How Our PVC Floor Tiles Are Made

A Behind-the-Scenes Look at Our Manufacturing Process

When you install our interlocking PVC floor or drainage tiles, you are not just laying down flooring. You are placing the result of a carefully managed process that combines recycled materials, precision manufacturing, hands-on quality control, and a team of people who genuinely care about the outcome.

We thought it was time to give you a behind-the-scenes look at how our PVC tiles are made.

 

Step 1: Giving PVC Waste a Second Life

Our process begins with purpose.

PVC waste material is sourced from suppliers whose offcuts and excess material might otherwise contribute to general waste in the broader ecosystem or end up in landfill. Instead of allowing that material to go to waste, it is brought into our manufacturing premises where it can be transformed into durable, long-lasting flooring.

Recycling PVC in this way reduces environmental impact while preserving the strength and performance characteristics that make PVC such a reliable flooring material.

 

Step 2: Sorting, Grinding, and Preparing the Material

Once delivered, the material is moved to the on-site sorting and grinding area. All stages of production take place on our manufacturing premises, allowing full control over quality maintenance.

The process involves:

• Rough grinding to break down larger pieces
• Fine grinding to create a consistent granule size
• Careful sorting to eliminate impurities
  

To achieve the even black finish of our standard tiles, specific colour granules are introduced at this stage. Precision matters here. Consistency in granule size and colour blending ensures the final product has uniform appearance and performance.

 

Step 3: Precision Formulation

Manufacturing high-performance interlocking PVC tiles is not simply about melting plastic and pouring it into a mould.

Exact quantities of fine and coarse grind are measured before feeding material into the injection moulding machines. A precise formulation is used to ensure:

• Correct density
• Structural strength
• Consistent surface finish
• No unwanted impurities
  

This stage is critical. The balance of materials directly influences durability, impact resistance, and long-term performance.

 

Step 4: Injection Moulding and Tile Formation

Six injection moulding production lines are in operation, located in two separate warehouse areas on the premises.

Injection moulding works by:

• Heating the PVC compound until it becomes pliable
• Injecting it into precision-engineered moulds
• Cooling and forming the tile into its final shape
  

This is where our tiles take their distinctive forms, whether with raised disc surfaces or open-grid drainage designs. Black tiles are manufactured as standard, as well as selected colour variants.

Each mould is engineered to ensure dimensional accuracy, so tiles interlock correctly and maintain structural integrity under load.

 

Step 5: Individual Quality Control

Once a tile is moulded and cooled, it is not simply boxed and shipped.

Every tile is individually removed and checked by hand.

This hands-on quality control ensures:

• Proper interlocking edges
• Surface consistency
• No defects or deformities
• Reliable performance on site
  

We believe quality is not something you inspect once at the end. It is something you protect at every stage.

 

Step 6: Packing and Distribution

After inspection, tiles are strapped into bundles and prepared for dispatch.

From our manufacturing facility:

• Orders are packed for courier delivery across the country
• Stock is transported to our pickup facility to ensure availability for customers who prefer collection

Maintaining stock on hand allows us to support both planned installations and more urgent project timelines.

 

Step 7: Supporting Installation

Flooring performance depends not only on the product but also on installation.

We work with vetted installers who provide professional, reliable services across Gauteng, and more broadly on an ad hoc request basis.

For customers who prefer to install themselves, we provide guidance and support to ensure a successful outcome.

 

The People Behind the Process

Manufacturing is not only machines and material. It is people.

Manufacturing operates both day and night shifts with two dedicated teams, allowing for strong production capacity and good turnaround times for larger orders.

We are committed to:

• Providing employment opportunities aligned with BEE requirements
• Supporting our local community
• Building long-term relationships with our staff
  

We are proud that many of our manufacturing team members have been with the business for years, and some since its inception over 18 years ago. We believe longevity comes from:

• Taking a genuine interest in people
• Supporting individuals beyond just the workplace
• Creating an environment where quality and integrity matter
  

The manufacturing side of the business is family run. That means decisions are personal. Standards are personal. Customer satisfaction is personal.

 

Integrity and Value at the Core

From recycled raw material to final inspection, every step of our process is driven by a commitment to:

• Conduct business with integrity
• Deliver consistent, durable products
• Provide real value for our customers
  

When you choose our tiles, you are choosing more than modular PVC flooring. You are choosing a product shaped by careful processes, experienced hands, and a team that genuinely stands behind what it produces.

 

Explore Our Range of PVC Flooring Solutions

Discover the full range of Interlocking PVC Floor Tiles and Interlocking PVC Drainage Tiles at The Floor Bar and find the perfect solution to protect, enhance, and modernise your space.

View the full PVC Flooring Products range at The Floor Bar.

Need assistance or a quote? View our contact details.