HPL Compact:
Properties and Applications
of the Material
What is HPL Compact?
HPL stands for High Pressure Laminate, referring to the product’s manufacturing process. For thicknesses ranging from 0.8 mm to 3 mm, it is called thin single-sided laminate. For thicknesses from 4 mm to 25 mm, it is classified as compact laminate, which is self-supporting and double-sided. This highly versatile and durable product is used in both interior and exterior design due to its exceptional mechanical, physical, and chemical resistance, easy workability, and low maintenance requirements.
HPL Sheet: Composition
An HPL Compact sheet is composed of:
Kraft paper layers: the number of layers depends on the desired thickness of the final product. Impregnated with thermosetting resins, they form the core of the panel.Decorative layers: impregnated with melamine resins, these can be applied on both sides, giving the panel its final appearance.
Protective layer: a transparent anti-scratch overlay or UV protection, applicable on both sides, provides additional wear resistance.
Production of HPL Compact
The process begins with the production of thermosetting resins, which are used to impregnate the kraft and decorative papers.
The decorative paper is impregnated with melamine resins, formed by combining formaldehyde with melamine. The kraft paper layers, instead, are generally impregnated with phenolic resins, obtained from a reaction between phenol and formaldehyde. A sustainable alternative to phenol is used by the Puricelli Group, which employs eco-friendly thermosetting resins made from agricultural urea, melamine, and additives.
After that, the excess resin is removed from the paper, which is then stored in clean, temperature-controlled environments.
At this point, the impregnated paper layers are then stacked and prepared for thermo-lamination. The kraft paper layers, which form the core of the material, are stacked until the desired thickness for the final product is reached. Then, the decorative layer is applied, providing the panel’s final visual appearance with decorations, pigments, and prints. Finally, a protective layer is added: a transparent anti-scratch overlay for interior use or UV protection for exterior use, depending on the intended application. Both of them melt completely into the melamine resin during the laminating press process, becoming entirely transparent.
Decorative and protective layers can be applied on both sides of the panel, even if one side remains hidden. This allows the panel to be flipped if damaged or worn and also provides greater stability and balance, reducing the risk of warping. Now, the stack of layers is placed into a special industrial multi-layer press that applies very high pressure, over 7 MPa, and a high temperature of about 140-150°C for 40-50 minutes.
During this phase, the combined action of pressure and temperature ensures that the phenolic and melamine resins bind stably to each other, compacting the paper layers and forming a durable, homogeneous, and non-porous laminate material. The surface texture (glossy, matte, etc.) is imprinted during this phase by press plates designed to impart the desired finish when in contact with the resin. Additionally, special “release” papers, which are highly resistant and engraved with patterns, can be placed between the press and the laminate, leaving an imprint upon contact.
After pressing, the laminate is cooled under pressure for about 30 minutes to stabilize the polymerized resins and prevent deformation.
Following these steps, the laminate undergoes finishing, where excess material is removed and cut to the desired length using specific machinery.
Quality checks and tests are conducted to ensure the final product meets mechanical, thermal, and chemical resistance standards, after which the material is prepared and packaged for transport and installation.
After that, the excess resin is removed from the paper, which is then stored in clean, temperature-controlled environments.
At this point, the impregnated paper layers are then stacked and prepared for thermo-lamination. The kraft paper layers, which form the core of the material, are stacked until the desired thickness for the final product is reached. Then, the decorative layer is applied, providing the panel’s final visual appearance with decorations, pigments, and prints. Finally, a protective layer is added: a transparent anti-scratch overlay for interior use or UV protection for exterior use, depending on the intended application. Both of them melt completely into the melamine resin during the laminating press process, becoming entirely transparent.
Decorative and protective layers can be applied on both sides of the panel, even if one side remains hidden. This allows the panel to be flipped if damaged or worn and also provides greater stability and balance, reducing the risk of warping. Now, the stack of layers is placed into a special industrial multi-layer press that applies very high pressure, over 7 MPa, and a high temperature of about 140-150°C for 40-50 minutes.
