Masters of Interior Resurfacing | Greater Toronto Area
The manufacturing process of vinyl films directly impacts their suitability for various applications, durability, and cost. The two main methods of vinyl production are casting and calendering, each offering different characteristics and performance.
In General.
Vinyl, or Polyvinyl Chloride (PVC), is primarily derived from two key materials: salt and crude oil. The production process begins with the extraction of chlorine from salt using electrolytic dissociation. Crude oil or natural gas is processed through a method called cracking, which breaks down the petroleum into ethylene, the base component used to manufacture vinyl.
The Types.
Manufacturing determines their suitability for various applications, their durability, and their cost. There are currently two primary forms of mass production of vinyl films and they are casting and calendaring.
(1) Calendered Film: This method involves extruding the vinyl mixture through heated rollers. The materials are kneaded and pressed into thin sheets, resulting in a thicker, stiffer film that is easier to handle but less flexible than cast vinyl.
(2) Cast Film: Cast vinyl is created by pouring a liquid mixture (known as organosol) onto a casting sheet and processing it through a series of ovens. The resulting film is thinner, more flexible, and conforms well to complex shapes and curves.
In Summary.
The manufacturing process for vinyl films is constantly evolving, with manufacturers innovating through proprietary methods and patents. This allows for tailored solutions depending on the specific use case, whether for architectural applications, vehicle wraps, or graphics. The continuous advancements make vinyl films highly versatile, but also explain why there is no “perfect” vinyl film—each application may require a different blend of performance characteristics.