Stone Plastic Composite (SPC) flooring is a highly sought-after flooring option, valued for its durability, water resistance, and low maintenance. A key component in its production is Calcium carbonate (CaCO₃), which significantly enhances the flooring’s performance, cost-effectiveness, and quality. In this article, TLD Vietnam outlines the process of incorporating Calcium carbonate in SPC flooring manufacturing, explaining its role, advantages, and the detailed steps involved.

What Is Calcium Carbonate?

Calcium carbonate is a naturally occurring mineral found in limestone, marble, and chalk. Its versatility and affordability make it a staple in industries like construction, plastics, rubber, paint, coatings and more. In SPC flooring, Calcium carbonate acts as a filler material, improving the physical properties and overall functionality of the products.

What Is SPC Flooring?

SPC flooring is a multilayered flooring product composed primarily of Calcium carbonate, Polyvinyl chloride (PVC), and stabilizers. It is an advanced version of traditional vinyl flooring, featuring a rigid, stable core. The inclusion of Calcium carbonate provides a lightweight yet robust structure, making the flooring resistant to wear, moisture, and environmental stress.

Role of Calcium Carbonate in SPC Flooring

SPC flooring is a popular flooring solution known for its durability, water resistance, and ease of maintenance. Calcium carbonate is the essential ingredients in the production of SPC flooring is Calcium carbonate, which plays a critical role in improving the performance, cost-efficiency, and overall quality of the flooring. The following section will show several key functions of Calcium carbonate in SPC flooring.

Filler Material

Calcium carbonate is mixed with PVC and other ingredients to act as a filler, which improves the bulk and volume of the flooring material without significantly increasing costs.

Enhancing Durability

Calcium carbonate adds rigidity and impact resistance to SPC flooring, allowing it to withstand heavy loads and high-traffic areas without deforming. This makes it ideal for residential, commercial, and industrial applications.

Thermal Stability

Calcium carbonate contributes to the flooring’s ability to resist temperature fluctuations, ensuring it maintains its integrity in both hot and cold climates.

Cost Reduction

Calcium carbonate is a relatively low-cost material, which helps reduce the overall manufacturing costs of SPC flooring, making it more affordable for consumers.

Improved Dimensional Stability

By adding Calcium carbonate to the SPC mix, manufacturers improve the flooring’s dimensional stability, ensuring that the planks or tiles retain their shape and resist deformation over time.

Eco-friendly Option

Calcium carbonate is a naturally abundant and non-toxic material, which helps in making SPC flooring more environmentally friendly compared to other synthetic fillers.

Benefits of Using Calcium Carbonate in SPC Flooring

The use of Calcium carbonate in SPC flooring production offers numerous advantages:

• Cost-Effective: Calcium carbonate is an affordable filler, reducing production costs without compromising quality.
• Durability: It enhances the flooring’s strength, scratch resistance, and ability to withstand wear and tear.
• Environmental Benefits: As a natural and eco-friendly material, Calcium carbonate supports sustainable manufacturing practices.
• Improved Aesthetics: By providing structural integrity, it contributes to a smooth, visually appealing surface finish.
• Better Dimensional Stability: The flooring resists deformation, maintaining its shape and performance over time.

Steps To Use Calcium Carbonate In SPC Flooring Making

The use of Calcium carbonate in SPC flooring is part of a carefully controlled production process. Here’s a step-by-step guide on how it is integrated into SPC flooring manufacturing:

Sourcing and Preparing Calcium carbonate

The process begins with sourcing high-quality Calcium carbonate. The mineral is ground into a fine powder, typically micronized, to ensure even distribution within the SPC mixture. Micronized Calcium carbonate integrates seamlessly with other materials, ensuring uniformity in the final product.

Mixing the Ingredients

The core components of SPC flooring include PVC resin, Calcium carbonate, plasticizers, stabilizers, and additives such as pigments or flame retardants. These are blended in precise ratios to form the base compound for the flooring.

• PVC Resin: Acts as the primary material, providing flexibility.
• Calcium Carbonate: Functions as a filler, enhancing strength and cost-efficiency.
• Plasticizers: Improve flexibility and ease of processing.
• Stabilizers and Additives: Enhance properties like UV resistance, fire resistance, and durability.

Calcium carbonate is added during the mixing phase to ensure it is evenly distributed throughout the formulation.

Extrusion Process

The mixed materials are fed into an extrusion machine, where they are heated and formed into a uniform molten compound. The extrusion process shapes the mixture into continuous sheets or planks. Proper control of temperature, pressure, and mixing speed is critical to ensure Calcium carbonate and other components are thoroughly blended, resulting in a high-quality SPC core.

Forming the SPC Core Layer

The extruded material is cut into the desired size for SPC flooring planks or tiles. The core, containing Calcium carbonate, is cooled and solidified, creating a rigid, waterproof, and durable foundation for the flooring.

Adding the Decorative and Wear Layers

A decorative film, often featuring high-resolution wood, stone, or tile designs, is applied over the SPC core. A wear layer is then added to protect the surface from scratches, stains, and wear. While Calcium carbonate primarily contributes to the core’s strength, the overall performance of SPC flooring relies on the synergy of all layers.

Cutting and Shaping the Final Product

After layering, the SPC flooring is cut into planks or tiles of various sizes based on market demand. This step ensures the flooring meets specific dimensional requirements for consumer use.

Packaging and Distribution

The finished SPC flooring undergoes rigorous quality inspections. Once approved, the planks or tiles are packaged and prepared for distribution. The use of Calcium carbonate ensures the flooring is strong, durable, and cost-competitive, appealing to both manufacturers and consumers.

Conclusion

Calcium carbonate is a critical component in SPC flooring production, enhancing its strength, durability, affordability, and environmental sustainability. By carefully integrating Calcium carbonate into the manufacturing process, producers can create high-quality, cost-effective, and eco-friendly flooring that meets the demands of diverse applications, from homes to commercial and industrial spaces. SPC flooring with Calcium carbonate combines functionality, aesthetics, and affordability, making it a top choice in the flooring industry.

TLD Vietnam – A Leading Manufacturer Of Ground Calcium Carbonate

While Calcium carbonate is widely available, its quality can vary depending on the source. Manufacturers of SPC flooring often seek suppliers who provide consistent, fine-quality powder to ensure product uniformity. 

TLD Vietnam is the leading calcium carbonate manufacturer in Vietnam. Our state-of-the-art factory boasts a robust monthly capacity of 50.000 MT. Our factory is equipped with advanced machinery, including Ball Mills, Roller Mills, Hydraulic Mills, and coating machines from top manufacturers in Germany, Taiwan, and China.

We adhere to rigorous international standards such as ISO, Reach, and FDA for quality control, ensuring each batch of our product meets the highest benchmarks for consistency and excellence. With a minimum purity of 98.5%, whiteness of 98%, and brightness of 96%, our Ground Calcium Carbonate finds widespread use in various industries. TLD Vietnam is committed to providing top-quality products at the best price and exceptional customer service.