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ABOUT US

We are family bussines. Minding every single detail and carying about the environment we manufacture beautiful wooden items that are wanted by pasionates of cooking and highly demanded in modern interiors.

COMPANY PROFILE

Founding year:      1992

 

Employment:  65 production workers

 

Owner:       Czeslaw Ryba (still in charge)

 

Material used for produciton:    Oak, Beech, Ash, Thermoash, American Walnut

 

Wood origin:    Poland (Apart from American Walnut)

 

Annual wood usage:    aprox. 2000 m3

 

Production capacity CUTTING BOARDS:    20-40.000 pcs/month

 

Production capacity CANDLE LIDS:    100-150.000 pcs/month

 

Production units:      All the production process take place at the same address.

Where we ship to:     EU countries, UK,  Norway, Switzerland, USA

 

PRODUCTION PROCESS

In this section we will present you our production and guide you on all the steps starting from the wood sourcing to the packing.

We will try to answer you the most common questions that you could ask regarding the most fascinating process – PRODUCTION.

LUMBER

Fresh oak wood in lumber arrived to the factory

Production begins with the purchase of lumber. Lumber is thick boards made of cutting a log into thick boards that are similar to slices.

 

Usually we buy fresh lumber with a moisture content of 60-80%.

Before starting production, lumber are left for natural drying in stacks for at least 6 months. Natural drying allow the wood to stabilise strengths and forses making it less sensitive to dimensional changes as a finished product.

For our products we buy wood in logs from Polish forests (oak/beech/ash).

 

Apart from american walnut which comes from… America

PICKING RIGHT WOOD TO THE PRODUCT

Oak lumber from polish forests

It is crutial to choose proper thickness and quality of material to match it to the product.

 

Picking right material allow us to minimise wastes of wood during production proces.

 

We mind the right manament of wood as our ecological duty.

 

Nothing should be wasted.

 

Standard thickness of products are:

10 mm  –  15 mm  –   20 mm  –  30 mm  –  40 mm

 

However there is not a problem to make product in other thicknes if customer require so.

Mr. Jan cut oak lumber (thick boards) on multisaw machine. Now we to define ne thickness
At this step lumber (the thick boards on left hand of mr. Jan on the picture) is cut on multisaw machine.
 

Now is the time to define the thickness of final product.  If we plan production of cutting board 20mm thick mr. Jan have to cut lumber in slices 28mm (2mm for shirnking in drying chamber and the rest for thicknessing and sanding).

WOOD DRYING PROCESS

Beechwood boards (slats) stappled before being put into drying chamber.

Before putting  the wet wood into drying chamber it is good practice to hold the wood on the fresh air for 1-2 weeks. Slats need to be assample in the that air have a access all around.

 

In this step some amount of moisture evaporates from wood steadily. Strenghts, forces and presuress that occure in the wood partialy loose and final product like cutting boards bends less. But sometimes bends anyways.

 

Further wood go to the drying chamber for 3-5 weeks, depending on the thickness of slats (thinner board – shorer drying), until it dry enough for the production. 

 

Good amount of moisture for wooden product is 4-6%.

OPTIMIZATION – CUTTING WITHOUT WASTES

Optimisation - Defining the length of final product. Getting rid of the knobs. Dawid sorts slats by the lengts.

Now it is time to optimize wood.

 

Slats that come out of drying chamber have usually 1 lengt (aproximately 130cm). 

 

Let’s say we have order for order for 500 pcs of

Big cutting board 45×30 cm,

Middle cutting board 34×24 cm

Small cutting board 30×20 cm. 

 

We need slats (lamelas):

Big board: 2500 slats length 47cm 

Middle board: 2000 slats length 36cm 

Middle board: 1700 slats length 32cm 

 

Question is how to cut the long slat 130cm (that get out from drying chamber) to get above amounts of slats and not to waste wood. You need to remember that  to cut out knobs and defects from the slats if any appeared. 

 

Optimizing saw machine help to solve the problem. Operator put needed amount of slats into the computer, mark knobs  to be cut out with special UV marker and machine does the rest of work. 

 

What you need to do is only to sort  cut slats type to type.

 

Definition: Lamelas = Slats

LAMELAS FOUR SIDE PLANNIG

Four side planning - making lamelas straight before being glued into cutting board

Chopping board is glued together out of couple slats. 

 

In order to get perfect quality of gluing (lamination) lamelas needs to b perfectly straigth,

 

Four side planer machine make lamelas straight on all 4 sides giving them a shape of perfect rectagular. This condition is obligatory to continue production.

 

Width of lamelas for cutting boards is between 40- 60 mm. But 20mm also can be used. Width of lamelas depends on the material that is actually avaliable. 