During this phase, the combined action of pressure and temperature ensures that the phenolic and melamine resins bind stably to each other, compacting the paper layers and forming a durable, homogeneous, and non-porous laminate material. The surface texture (glossy, matte, etc.) is imprinted during this phase by press plates designed to impart the desired finish when in contact with the resin. Additionally, special “release” papers, which are highly resistant and engraved with patterns, can be placed between the press and the laminate, leaving an imprint upon contact.
After pressing, the laminate is cooled under pressure for about 30 minutes to stabilize the polymerized resins and prevent deformation.
Following these steps, the laminate undergoes finishing, where excess material is removed and cut to the desired length using specific machinery.
Quality checks and tests are conducted to ensure the final product meets mechanical, thermal, and chemical resistance standards, after which the material is prepared and packaged for transport and installation.
The Origin and Evolution of HPL Compact
In 1896, Leo Baekeland, an American chemist of Belgian origin, combined phenol and formaldehyde to create the first thermosetting resin. Shortly after, he introduced a fine sawdust filler into this resin, creating the “precursor” of HPL: a material he patented in 1907 under the name Bakelite. It exhibited excellent mechanical properties and electrical non-conductivity, replacing porcelain and mica as insulating materials.
During the same period, Emil Liebich had the idea to mix phenol-formaldehyde-based resins with paper, resulting in a solid material with excellent mechanical properties, light and abrasion stability, and electrical non-conductivity.
In the 1920s, panels were produced by saturating paper with these resins and polymerizing it between steel plates. These early laminates were technical, not decorative: they were only available in black or brown and were mainly used for electrical components due to their insulating properties.
The Formica Corporation, founded in 1913, was among the first companies to produce and sell laminates. In 1927, with the hiring of chemist Jack Cochrane, the company developed a new type of laminate using decorative paper, enabling furniture to be coated at lower costs and solidifying the company’s position as a market leader. The development of decorative papers with a high capacity to absorb melamine resin and formaldehyde also improved the aesthetic appearance of panels, giving birth to the modern HPL Compact.
The true revolution came when HPL began to be used as a coating for kitchen furniture, modular kitchens, tables, shelving, restaurant counters, and other food-handling areas.
Around the same time, numerous laminate manufacturers were founded, and existing companies adopted the patents and know-how of this technology, including in Europe. In Italy, Puricelli was established in 1948 and, in 1962, inaugurated a pioneering new plastic laminate production plant in Costa Masnaga.
In the following decades, research, innovation and the development of new types of HPL opened the way to countless possibilities of application in different market segments, generating a wide range of product types. Applications diversified further to include ventilated facades and outdoor furniture.
During this time, the introduction of international quality standards helped to standardize the characteristics of the product and ensure high performance.
In the 2000s, digital printing technology allowed for customization of laminates with complex designs and high-resolution images, opening up new creative possibilities.
Growing attention to sustainability in recent years led to the development of eco-friendly HPL with low formaldehyde emissions and paper sourced from sustainably managed forests.
The Puricelli Group had already introduced laminates made with water-based resins to the market years earlier. In 2007, further emphasizing their commitment to the environment and their products’ users, they introduced a new phenol-free resin into production, which is still used today. The use of this innovative eco-friendly resin enabled the company to achieve certification for the near-total absence of emissions across the Group’s entire product range.
Today, HPL Compact is also used in the transport sector, in the interiors of trains, airplanes, and ships, thanks to its lightness and durability. Recent developments have introduced antibacterial surface treatments, making the material ideal for healthcare and public environments.
The laminate industry has grown steadily worldwide and continues to do so today, driven by research, innovation, and design.
During the same period, Emil Liebich had the idea to mix phenol-formaldehyde-based resins with paper, resulting in a solid material with excellent mechanical properties, light and abrasion stability, and electrical non-conductivity.
In the 1920s, panels were produced by saturating paper with these resins and polymerizing it between steel plates. These early laminates were technical, not decorative: they were only available in black or brown and were mainly used for electrical components due to their insulating properties.
The Formica Corporation, founded in 1913, was among the first companies to produce and sell laminates. In 1927, with the hiring of chemist Jack Cochrane, the company developed a new type of laminate using decorative paper, enabling furniture to be coated at lower costs and solidifying the company’s position as a market leader. The development of decorative papers with a high capacity to absorb melamine resin and formaldehyde also improved the aesthetic appearance of panels, giving birth to the modern HPL Compact.
