"We’ve changed almost out of all recognition in the past two years," Fibre7 director Paul Duncan told TTJ.
Mr Duncan said the Lignia modified wood manufacturer was preparing to announce a new European distributor, was in discussions about opening a European production plant and now had an exterior version – LigniaXD.
Lignia’s brand of modifying wood is about densification – a process developed by New Zealand’s forest research institute, Scion. Plantation-grown radiata pine is put through a process similar to pressure impregnation of preservatives to timber, where an amino compound is impregnated into the wood. The result is increased density and hardness, improved stability and strength and the addition of colour right through the timber.
Until last year the product had been aimed largely at internal applications, typically door lippings, flooring and worktops, but Fibre7 has completed exterior product testing, which has revealed a Class 1 durability. Further refinements have resulted in LigniaXD for outdoor applications.
"The exterior joinery market represents bigger volumes where durability is king," said Mr Duncan. "You wouldn’t use walnut outdoors because it’s not durable enough, but we can deliver a walnut-looking exterior deck."
Fibre7 has been working with European window component manufacturers, including Holz Schiller, to develop the product for windows. Now major window manufacturers are also interested, said Mr Duncan.
The product, which carries a 35-year warranty against rot and fungal decay when used above ground level, is being supplied to decking, window and door manufacturers in Germany, including Parador which has added LigniaXD 150x32mm decking to its range.
"We have bedded the product in with European manufacturers and we’re ready to push into the UK market," said Mr Duncan.
Meanwhile, Fibre7 will soon announce a European distribution deal which will see packs of product available for customers, rather than just the container loads currently available.
Lignia is currently stocked at DW Mouldings in Bedfordshire and at Fintrim near Boston, Lincolnshire. The latter makes Lignia flooring for the Floors2Go flooring retailer, while Brooks Brothers also stocks components.
Several major UK door manufacturers use Lignia as door lippings – the most common use of the material in the UK.
Lignia worktops made by Denmark-based Spekva are the company’s biggest selling worktop in the UK.
The striking "riverwash" worktops’ looks are achieved by ripping 100mm rough boards to reveal the quarter-sawn grain, then laminating staves together and sand-blasting the surface to take out the inter-year growth between growth rings, giving a 0.5mm-deep texture. No finger-joints are used.
Elite markets
Further applications include bi-fold doors by Totali Timber Solutions Ltd, which is able to make use of long sections of Lignia – up to 6m.
"That’s the sort of elite market we are dialling into, producing high-value, beautiful joinery," said Mr Duncan.
A range of long-length defect-free stair parts will also be available from a UK staircase manufacturer soon. "They wanted to use walnut but couldn’t get hold of 3m or 4m defectfree sections. We can supply 4.2-6m boards.
"We’ve also started work in Burma. There are some large manufacturers out there who are finding it hard to find teak and that affects their ability to trade internationally."
Outdoor furniture manufacturer Sanfoco recently exhibited LigniaXD furniture in Bangkok. "It looks like teak, has FSC certification and is much cheaper," said Mr Duncan.
Colour and density management are two of the big advantages for Lignia. Four basic colours are produced – Morocco, Tuscany, Bavarian and Brasilica – but any colour pigment can be added in the modification process, which imparts colour throughout the timber.
The hardness and weight of the wood can also be engineered by changing the mix of the compound. Normally Lignia is produced at 670kg/m3 but it has been engineered up to 1,200kg/m3 – on a par with the densest tropical hardwoods.
Perhaps one of Fibre7’s biggest developments is a plan to have a European processing plant, using local timber species. A wood species has been identified and Fibre7 hopes to enter into an agreement shortly with a German treatment technology company using pine. It should be running within 12 months.
Selling out of New Zealand has proved difficult from a currency perspective.
"The New Zealand currency is strong which has had a large effect on our business. We can compete with walnut, teak and cherry on price but that is a small part of the market," said Mr Duncan. "We will continue to trade the long lengths out of New Zealand but we plan to source European timber and produce Lignia in Europe, selling into the European component manufacturing market. It is more cost-effective.
"We believe [by producing Lignia in Europe] we can better compete in the meranti/sapele end of the market."
Mr Duncan said the costs of establishing a Lignia plant (capacity 20,000-30,000m3) would be comparable to standard pressure impregnation treatment facilities, and a fraction of the cost of its modified wood rivals.
But Europe won’t be the next region to have a Lignia production plant. A North American licensing deal will be announced shortly that will see the product manufactured in the US.
