Unloading and storage of logs in special designated areas to conform to FSC standards. Relocation of logs to the sawmill for sawing on unedged lumber. Sawing of logs on T-32 mm lumber for the subsequent production of engineered flooring. Transportation and unloading of raw lumber to the kilns and further drying process.

The Head of sawmill & drying department Nadiya Chaban is responsible for all documentation and overseeing procedures for stage 1.
Nadiya Chaban will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Nadiya Chaban is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

  • Drying of lumber (boards) in drying kilns according to the drying modes. Unloading of drying kilns and transportation of dry lumber to the warehouse of the main production facility. Sorting of dry lumber and its preparation for submission to the workshop according to internal waybills by grades and purpose in production.

Stage 2:     Cutting of dried lumbers for further technological process on a multi rip saw. The opening of wooden, AKA the first planing of S4S lumbers, with pre-calibration into blanks with a rectangular cross-section. Quality control and marking of rough blanks along the length before entering the optimization line or pneumatic trimming. Cutting of natural defects in pre-calibrated blanks. Fine calibration of blanks for top lays on the 4-sided Weinig Hydromat-23 heavy moulder. Cutting of finely calibrated blanks on 2.5; 4 or 6 mm thick top lays on the NEVA thin cutting frame machine. Transportation and transfer of top layers in different thickness to Stage 3.

The Head of stage 2, Oleksander Averkin, foremen Oleksander Zavgorodniy (1st shift) and Oleskander Verezub (2nd shift) .
Oleksander Averkin will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Oleksander Averkin is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

Stage 3:     Checking the delivered plywood according to the waybills. Unloading and storage of plywood sheets in special designated areas. Cutting of plywood sheets to plywood strips according to a variable task for further technological processing.

Chief- technologist Yaroslav Zheleznjak, The Head of stage 3: Volodimir Pavitskiy, foreman of stage 3:Volodimir Lukashuk.
Volodimir Pavitskiy will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Volodimir Pavitskiy is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

  • Stage 4:     Gluing of engineered blanks in the PVG 6500-U press – Top lays in combination with plywood strips glued together by PVA adhesive, class D4. Format machining of tongue & grove on blanks lengthwise with calibration into final thickness and width on heavy moulder Weining Hydromat – 22P machine. Cross-cutting and end matching Нomag double-ender. Natural defects repair’s zone with further final sanding on 3-v belts sanding machine SandingMaster 180 grit paper surface.

    The Head of stage 4, Volodimir Pavitckiy, foreman of stage 4, Volodimir Lukashuk.
    Volodimir Pavitskiy will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Volodimir Pavitskiy is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

Intermediate stage:     Treatment of floors with stains, oxidative oils, hard wax oils and UV materials (meanwhile intermediate sanding is made before applying of top UV layer).

Chief-technologist Jaroslav Zheleznyak, treatment processing technologist Lesya Grigorieva, foreman of Modul #3 Mykhailo Zhelznyak.

Jaroslav Zheleznyak will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Jaroslav Zheleznyak is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

Stage 5:     Transportation of all ready products to the packaging area. The final stage of QC on ready products and their sorting. Packing of ready products and stacking it in pallets. Transfer to the warehouse of finished products according to inner waybills. Storage of pallets of finished products in special areas.

Traceability and marking Individual product batches or packages are identifiable and traceable with regard to their production origin. Procedures ensuring that processes related to affixing traceability codes and/or markings are inspected regularly. Each pack of flooring is labelled with specific information to the product and CE marking. Each pallet has two labels. One showing product description and the batch date and one showing shipping information.

All products are compliant to FSC standards including chain of custody and traceability and UTR Standards of Traceability.

 Suppliers documentation of raw materials used in the batch of production is recorded and filed for traceability. 

Chief-technologist Jarosla Zheleznyak, treatment processing technologist Lesya Grigorieva, foreman of Modul #3 Mykhailo Zhelznyak.

Jaroslav Zheleznyak will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems. Jaroslav Zheleznyak is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

Stage 6:      Labelling of ready for dispatch orders

Each pack to be labelled with CE label.
Each pack to be labelled with a pack label showing floor type and batch date.
Each pallet to be labelled with a product type label showing the batch date.
Each pallet labelled with a transport loading data label.

Warehouse manager Nadiya Zheleznyak

Labels

CE label

Pack Label

Product type label

Transport loading data label

Export sales paperwork including FSC claims.

PCI: Sales manager Yana Zhystovska

Yana Zhystovska will initiate actions preventing product non-conformities from occurring. Actions in case of non-conformities will be to identify and register product conformity problems.Yana Zhystovska is competent on the basis of appropriate education, training, skills and experience for which records are maintained.

Loading of engineered floors on vehicles.

Warehouse manager Nadiya Zheleznyak.

Handling, storage, packaging and Transportation

To be kept in dry conditions at all times.

Any part opened or torn packs, the packaging to be resealed for moisture tightness.

Technical file

EC declaration of conformity

PSC Dniprowood used The International Centre For Quality Certification to obtain an EC declaration of conformity for its flooring products in 2013. After examination of the contract, invoices and test results as attached, we are confident that we have genuine documentation to for the basis 0f our Declaration of performance for products they make for us to our design.
We have had to update the CE label to conform to the latest regulations. We can declare that there have been no changes to the type of materials used or production processes that would change the declared characteristics of the products.

Scan1047

EC Delaration Of comformity

Fire Test report

Fire Test report

Fire Test report

Fire Test Summery

Contract PSC Dniprowwod
& ICQC

Contract PSC Dniprowwod
& ICQC Translation

 ICQC Invoice

UkrSEPRO certification system. Mark of conformity

Due diligence to prove UKr SEPRO certification 

Declaration of Performance