The true revolution came when HPL began to be used as a coating for kitchen furniture, modular kitchens, tables, shelving, restaurant counters, and other food-handling areas.
Around the same time, numerous laminate manufacturers were founded, and existing companies adopted the patents and know-how of this technology, including in Europe. In Italy, Puricelli was established in 1948 and, in 1962, inaugurated a pioneering new plastic laminate production plant in Costa Masnaga.
In the following decades, research, innovation and the development of new types of HPL opened the way to countless possibilities of application in different market segments, generating a wide range of product types. Applications diversified further to include ventilated facades and outdoor furniture.
During this time, the introduction of international quality standards helped to standardize the characteristics of the product and ensure high performance.
In the 2000s, digital printing technology allowed for customization of laminates with complex designs and high-resolution images, opening up new creative possibilities.
Growing attention to sustainability in recent years led to the development of eco-friendly HPL with low formaldehyde emissions and paper sourced from sustainably managed forests.
The Puricelli Group had already introduced laminates made with water-based resins to the market years earlier. In 2007, further emphasizing their commitment to the environment and their products’ users, they introduced a new phenol-free resin into production, which is still used today. The use of this innovative eco-friendly resin enabled the company to achieve certification for the near-total absence of emissions across the Group’s entire product range.
Today, HPL Compact is also used in the transport sector, in the interiors of trains, airplanes, and ships, thanks to its lightness and durability. Recent developments have introduced antibacterial surface treatments, making the material ideal for healthcare and public environments.
The laminate industry has grown steadily worldwide and continues to do so today, driven by research, innovation, and design.
Characteristics and Properties of HPL Compact
- Resistance
The surface of HPL Compact is extremely resistant to scratches and abrasion, making it ideal for high-traffic areas. Thanks to its laminated structure and high density, it is highly resistant to impacts and shocks. - Hygiene
The robust, compact, and non-porous surface of HPL Compact prevents the absorption of liquids and inhibits bacterial growth, making cleaning and maintenance easy. These panels are particularly suited to environments where maximum hygiene is required, such as kitchens and operating rooms. - Chemical Inertia
Resistant to many chemicals, solvents, and cleaners, HPL Compact is suitable for industrial settings, laboratories, and healthcare facilities. - Antistatic Properties
The laminate exhibits antistatic behavior, minimizing the generation of static electricity by dissipating or redirecting it to other materials without needing grounding. - Resistance to Climatic Changes
HPL Compact can withstand adverse weather conditions, such as prolonged UV exposure, humidity, frost, and high temperatures, without significant damage. This material maintains its shape and size under temperature and humidity fluctuations, preventing warping and cracking, making it ideal for outdoor applications like facade cladding, garden furniture, and structures exposed to the elements. - Heat and Fire Resistance
HPL laminates boast excellent fire resistance with low smoke development. In the event of a fire, they are difficult to ignite, do not soften or drip, and slow the spread of flames. Many HPL Compact types are certified as self-extinguishing and meet fire safety regulations. - Aesthetic Versatility
HPL Compact is highly versatile aesthetically, available in a wide range of colors, patterns, and textures, and also in terms of applications. Additionally, the material offers the possibility to customize designs through digital printing to meet specific aesthetic needs. - Environmental Sustainability
HPL Compact can be considered a sustainable material when produced with recycled paper and phenol-free resins with low formaldehyde emissions.
HPL Compact for Interiors
HPL Compact is an extremely versatile product suitable for a wide range of applications. These panels offer maximum configurational freedom, with various designs and surfaces that allow for creative and personalized solutions.
In interior applications, HPL Compact is used to make countertops, doors, furniture, walls, ceilings, and wall panels in various spaces such as living rooms, bathrooms, kitchens, as well as in healthcare facilities, public areas, and commercial spaces.
This product is particularly suitable for these applications not only due to its remarkable aesthetic and design qualities but also thanks to its unique features in terms of durability, antibacterial properties, heat resistance, ease of cleaning, and maintenance.
This product is particularly suitable for these applications not only due to its remarkable aesthetic and design qualities but also thanks to its unique features in terms of durability, antibacterial properties, heat resistance, ease of cleaning, and maintenance.