GLUING (LAMINATIG) PROCESS OF CUTTING BOARDS

Mariusz is gluing cutting boards out of lamelas on press.

 

 Each cutting board consist of couple salts (lamelas).  

 

Perfectly planned lamelas are sticked together using specaial glue. The glue we use is waterbase and ecological with certificate for food contact safety.

 

WHY CUTTING BOARDS HAVE SO MANY SHADES – COLOR MATCHING

Beech lamelas are matched by color.

Wood has a lot of color shades. Each slat (or lamela) . Color of wood can be vary for each cutting board. 

 

Color of wood product depends on:

– species of wood

– where the tree was grown

– when the tree was cut (in winter – wood brighter, in summer – wood darker)

– out of which part of wood the lamela comes from (inside the wood can be darker – of for instance core beech wood, outside can be darker)

– finish (after oiling, lacqureing, wood is darker)

 

The thing is to match the lamelas by color on gluing step. It takes a bit more time and hassle but in the effect perfect matched lamelas over cutting board gives awesome effect. 

 

CNC – CAN YOU MAKE ANY SHAPE OF PRODUCT?

Jeremiasz and Wiola program the CNC machines.

CNC  machines (Computer Numerical Control) alow to produce almost any shape of the cutting.

 

Of course the proper tool is required to get any shape, but we have already a lot of them.

 

What is thechnical size restriciton for products?

 

SIZE

The longest board that we made was 120 cm

the shortest 14cm

 

However we produce also a lot of POSTCARD HOLDERS wich size is also small 120x30x20 mm

Or candle lids: dia. 80x8mm

CNC – MACHINES

Ela put boards on CNC table.

CNC  machines (Computer Numerical Control) 

 

We have 7 CNC machines on our park.  Each one chan make 1000-1500 boars/day. Depending on size on complexity. 

 

Despite its age we found german Reichenbacher machines the best for our production.

 

TOOLS FOR CNC – DIAMONDS

CNC tools.

Having a lot of tools allow you be flexible when it comes to desig, side finishig etc.

 

For mass production with tools diamond coating we found the best. When sharpness of tool is on a good level you the side of the product will be perfect and you feel softness when you touch the side of product. 

A lot of standard  tools  (are produced in our workshop. Czeslaw Ryba – owner and founder – is able to produce tools by himsef.  Making tools at the company is convinient when a sample or production must be done urgently

CLASSIC MACHINES

Tomasz (head of production) is checking accuracy of the work.

Straight cut boards have a very simple look but in order to get perfectly done side careful supervision is relevant. 

 

 

Shaping of standard styles is held on classic machines.
Drilling for holes in handles.
Hole drilled in bech board.

SANDING – MAKING SURFACE 

Sanding of the surface.

Sanding machines have 2 sanding belts with different gradation. Board put into the machine firstly is sanded with 60g sanding paper and later finished with 150g.

 

If product is later lacquered we finish with 200g sanding belt. For cutting board sanding is 150g is suffiecient.

 

 

At the moment (end of 2022) 2 sanding machines are in use 16 hours a day.

 

SANDING – MAKING THE SIDES – Soft like a silk 

SOFT LIKE A SILK. This is what you should imagine when take well finished product. It took us some time to find out how to make this effect  and the solution was easy, as usual: try harder and make it better. 

Sanding the sides - Ela - she does this work waiting for CNC round finish.
Sanding the sides with hand machines.
Some complexed places must be polishe manually.

LASER LOGO ENGRAVING

Laser engraving of cutting board, tray or any other wooden product is a great solution to present logo of the company, wishes, motto or message like “home, sweet home”, “Liebe opa”, “the Chief of kitchen” etc.

 

Engraving can be very small like 5x5mm up to very big like  900×600.

LASER CUTTING

Laser cutting allow to cut very accurate shape or detail in the wood or plywood. 

 

The thing is  to cut the material in the way that do not leave smoked area around the cut places. It is difficult but possible.

 
Laser cut in beech board 9mm thick.

LEATHER STRAP ATTACHMENT

Lether strap.
Lether belt with gold closing

PACKING TO UNIT BOXES 

Magdalena is packing intems to unit boxes.

CHECKING THE ORDER DURING PACKING – LABEL PRINTING

Jacek (head of warehouse) is checking that all is packed well and print labels for boxes.

PACKING BOXES ON PALLET

Marzena and Pawel pack boxes on pallet.

PALLET IS WRAPPED AUTOMATICALLY USING A WRAPPING MACHINE

Pallet is wrapped with plastic film using wrapping machine.

PALLET IS READY FOR SHIPPING

Pallet ready to be shipped.