Finishing Process

Preparing the pieces

1 – Sanding

The multiple sanding processes needed to level both primers and topcoats demand the use of complex machinery. The segmented heads of the automated sander detect minute differences in material height across flat surfaces. Each head then sands off only the amount required to produce a perfectly flat plane.

Calibrating Sander – The calibrating sander, with capacity up to 108″ wide , allows Cavalieri to perfectly calibrate a surface. This calibration is fundamental to obtaining a smooth surface whose light reflection, once polished, is uninterrupted or wavy.

Finishing Sander – This sander is specialized in further refining the surface of the panel, making sure that all the scratches and lines created by the calibrating sander are removed before polishing.

Again, this ensures that the light reflection on the surface of each panel is not interrupted or wavy. Both machines must work together in order to achieve a very high level of gloss.

While automation is necessary in order to achieve maximum and consistent quality levels on flat surfaces, intricate or round surfaces still need to be hand sanded by skilled craftsmen.

For such surfaces, nothing can substitute the know-how of a well trained finish sander whose job it is to match or exceed the quality level of the automation.

Polyurethane and Polyester Finishing

2 – Finish Application

Pressurized Spray Booth – This state-of-the-art pressurized, waterfall spray booth allows us to achieve maximum quality finishing thanks to its ability to produce a constant 75 degree temperature all year round, combined with an efficient system that controls the humidity within the booth’s environment.

Both the booth and the surrounding environments are temperature controlled, anti-static, and free of dust and humidity.

This elaborate control over the environment guarantees a consistent, quality finish.

Automatic Coater – Our automatic coater and oven are used to finish large, flat panel, commercial projects.

With a capability of finishing 3000 square feet of flat panels per day, this automated machine is ideally used for commercial paneling, multiple kitchen units, interior door runs, and any flat panel application requiring at least 1000 square feet of surface to be finished. This machine coats each panel with a precise amount of finishing material allowing us to control, within 1 mil, the thickness of the finish.

The coater can apply solid color on mdf and clear coat on veneer. This rapid application process particularly helps projects with budget issues and short turn-around times, without compromising quality.

Robotic Line – The newest addition to Cavalieri’s process, this custom engineered line consists of the latest generation robotic spraying arm and a high efficiency, high capacity drying oven. The entire system is under pressurization. A sophisticated computer system ensures perfect air volume, both incoming and outgoing, along with an ideal temperature and humidity level. This gives Cavalieri the capability to obtain a level of finishing that is impossible to reach with manual/conventional spraying systems.

 

Blending automated finishing with hand finishing enables Cavalieri to offer versatility in production; versatility being perhaps the most difficult element to achieve after quality.

 

A mirror-like finish

3 – Polishing

To obtain the mirror-like finish that only polyester can offer, particular attention is given to the polishing process. Here a series of abrasive pastes are applied, in a specific order, so that the scratches left behind from the sanding process are removed.

Polishing – In order to achieve a flawless, high gloss sheen, Cavalieri employs two fully automated polishers; one exclusively for production in polyurethane and the second for production in polyester.

Even if the machines appear to be similar, the concept behind each polisher is very different due to the different physical characteristics of the two finishes .

On irregular surfaces, nothing can substitute the experience of a hand polisher with 30 years of dedication of his craft. Cavalieri Finishing Company has strived to make High Gloss our specialty and takes pride in offering a finish that cannot be matched for its beauty and durability.