HPL in Kitchens and Bathrooms
It features anti-fingerprint, super-matte surfaces that are soft to the touch, enhancing the panel’s aesthetics and meeting modern design standards.
It is particularly suitable for covering walls and furnishing areas between furniture and cupboards or mirrors in bathrooms and kitchens, as it is resistant to moisture and heat and easy to clean. In bathrooms, HPL Compact is also used for making cubicles, being highly resistant even in high-traffic environments like airports, commercial spaces, and hospitals.
HPL Top commonly refers to kitchen worktops made with HPL Compact. The blend of aesthetics and practicality makes this material an ideal solution for tables and worktops. Impact and scratch resistant, it makes the surface highly resilient to daily use.
Additionally, it is stain-resistant, abrasion-resistant, steam-resistant, non-toxic, and made with an innovative antibacterial formula that makes surfaces safe for food contact.
Additionally, it is stain-resistant, abrasion-resistant, steam-resistant, non-toxic, and made with an innovative antibacterial formula that makes surfaces safe for food contact.
HPL Compact for Exteriors
In exterior applications, HPL Compact is an alternative to traditional architectural materials for ventilated facades, balconies, and urban furniture due to its proven characteristics: it is weather-resistant, antistatic, fire-resistant, robust, compact, durable, and easy to install and maintain.
Ideal for cladding buildings, these laminates are used for both new constructions and renovations of public and private buildings.
A key feature that makes this product particularly suitable for outdoor environments is its high resistance to UV rays and weather conditions, achieved through careful selection of raw materials and a dedicated production process.
Given the proven durability of the panels, they are also used to clad balconies and railings, completing the external architecture of a building.
The specific composition of HPL Compact also makes it ideal for urban furniture, such as benches and tables.
It is a product with high aesthetic and technical value, adaptable to diverse environments and tailored to every client request, thanks to a wide range of colors and finishes.
This versatility also makes it perfect for designing outdoor flooring.
HPL Ventilated Facades
Ventilated facades are an innovative construction system that involves installing an “external wall” separated from the building’s load-bearing structure by a cavity. This space allows natural ventilation, improving the building’s energy efficiency, preventing condensation and mold formation, and enhancing living comfort.
In ventilated facades, HPL panels are used to clad the substructure that acts as the “external wall.” Thanks to their resistance to UV rays and weather conditions (sun, rain, snow, heat, ice, etc.), as well as their impact and scratch resistance, they are perfect for this type of system, ensuring not only long durability but also minimal maintenance.
HPL in the Naval Sector
One of the main features that makes compact HPL ideal for the naval sector is its resistance to water and corrosion. Unlike other materials that can degrade or rust, HPL maintains its structural integrity and aesthetic appearance over time.
This makes it perfect for both interior and exterior furnishings on ships, such as floors, claddings, furniture, and work surfaces. Ease of cleaning and stain resistance are further advantages that help reduce maintenance costs and improve the hygiene of naval spaces.
Thickness and Formats of HPL
A distinctive feature of HPL is its versatility, which is achievable thanks to the variety of thicknesses and formats in which it can be produced, meeting diverse and specific needs.
HPL can be manufactured in a wide range of thicknesses, generally from 0.8 mm up to 25/30 mm. Thin thicknesses are ideal for wall coverings, decorative panels, and applications requiring flexibility. Medium thicknesses are suitable for furniture, countertops, and durable decorative applications. Thick sheets are used for heavy-duty applications such as benches and architectural structures.
In terms of formats, HPL is available in various dimensions. The most common standard formats include 3050 x 1300 mm, 4200 x 1310 mm, and 4200 x 1620 mm, but other sizes are available upon request to meet specific project needs. This flexibility makes HPL an excellent choice for architects and designers seeking a material that adapts to different contexts and applications. HPL Compact can also be custom-cut to fit various sizes and configurations, ensuring a tailored and adaptable design.
HPL can be manufactured in a wide range of thicknesses, generally from 0.8 mm up to 25/30 mm. Thin thicknesses are ideal for wall coverings, decorative panels, and applications requiring flexibility. Medium thicknesses are suitable for furniture, countertops, and durable decorative applications. Thick sheets are used for heavy-duty applications such as benches and architectural structures.
