LOG SELECTION
PEELING THE LOGS
DYING
MAKING BRAEWOOD®
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Log Selection
The first step in the manufacturing process is our selection of high
quality hardwood logs from managed forests in Africa. Timber experts
cruise the forest to hand select each tree, choosing no more than
two per acre. Only obeche and koto are harvested from Africa. Alpi,
our Italian manufacturer, supplements production with plantation grown
poplar.
Peeling the Logs
Once harvested, the trees are transported to the mill where they are
trimmed, sawed to length and then debarked. The prepared logs are
then mounted on a lathe, peeled into rotary veneer, and clipped to
25” veneer leaves. They are then dried, stacked and shipped to Italy
for further processing.
Dyeing
Dyeing is the key to the remarkable color consistency of Brookline®
and Braewood®. Technicians select the veneer leaves according to the
color they wish to create and then stack the veneers in a stainless
steel cage. The cage is submerged in a heated, pressurized vat which
contains a water soluble dye. Once the dye has completely penetrated
the veneer leaves they are removed and dried. The veneer is now ready
for gluing.
Gluing
Glue is layered between each leaf to create a stack. The stack is
then pressed in a high pressure press to form a large rectangular
block. The glue serves two important functions. It not only bonds
the layers of veneer together, but by adding dye to the glue, it enhances
the grain and adds character to the veneer.
Creating
the Grain Pattern
The dyeing process ensures color consistency while the shape of the
laminated block and the angle of cut control the grain pattern. Veneer
leaves are glued together to form a block which is then shaped to
produce a particular pattern (see diagrams at right). The veneer is
pressed between a top and bottom mold to achieve the desired shape,
which will then be sliced into individual veneer leaves.
Making Braewood®
Braewood® is created from two leaves of Brookline® which are spliced
together. The actual size of the finished face – 48” x 132” or 48”
x 96” – is determined by the grain pattern. The sheet is combined
with three layers of phenolic resin saturated paper, and mounted on
the press. Intense heat and pressure fuse the veneer onto the phenolic
paper backing. Finally, the sheet of Braewood® is removed from the
press and trimmed. |
 
CREATING THE GRAIN PATTERN
From Top to Bottom: 1 Heart, 3 Heart, 2 Heart, 4 Heart
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