When you choose a product for your home or project, you're not just choosing how it looks — you're choosing how it's made. At ESTA, we believe transparency is part of quality. That's why we manufacture all our WPC doors, wall panels, door frames, and architraves in-house at our own facility in Pakistan.
In this article, we'll take you behind the scenes of our WPC production process — step by step — so you can understand exactly what goes into every product we make.
Step 1: Raw Material Mixing
Our process begins with a carefully measured blend of wood fibers, PVC resin, and additives (for strength, fire resistance, and UV stability). These raw materials are mixed in controlled conditions to ensure consistency and quality.
Why it matters:
- Uniform mixture = consistent strength
- Recycled content = ecofriendly product
- Additives = waterproof and fire-retardant performance
Step 2: Extrusion and Molding
The mixed compound is passed through high-temperature extrusion machines where it is shaped into doors, boards, or frames using custom molds.
This is where each product's dimensions, thickness, and core design are set.
Why it matters:
- Allows for custom sizes and profiles
- Delivers dimensional accuracy
- Forms the structural base of every product
Step 3: Cooling and Cutting
Freshly extruded profiles are cooled and cut to required sizes. This ensures dimensional stability and minimizes internal stress, which helps prevent warping over time.
Why it matters:
- Products stay true to shape
- Ideal for exact installations
- Critical for high-precision CNC designs
Step 4: Surface Finishing
Here, the door or panel receives its final outer treatment — depending on your selected style.
This may include:
- Sanding for a smooth texture
- Embossing for wooden grain patterns
- Lamination for color
Why it matters:
- Adds beauty to strength
- Allows you to match interiors
- Improves scratch and stain resistance
Step 5: Quality Inspection
Before packaging, each product goes through multiple rounds of visual, structural, and dimensional checks.
We inspect for:
- Surface consistency
- Size accuracy
- Strength parameters
Why it matters:
- Fewer rejections during site installation
- Trusted by architects and contractors
- Keeps our reputation strong
Step 6: Packaging and Dispatch
Once approved, the products are packed in plastic bubble wrap, wrapped for moisture resistance, and labeled for dispatch. Whether you're ordering for a home renovation or a large-scale commercial fit-out, our packaging ensures that the product arrives in perfect condition.
Why In-House Manufacturing Matters
Unlike many suppliers who outsource their production, ESTA controls the entire process. That means:
- Better quality consistency
- Shorter lead times
- Customized solutions
- Reliable after-sales support
This makes us a trusted partner for both homeowners and architects across Pakistan.
✅ Want to See the Results for Yourself?
Explore our complete range of WPC doors, wall panels, and accessories — made in Pakistan, built to last.