In terms of formats, HPL is available in various dimensions. The most common standard formats include 3050 x 1300 mm, 4200 x 1310 mm, and 4200 x 1620 mm, but other sizes are available upon request to meet specific project needs. This flexibility makes HPL an excellent choice for architects and designers seeking a material that adapts to different contexts and applications. HPL Compact can also be custom-cut to fit various sizes and configurations, ensuring a tailored and adaptable design.
Customization of HPL:
Textures and Digital Printing
Unlike many other products, HPL Compact offers a high degree of customization: it can be adapted according to user needs and requests.
HPL Compact is available in a wide range of colors, from neutral to vibrant tones. Not only can the panels be applied to any type of product, but thanks to the introduction of digital printing, they can be decorated with any graphic or photographic image the client desires. With HPL Digital Print, any design can be tailor-made without limits, allowing each project to be unique and turning the laminate into a canvas for artistic expression and branding.
This material also offers a wide variety of decorative designs and textures. “Texture” refers to the visible and tactile quality of a surface. Creating a texture on a panel means replicating specific surface characteristics, such as matte, rough, glossy, or satin finishes.
Sometimes textures are created to give the material a more realistic look, imitating and reproducing naturally existing surfaces, such as the roughness of wood. Other times, applying a particular finish enhances sensory and aesthetic value.
The choice of finish, beyond aesthetic value, must be considered based on the intended use of the finished product. For example, glossy finishes are less scratch-resistant and therefore less suitable for kitchen countertops. Shallow textures, on the other hand, facilitate better and easier cleaning, making HPL Compact ideal for places requiring high hygiene standards.
HPL Compact is available in a wide range of colors, from neutral to vibrant tones. Not only can the panels be applied to any type of product, but thanks to the introduction of digital printing, they can be decorated with any graphic or photographic image the client desires. With HPL Digital Print, any design can be tailor-made without limits, allowing each project to be unique and turning the laminate into a canvas for artistic expression and branding.
This material also offers a wide variety of decorative designs and textures. “Texture” refers to the visible and tactile quality of a surface. Creating a texture on a panel means replicating specific surface characteristics, such as matte, rough, glossy, or satin finishes.
Sometimes textures are created to give the material a more realistic look, imitating and reproducing naturally existing surfaces, such as the roughness of wood. Other times, applying a particular finish enhances sensory and aesthetic value.
The choice of finish, beyond aesthetic value, must be considered based on the intended use of the finished product. For example, glossy finishes are less scratch-resistant and therefore less suitable for kitchen countertops. Shallow textures, on the other hand, facilitate better and easier cleaning, making HPL Compact ideal for places requiring high hygiene standards.
Maintenance of HPL
HPL Compact, thanks to its specific resistance features, is designed to last many years, often exceeding 20-30 years depending on use and environmental conditions.
The maintenance of HPL is extremely simple. If a stain occurs, it is sufficient to clean the surface with a damp cloth, hot water, or a standard mild household detergent, as long as it is not abrasive or highly alkaline.
During cleaning, it is advisable to avoid aggressive and/or abrasive products such as steel wool, abrasive powders, and other commonly used polishing products, as these could cause surface scratches that would irreparably damage the product. Additionally, special care should be taken with descaling products, as they may contain highly corrosive substances that can damage the surface of the laminate. If the HPL Compact sustains minor damage, such as surface scratches, HPL repair kits can be used. These kits typically contain specific waxes or resins in the same color as the laminate, allowing scratches to be filled and the surface restored, thus locally correcting the damage and avoiding the need to replace the entire panel.
However, if the product is severely damaged or cannot be repaired, it is possible to replace the damaged panel without replacing the entire structure. This reduces long-term maintenance costs and extends the overall lifespan of the installation.
To ensure proper maintenance and management of HPL Compact, it is advisable to follow the specific recommendations of the manufacturer, who generally provides detailed guides on the use, cleaning, and maintenance of their HPL to maximize its durability and performance.
The maintenance of HPL is extremely simple. If a stain occurs, it is sufficient to clean the surface with a damp cloth, hot water, or a standard mild household detergent, as long as it is not abrasive or highly alkaline.
