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    Vertical Integration

    Boulanger applies vertical integration as a management model for quality control purposes. This process allows for control at each stage of the supply chain, manufacturing, and distribution. That is to say, our company is responsible of the entire production, from lumber cutting to finished product distribution.

    Our raw materials come mainly from the United States and Canada.

    See the major stages of this process in pictures.

    Step  1 - 10

    Sawing

    The process begins in our Woburn sawmill, where we primarily treat Eastern white pine logs. Other tree species are occasionally sawn. The sawn timber is then lathed and submerged in a special solution to prevent the growth of fungi that may stain the wood.

    Step  2 - 10

    Drying

    Drying wood is an art we practise with extreme care to ensure that our finished products are of the highest possible quality. First, the lumber is piled on sticks to facilitate air circulation and prevent staining. Kiln drying lasts 6 to 30 days, depending on the season and level of humidity and thickness of the wood. Our wood is dried at our main plant in Warwick, as well as at our Daveluyville plant (Les Industries Daveluyville), where we also dry wood for other companies.

    Step  3 - 10

    Planing

    Before planing, we rigorously check the humidity level of each board with a hygrometer. Any pieces that exceed our acceptable limit are rejected. Next, the wood is hewn and planed to obtain a rectangular work surface. Optical sensors and a computer are used to optimize the use of wood.

    Step  4 - 10

    Trimming

    This step involves removing knots and other imperfections to obtain defect-free pieces of wood that are of equal length and thickness and which will later be finger-jointed. Pieces containing knots or other imperfections are recycled as by-products.
    To detect the wood defects, we rely on state-of-the-art equipment using automated vision. We have two identical lines consisting of the following:
    • a scanner equipped with cameras on all four sides of the piece of wood;
    • two automated saws that execute the cutting plans generated by the scanner;
    • sorting lines that organize the blocks according to their quality.
    Following the reading performed by the scanner, a computer analyzes the images of each of the board’s four sides and generates a cutting plan that ensures the optimal use of the material.

    Step  5 - 10

    Fingerjointing

    Thanks to high-precision fingerjointing, we are able to obtain a surface that’s as smooth and unified as a non-jointed piece of solid wood. This process enables us to maximize our wood resources.

    Our state-of-the-art equipment allows us to optimize productivity while keeping manufacturing costs to a minimum.

    Step  6 - 10

    Slitting

    Band saws slit lengths of jointed wood according to the thickness required for the manufacture of mouldings. The pieces can be cut on a right or inclined angle, always with the purpose of optimizing the use of wood.

    Step  7 - 10

    Moulding

    The slit pieces of wood are moulded while respecting the tolerance predetermined to ensure a quality production.

    Latest generation computerized moulding machines ensure precision, instant adjustment, and reduced costs.

    During production, the operator systematically checks all dimensions to ensure product conformity. This results in perfectly identical mouldings, regardless of their batch of origin. In addition, a final visual inspection occurs when the mouldings come out of the machine.

    Step  8 - 10

    Painting

    Cutting-edge technology allows Boulanger to control the application of water-based primer on all surfaces of the product with remarkable precision.

    The primer used covers the entire surface and ensures the adherence of the top coat. The primed surface is then sanded, eliminating the need for the user to sand the moulding.

    Paint is applied by a system known as “vacuum coaters”. This reduces the harmful emissions that are released into the atmosphere. A gesso painting process has also been implemented for primed products with a superior finish.

    Step  9 - 10

    Wrapping

    Thanks to the expertise developed at our St-Ferreol plant, Boulanger offers mouldings and components finished in a wide variety of materials such as
    • Vinyl
    • Paper
    • Polyester
    • Wood veneer
    This unique know-how has allowed Boulanger to position itself as a preferred partner for manufacturers of kitchen cabinets and furniture.

    At this plant, we have also developed leading expertise in the following areas:
    • Cutting
    • Drilling
    • End finishing
    • Door assembly

    Step  10 - 10

    Transport and Distribution

    Boulanger’s distribution centre is entirely computerized, allowing us to offer quick turnaround on order fulfillment while reducing picking errors.
    The company operates its own fleet of trucks servicing the province of Quebec. As a result, most of our clients receive their orders directly from us. Boulanger’s crew of about 20 experienced truck drivers has been specially trained to offer top-rate customer service.

    Respect for the Environment

    At Boulanger, we consider reducing our ecological footprint in all our practices to be very important. Thus, we have put forward several initiatives that show our commitment. In recognition of all these efforts, we received a Level 3 Performance Certification, the highest distinction of the Recyc-Québec’s ICI ON RECYCLE! program.

    We are also working to ensure that the various stakeholders in our supply chain are making similar efforts to protect the environment. This is one of the benefits of being a vertically integrated company!

    Certifications and associations

    Logo_Association forestière du sud du Québec
    Logo_ICI-on-recyle
    Logo_mouvement quebecois de la qualite

    For more information, contact us at 1-800-567-5813 or by email