From seed to full stave worktop

The seeds that will into the trees from which we make our worktops

 

1. From humble beginnings

The wood we use comes from trees planted from seedlings, usually in the United States. Once a seedling reaches one to two years of age it is planted out into the forestry.

 

 

 

 

Fully grown trees are pruned and cleared to produce stright trunks

Fully grown trees are pruned and cleared to produce stright trunks

 

2. Old age

As the trees grow, good forest management is important. Trees will be pruned and cleared to produce trunks that a as straight as possible. As the trees reach between 90 and 120 years of age they will be felled. We produce worktops in many timbers, most of them come from North America.

 

 

 

Kilning drys to tinber slowly and carefully.

 

3. Things heat up

The felled trees are transported to the mill where they are machined into planks. These planks are stacked with spacers in-between them to air dry. After 6 months of air drying they are moved to a kiln for 4 months.

 

 

 

 

The dry timber is transported by sea to the UK

 

 

4. A long way to come

The dry planks are taken to port for a sea crossing over the Atlantic. A short road journey later sees them arrive at our workshop, ready to be turned into your worktop.

 

 

 

 

 

This cleans each of the four rough edges           This cleans each of the four rough edges

 

5. A short back and sides

The first step of creating usable planks is top run them through a 4 sided planer. This cleans up each of the four rough edges created by the kilning process.

 

 

 

 

Used for making the first "rough" cuts           Ready for the next stage of manufacture

6. The buzz cut

The planks are now given their first cut; known as a rough cut. Notice the long length of the timber, this is what allows us to create our high-quality full width, full stave worktops.

 

 

 

 

The creation of a smooth surface

 

 

 

7. Smoothly does it

To create a smooth edge that can be joined and laminated together, we plane the boards.

 

 

 

 

The boards are kept under high pressure for 4-6 hours

 

 

 

8. A high-pressure environment

The planks are laminated together and then cramped under high pressure for 4-6 hours. This creates a bond between the planks which is pretty much as strong at the wood itself.

 

 

 

 

Creating a perfectly  uniform thickness Creating a perfectly  uniform thickness

 

 

 

9. Sanded to a smooth finish

After removal from the cramps we put the worktop through a calibrating sander. This produces a perfectly uniform thickness of worktop.

 

 

 

 

We cut to millimeter perfect accuracy.

 

 

10. And not a millimeter more

Since all our worktops are bespoke, we now cut them to the exact size the customer has ordered; to the millimeter. It’s at this stage we also add cut-outs for sinks and hobs, draining grooves and joints. All done with pinpoint accuracy.

 

 

 

 

Cutting one of the 15 edge profile we offer

 

 

 

11. Our competitive edge

It is now that we cut the edge profile that the customer has selected. We offer 15 different edge profiles and they can be mixed across any of our products.

 

 

 

 

To remove any marks caused by the previous steps

 

 

 

12. The pad sand

We now place the worktop of a pad sander. This will remove any of the small marks from the previous manufacturing stages.

 

 

 

 

For a fine smooth finish

 

 

 

13. The orbital sand

The orbital sander produces a smooth fine finish to the worktop, which is now ready for installation.

 

 

 

Our finished product ready for delivery

 

 

 

14. Does not include batteries

We now carefully pack the worktop for its onward destination. We have dispatched to every corner of the world.