Unilin Panels Oostrozebeke invests more than €100 million in new state-of-the-art technology

Investing when others wait 

It is no coincidence that Unilin is launching such an ambitious project at a time when European industry is under pressure. President Unilin Panels Bert Vandenkendelaere explains: "This is not an investment for the next two or five years. We are talking about a transformation that will shape the site for the next thirty to forty years. A decision of this magnitude transcends today's economic reality. It is precisely challenging times like these that call for the courage to look ahead. We want to give our customers the strongest tools to remain successful in the future as well."

The planned investment fits within a clear long-term strategy. The Oostrozebeke site is being developed into the reference site for high-quality decorative panels within Unilin Panels. Ben Vandenbroucke, General Manager Chipboards: "In recent years we have made substantial investments in the finishing of our products. For example, five years ago, our Oostrozebeke plant commissioned one of the most modern melamine presses in Europe. At the moment we are investing further in our chipboard production."

A key step towards a state-of-the-art factory

At the heart of the project is the replacement of two existing chipboard presses with a single new, ultra-modern press. But the story doesn’t end there. A team of experts is completely re-evaluating the production steps both before and after pressing. Ben: "In fact, we are modernising the entire heart of the factory. It’s much more than a replacement investment for the presses, all material flows are being optimised." Bert: "Our primary aim is not to boost production but to produce in a safer manner, with even higher quality and more efficiency. When the project’s complete, this chipboard factory will be the state-of-the-art production facility in Western Europe."

The new technology will also further enhance product quality through additional refinements of the technical characteristics. Ben: “With certain of our latest innovations, we are reaching the limits of our existing presses, which are almost forty years old. With the new technologies, we will continue to improve the surface quality and robustness of our chipboards, among other things." For premium decorative products such as Master Oak, this is crucial. Bert: “For those products not just the top layer is important but the board material itself must also be perfect. We continue to focus on quality improvement. This project will help us acquire additional expertise and this will drive further innovation."

In addition to replacing the presses, the investment plan includes a second major component: the automation of internal transport through automated guided vehicles (AGVs). These autonomous vehicles will replace part of the current forklift traffic and this comes with significant advantages. “AGVs further reduce the risk of potential damage to our products and increase on-site safety as less manual intervention is required,” Bert explains. “Moreover, forklift operator is currently a shortage profession. This is yet another aspect where we are preparing for the future. Our current operators don’t have to worry: their experience remains essential, and there is sufficient work at this and other sites.”

A European example of circular industry

The investment also strengthens Unilin’s sustainability ambitions. Ben: “Oostrozebeke is already one of the most circular sites in Europe. The factory produces chipboards based on 100% recycled wood, of which 90% is even post-consumer wood. Thanks to the A&S energy plant nearby, its electrical and thermal energy supply runs almost entirely on green energy. The new installation will enable us to further refine and optimise the process, both in terms of raw materials and energy use.”

The logistical footprint will also be reduced. Bert: “As part of Unilin Panels’ overall strategy, we are implementing smarter product allocation: each site will focus on specific products. That means up to 3,800 fewer truck transports per year between our West Flanders sites.”

A project of technology and people

They are quick to emphasise that such a large-scale, multi-year project is a huge collective effort. Ben: “Hundreds of employees across Unilin Panels will help shape this transformation in the coming years. Not only our engineers, operators and technicians, but also our colleagues in IT, digital operations, finance, HR, product management and supply chain are contributing to the project. Those who work with the installations every day know the factory best. Their knowledge is essential in making this project a success.”

Training is also an important part of the process. New technology requires new competencies, and employees are given the opportunity to grow along with the changes. Bert feels this is one of the most rewarding aspects of the project. “The enthusiasm is everywhere. Our people want to contribute, look for solutions and help build something that goes way beyond a regular investment. Everyone has the sense that we’re building something really special.”

Neighbours are also being involved

Clear communication is crucial to ensuring broad support for this transformation. Through information sessions, consultation meetings, notice boards and mailings, employees are kept informed of every phase. Ben: “We are also involving our neighbours. For instance, we’re organising an information session to share our plans with them and we will continue to keep them informed through our regular consultation meetings. The works will take time and involve significant change, which is why transparent communication is so important. At the same time, we expect the environmental impact on the surrounding area to keep improving, with less noise, less dust and lower emission levels.”

What comes next?

The coming months will centre around further engineering and obtaining the necessary permits. If everything proceeds according to plan, preparatory works will start in the bottom half of 2026. The first chipboard is expected to come off the new press in the summer of 2028. The full transformation should be completed by early 2029.

“This investment shows that industrial production in Flanders has a future”, Bert concludes. “And that we want to build that future together.”