During cleaning, it is advisable to avoid aggressive and/or abrasive products such as steel wool, abrasive powders, and other commonly used polishing products, as these could cause surface scratches that would irreparably damage the product. Additionally, special care should be taken with descaling products, as they may contain highly corrosive substances that can damage the surface of the laminate. If the HPL Compact sustains minor damage, such as surface scratches, HPL repair kits can be used. These kits typically contain specific waxes or resins in the same color as the laminate, allowing scratches to be filled and the surface restored, thus locally correcting the damage and avoiding the need to replace the entire panel.
However, if the product is severely damaged or cannot be repaired, it is possible to replace the damaged panel without replacing the entire structure. This reduces long-term maintenance costs and extends the overall lifespan of the installation.
To ensure proper maintenance and management of HPL Compact, it is advisable to follow the specific recommendations of the manufacturer, who generally provides detailed guides on the use, cleaning, and maintenance of their HPL to maximize its durability and performance.
Installation of HPL Compact Panels
In construction sites and design projects, from the simplest to the most complex, the ease of installation of materials is certainly an aspect to consider. One of the advantages of using HPL Compact, both for interior and exterior applications, is the ease of installation of this material. Thanks to its easy cutting and installation, HPL Compact saves time on the construction site: installing HPL Compact requires less specialized labor, which can cover larger surfaces in less time, also resulting in cost savings. Additionally, the easy shaping and adaptation of these panels allow for the creation of customized and complex projects without added difficulty.
Specifically, HPL Compact panels can be installed using two different techniques, depending on the final application.
The technique best suited for interior design applications is laminating the HPL onto a substrate using water-based two-component adhesives. These are eco-friendly, non-harmful, and non-toxic glues, making them ideal for enclosed environments where excellent air quality is essential. Another significant advantage of this method is achieving a smooth and uniform surface without visible screws or other elements. However, it is crucial to ensure the glue is evenly distributed and the panels are correctly positioned before it dries.
Mechanical installation, on the other hand, is more suitable for external applications or where greater structural strength is required. This method involves the use of screws, bolts, or special substructures to attach, screw, or interlock the HPL panels to the supporting structure. This technique is advantageous for its ease of installation and removal, allowing easier maintenance and the possibility of replacing individual panels without compromising the entire structure. This also offers greater design flexibility. Moreover, it provides higher resistance to impacts and mechanical stress, making it ideal for applications in public or industrial environments. It is also a preferable solution when panels need to be installed on uneven surfaces or on structures that may experience movement or vibrations.
Specifically, HPL Compact panels can be installed using two different techniques, depending on the final application.
The technique best suited for interior design applications is laminating the HPL onto a substrate using water-based two-component adhesives. These are eco-friendly, non-harmful, and non-toxic glues, making them ideal for enclosed environments where excellent air quality is essential. Another significant advantage of this method is achieving a smooth and uniform surface without visible screws or other elements. However, it is crucial to ensure the glue is evenly distributed and the panels are correctly positioned before it dries.
Mechanical installation, on the other hand, is more suitable for external applications or where greater structural strength is required. This method involves the use of screws, bolts, or special substructures to attach, screw, or interlock the HPL panels to the supporting structure. This technique is advantageous for its ease of installation and removal, allowing easier maintenance and the possibility of replacing individual panels without compromising the entire structure. This also offers greater design flexibility. Moreover, it provides higher resistance to impacts and mechanical stress, making it ideal for applications in public or industrial environments. It is also a preferable solution when panels need to be installed on uneven surfaces or on structures that may experience movement or vibrations.
The Difference Between HPL Compact and Other Materials
Used for both interior and exterior design, HPL Compact belongs to the category of decorative surfaces, specifically laminates. After understanding the composition and production process of this material, the question arises: why are they called “plastic” laminates?
Firstly, the term “laminate” refers to a semi-finished product obtained through a lamination or layering process that involves assembling layers of kraft, decorative, and protective paper. The composition and production of the laminate do not involve the use of plastic substances in the chemical sense of the term. It is a sustainable product, and in this context, the term “plastic” refers to its flexibility, malleability, and workability.
At this point, its distinction from other seemingly similar materials becomes evident, not only in terms of appearance but also in usage.
