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Introduction — short answer: LVT (Luxury Vinyl Tile) is manufactured as a multi-layer vinyl product that reproduces wood, stone, or tile appearances with a durable wear layer. The manufacturing chain includes raw material preparation, printing, embossing/texture registration, lamination, hot-pressing or calendaring, cutting/formatting, edge finishing and quality control.
This guide answers common Google queries such as “how LVT flooring is made”, “what is LVT flooring made of”, “LVT manufacturing process” and related long-tail questions. It is written for buyers, specifiers, architects and flooring professionals who want both technical detail and usable specifications.
Core raw materials used in LVT production:
Although LVT formats vary by manufacturer, a typical LVT product consists of these layers (top → bottom):
The process below outlines typical production steps for modern LVT (both flexible vinyl LVT and rigid core variants like SPC):
Precise formulation is critical. PVC resin, fillers (calcium carbonate), plasticizers, stabilizers and pigments are weighed and blended in mixers to create compound pellets or pastes. Masterbatch batches control color and performance.
For flexible LVT: a calendaring line produces thin vinyl films (transparent wear film and colored base films). For rigid core (SPC) systems, core slurries may be mixed and extruded to form the rigid composite core.
High-resolution rotary or digital printing reproduces wood grain, stone veins or tile patterns onto the decorative film. Modern printers use multiple color stations to achieve photorealistic images. Digital printing allows rapid pattern changes and customization.
Embossing presses imprint texture into the surface in register with the printed pattern (Embossed-In-Register, or EIR). This step creates realistic tactile feel (grain, knots, or stone texture).
The transparent wear layer (acrylic, urethane or specialized coatings) is applied over the printed film. UV curing (or thermal curing) hardens the coating, giving excellent scratch and stain resistance.
Multiple layers are laminated together — decorative film + wear layer + core + backing — using hot presses or continuous lamination lines. In hot pressing, heat and pressure consolidate layers into a single board, ensuring adhesion and flatness.
After lamination/hot pressing, panels pass through cooling beds or rollers to stabilize dimensions and relieve internal stresses.
Large laminated sheets are cut into standard plank/tile sizes. Edge profiling (tongue and groove or click profiles) is machined for click-lock systems or squared for glue-down products.
Edges may be beveled, sealed, or micro-beveled to create realistic grout lines or plank seams.
QC includes visual inspection for print defects, dimensional checks (length/width/thickness), wear layer thickness measurement, adhesion testing, abrasion tests (Taber), slip resistance, color fastness, VOC testing and fire classification where required.
Products are packed (often with protective film), labeled with batch/lot numbers, and boxed on pallets with protective bands. Export shipments include technical datasheets, certificates and QC reports.
SPC (Stone Plastic Composite) uses a mineral (calcium carbonate/stone powder) heavy core with PVC binder and stabilizers. SPC lamination typically requires molding/extrusion of the rigid core followed by lamination of printed film and wear layer. SPC offers enhanced dimensional stability and is often sold as "rigid LVT."
| Parameter | Typical Range / Example | Notes |
|---|---|---|
| Overall thickness | 2.0 mm – 8.0 mm (common: 4.0–5.5 mm) | Thicker products feel more solid & reduce subfloor telegraphing. |
| Wear layer thickness | 0.10 mm – 0.70 mm (10–70 mil) | Residential: 0.20–0.30 mm; commercial heavy use: 0.50–0.70 mm. |
| Plank/tile size examples | 1220×180 mm, 1524×228 mm; tiles: 457×457 mm | Formats vary by style and market. |
| Core type | Flexible PVC / SPC / WPC | SPC = rigid composite; WPC = wood-plastic composite (cushion). |
| Abrasion resistance | Taber Test values per EN/ASTM | Specify per SKU. |
| Fire rating | Bfl-s1 / Class C (regional dependent) | Check local code compliance. |
| VOC emissions | Low VOC / FloorScore options | Important for indoor air quality certifications. |
| Underfloor heating | Compatible if rated (follow max temp) | Thermal resistance must be provided. |
Common QC tests during and after manufacturing:
Manufacturers increasingly use low-VOC formulations, phthalate-free plasticizers, and recyclable packaging. Recycling of post-industrial vinyl scrap and initiatives for take-back programs are emerging in the market.
LVT is widely used in:
A: EIR embossing matches the surface texture to the printed pattern, producing a tactile and visual match (wood grain aligned with printed grain), increasing realism.
A: A thicker wear layer increases resistance to scratches and wear. For heavy commercial use, select wear layers ≥0.5 mm.
A: Yes — digital printing enables short runs and customized patterns without the need for rotary print cylinders, enabling on-demand designs.
A: Many modern LVT and SPC products are engineered to be waterproof at the plank/tile level, but waterproof performance also depends on installation quality and seam treatment.
On product pages include: SKU, overall thickness, wear layer thickness, core type, plank/tile sizes, finish type (matte/EIR), fire and slip ratings, VOC certificates, installation method and warranty. These structured details help Google produce rich snippets and buyer trust.
Understanding how LVT flooring is made helps you specify the right product for your project. When evaluating manufacturers, ask for technical datasheets (TDS), test reports, sample boards and production batch traceability. For custom projects or samples, contact your supplier's technical team and request sample reports for wear, fire and VOC performance.
Action: Want a ready-to-use product spec sheet or sample for your next project? Contact 3C-Floor (or your preferred supplier) and request a datasheet with wear layer, core type, fire rating and VOC test results.
