Boulanger

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Fabrication

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11 stages : Sawing, Drying, Planing, Trimming, Jointing, Slitting, Moulding, Priming, Finishing, Transport and distribution and R&D


Stages :

Sawing

The process begins in our Woburn sawmill, where we primarily treat eastern white pine bolts. Other wood species are occasionally sawn. The sawn timber is then lathed and submerged in a special solution to prevent the growth of fungi susceptible of staining the wood.

Drying

Drying wood is an art that we practice with extreme care to ensure that our finished products are of the highest possible quality. First, the lumber is piled on stickers to facilitate air circulation and to prevent staining. Kiln drying lasts 6 to 30 days, depending on the season, level of humidity and thickness of the wood. Our wood is dried at our main plant in Warwick, as well as at our Daveluyville plant (Les Industries Daveluyville), where we also subcontract to dry other species of wood.

Planing

Before planing, we rigorously check the humidity level of each board with a hygrometer. Any pieces that exceed our acceptable limit are rejected. Next, the wood is hewn and planed to obtain a rectangular work surface. Optical sensors and a computer are used to optimize the use of wood.

Trimming

This step involves removing knots and other imperfections to obtain defect-free pieces of wood that are of equal length and thickness, and which will later be finger-jointed. Pieces containing knots or other imperfections are recycled as by-products.

To correct the wood’s defects, we rely on state-of-the-art equipment utilizing artificial vision. We have two identical lines consisting of: 

1. a scanner equipped with cameras on all four sides of the piece of wood
2. two automated saws that execute the cuts generated by the scanner
3. sorting lines that organize the blocks according to quality 

Following the reading performed by the scanner, a computer analyzes the images of each of the board’s four sides and generates a cutting plan that ensures the optimal use of the material.

Jointing

Thanks to high precision jointing, we are able to obtain a surface that’s as smooth and unified as a non-jointed piece of solid wood. This process enables us to maximize our wood resources.

Our state-of-the-art equipment allows us to optimize productivity while keeping manufacturing costs to a minimum.

Slitting

Band saws slit lengths of jointed wood according to the thickness required for the manufacture of mouldings. The pieces can be cut on a right or inclined angle - always with the purpose of optimizing the use of wood.

Moulding

The slit pieces of wood are moulded, respecting the tolerance predetermined in our ISO 9002 quality insurance program.

Late generation computerized moulding machines ensure precision, instant adjustments and reduced costs.

During production, the operator systematically checks all dimensions to ensure product conformity. This results in perfectly identical mouldings, regardless of their batch of origin. In addition, a final visual inspection occurs when the mouldings come out of the machine.

Priming

Cutting-edge technology allows Boulanger to control with remarkable precision the application of water-based primer on all surfaces of the product.

The primer used covers the entire surface and ensures the adherence of the final finishing coat. The primed surface is then sanded, eliminating the need for the user to sand the moulding.

Paint is applied via a system known as “Vacuum coaters”. This reduces the amount of harmful emissions that are released into the atmosphere.

Finishing

Thanks to the expertise developed at our Ste-Clotilde plant, Boulanger is able to offer mouldings and components finished in a wide variety of materials such as: 

  • vinyl
  • paper
  • polyester
  • wood veneer 

This unique know-how has allowed Boulanger to position itself as a preferred partner for manufacturers of kitchen cabinets and furniture.

At this plant, we have also developed leading expertise in the areas of: 

  • Cutting
  • Drilling 
  • End finishing 
  • Door assembly

Transport and distribution

Boulanger’s distribution centre is entirely computerized, allowing us to offer quick turnaround on order fulfillment while reducing order errors.

The company operates its own fleet of trucks servicing the province of Quebec. As a result, the vast majority of our clients receive their orders directly from us. Boulanger’s crew of experienced truck drivers has been specially trained to offer top-rate customer service.

R&D

Roland Boulanger and Co. Ltd. is an innovative enterprise that constantly strives to provide products of the highest possible quality. We are able to do this by staying ahead of the latest advances in the areas of design and technology.

Our research, development and innovation department directs our continual efforts to improve our products, processes and the quality of our service.