Kerlux Chooses Innova Group to Equip Its New Vinyl Flooring Plant
The manufacturer Kerlux, part of Novalam Innovación S.A., has selected Innova Group for the design and installation of an automated packaging line at its new plant in Castellón, Spain. This facility specializes in producing SPC vinyl flooring, an innovative product in the Spanish construction sector. Kerlux is the first manufacturer in the country to specialize in this type of material.
Innova responded to Kerlux’s requirements with a custom-designed packaging line, tailored to meet their specific demands of protection and load stability. The installation includes protection, securing, and wrapping systems that ensure safe transport of the pallets from the end of the production line to the point of sale at hundreds of retail stores and construction shopping centers.
From its new facility, Kerlux has become a pioneer in the construction materials industry, as the first Spanish manufacturer of SPC vinyl flooring. SPC (Stone Plastic Composite or Stone Polymer Composite) is a next-generation rigid vinyl flooring widely used in construction and interior design due to its high durability, easy installation, and aesthetic appeal, making it superior to traditional flexible vinyl.
The Challenge: Tailored Protection for an Innovative Product
Kerlux’s new packaging line faced a technical challenge in finding a suitable packaging system that accommodates the specific characteristics of SPC flooring. Unlike ceramic products, SPC flooring is packaged in boxes but comes in various formats, dimensions, and weights. Since these loads must be transported both domestically and internationally, the priority was to ensure firm securing and total load stability throughout the logistics process.
Unlike traditional ceramic products, SPC vinyl flooring is lighter, which presents new packaging challenges. While the reduced weight makes handling easier, it also necessitates packaging systems designed to secure and stabilize the load, preventing movement or deformation during transport. To address this, Innova proposed an automatic packaging line focused on load securing, featuring a vertical strapping system with edge protector applicator and four-side strapping, along with a large-format automatic ring stretch wrapper, both adapted to Kerlux’s oversized pallets.
The Solution: Securing Systems for Boxed Products
As a result, the packaging line design diverged from typical ceramic lines, requiring stronger securing mechanisms tailored to this innovative product. The new Kerlux line in Nules includes the following packaging systems (in order):
1. Automatic Cardboard Sheet Dispenser
As the first step, a cardboard dispenser was installed specifically for export loads. For pallets that require it, this system places a cardboard sheet over the product, offering additional protection against potential damage during transport.
2. Large-Format Vertical Strapping on Four Sides
Next, the automatic vertical strapping system secures the load to the pallet base—an essential step for product stability. The installed system is one of the most advanced, providing four-sided strapping with a large-format rotating platform. It also includes a lateral shifting system for the strapping frame, designed to minimize box movement during the strapping process. Given the lightweight nature of SPC flooring, this setup ensures firm and consistent fastening on all four sides.
Additionally, the strapping system includes a small-format horizontal edge protector applicator, perfectly suited to the size of Kerlux’s product boxes. These edge protectors are applied before strapping, providing extra box protection during the process.
3. Large-Format Automatic Stretch Wrapper
As the final stage of packaging, the line features a large-format automatic ring wrapper, which provides complete coverage and securing of the pallet using stretch film for optimal protection and load stability. This system also includes a top film cover applicator, adapted for large-format pallets, which protects the loads from dust, moisture, and environmental elements, especially during long-distance shipping.
4. Conveyor Line
The installation is completed with conveyor systems featuring pallet centering at entry, and accumulation and pickup conveyors for finished pallets at the exit. The packaging systems are also integrated with two labeling systems placed before and after the stretch wrapper, allowing for complete logistics traceability.
Results: A Tailored Solution for a Unique Product
Thanks to this new automated packaging line, Kerlux has achieved optimal protection for its SPC flooring throughout the entire logistics chain—from the production plant to the final customer. The solution developed by Innova provides packaging adaptation to a lighter, more delicate product, improving load securing and preventing movement or damage during transport, especially for international shipments.
The automation of the strapping and wrapping processes has greatly increased end-of-line operational efficiency by minimizing time, manual handling, and human error. Additionally, the inclusion of protective elements, such as the edge protectors or the cardboard sheets, has improved the product’s presentation, which is crucial for Kerlux’s positioning in the premium market.
This project reinforces the company’s commitment to industrial innovation and product diversification, incorporating not only new manufacturing technologies but also advanced packaging solutions to support its growth and expansion into new markets.
From Kerlux – Novalam Innovación, we have received very positive feedback and satisfaction regarding the packaging line installation, and their trust in Innova as a technological partner, capable of understanding and adapting to the challenges of a completely new product in the Spanish market.
From Innova’s perspective: “It has been a pleasure to work with a company like Novalam Innovación. We are proud to have supported them on such a unique and innovative project.”