Firstly, the term “laminate” refers to a semi-finished product obtained through a lamination or layering process that involves assembling layers of kraft, decorative, and protective paper. The composition and production of the laminate do not involve the use of plastic substances in the chemical sense of the term. It is a sustainable product, and in this context, the term “plastic” refers to its flexibility, malleability, and workability.
At this point, its distinction from other seemingly similar materials becomes evident, not only in terms of appearance but also in usage.
HPL Compact vs CPL
There are two main types of laminates on the market: HPL and CPL.
Both have the same composition: layers of kraft and decorative paper impregnated with thermosetting resins, with an added protective layer. They are both used to cover surfaces and create design products, offering a wide range of finishes and colors and allowing great creative freedom.
The main difference lies in the production process, thicknesses, and, consequently, their resistance.
In the HPL production process, kraft and decorative paper layers are stacked and compressed under high pressure and high temperature. The CPL production process, however, is continuous, with the layers subjected to lower pressure but higher temperature than HPL.
HPL is made in thicknesses from 0.8 mm to 3 mm for thin thicknesses and from 4 mm to 25 mm for Compact, while CPL is produced in thicknesses ranging from 0.1 mm to 1.2 mm.
The production process of HPL takes about 40-50 minutes, while CPL is much faster, lasting only a few minutes.
All of this gives HPL Compact extraordinary resistance to scratches, impacts, abrasion, moisture, and many chemical agents. As a result, it is often used for surfaces that require high durability, such as worktops, tables, kitchen furniture, and wall coverings. CPL, instead, is less expensive to produce as more square meters of product can be made in the same time, but it is also less resistant than HPL. It is, therefore, often used for vertical surfaces like doors, cabinet fronts, and partition panels, where a high level of resistance is not necessary.
HPL Compact vs Porcelain Stoneware
HPL Compact and porcelain stoneware are two materials widely used in the construction and furnishing sectors.
Porcelain stoneware is a ceramic material obtained from a mixture of clay and natural minerals fired at very high temperatures. This process gives it a compact structure and high mechanical strength. It is known for its durability, stain resistance, and resistance to chemicals and abrasions. It is generally used for flooring, bathroom and kitchen cladding, and commercial and industrial spaces. Porcelain stoneware can be glazed or unglazed and can mimic the appearance of various materials such as wood, marble, and natural stone.
The main difference with HPL Compact is not only in their production but also in the application and installation of these materials.
As we know, HPL Compact is produced by high-pressure and temperature pressing, while porcelain stoneware is fired at high temperatures in specialized kilns.
While both materials offer high resistance and durability, HPL Compact is more versatile in terms of design and customization, suitable for furniture, cladding, and urban furnishings, whereas porcelain stoneware is preferred for floors and cladding.
In terms of installation, porcelain stoneware requires greater precision and skill, as large formats and the weight of the slabs require specific tools. The tiles must be laid with special adhesive mortars, ensuring perfect adhesion and precise alignment of the joints. Therefore, the lightness of HPL Compact makes it easier to handle and lay, reducing installation time and labor costs. The choice between the two materials thus depends on the specific project requirements, environmental conditions, and aesthetic preferences.
HPL Compact vs Melamine-Faced Chipboard
“Melamine-Faced Chipboard” refers to panels made typically with chipboard (shredded wood particles) or MDF (Medium Density Fiberboard), which are coated, or rather, “nobilitated,” with decorative paper impregnated with melamine on both sides. The paper is applied to the panel using presses that heat the thermosetting resin in the paper, causing it to react and adhere to the panel, creating a single product. The resistance of Melamine-Faced Chipboard depends on the quality of the surface that covers them. However, by default, they are not particularly resistant to impacts and abrasions.
The difference with HPL Compact mainly concerns the materials and applications of the panels.
As for the base material, HPL does not have a separate base panel; it is a single, solid, and homogeneous layer of compact laminate, which makes it more resistant and durable. It is known for its excellent resistance to impacts, water, heat, scratches, and chemicals, making it widely used in high-traffic environments such as public restrooms, kitchens, laboratories, and hospitals, where material performance is critical.
Melamine-faced chipboards, however, are very common in the furniture industry due to their relatively low cost and ease of processing. They are ideal for interior furniture such as wardrobes, chests of drawers, and shelves, where use is not excessively intensive. However, their resistance to moisture and impacts is limited.
