Indian Door Manufacturers Witness Cutting-Edge Innovation at Sauerland’s Factory in Germany

The seventh educational delegation of Indian door manufacturers and consultants has successfully completed an insightful tour of Sauerland Spanplatte’s state-of-the-art facility in Gotha, Germany. The visit aimed to introduce Indian industry professionals to globally established, sustainable alternatives to conventional timber-based door construction, with a strong focus on performance, durability, and environmental impact.

Over the course of the multi-day visit, the delegation observed firsthand the advanced production process of Sauerland’s 100% engineered tubular boards. A highlight of the tour was a live fire resistance test, where participants witnessed how Sauerland’s lightweight, fire-rated door cores deliver exceptional performance without additives or inorganic fillers-offering both economic and ecological advantages.

Sauerland also showcased a live acoustic test on a 34mm thick door, constructed using its 28mm Acoustic Sandwich Core, softwood stiles and rails, and 3mm HDF skins. This demonstration highlighted the core’s ability to deliver excellent sound insulation while maintaining a lightweight and easy-to-handle structure-addressing the growing demand for high-performance acoustic doors in both residential and commercial buildings.

The delegation further visited a leading German door manufacturing facility. A key observation was the complete absence of flat-pressed board as door infill-a material widely avoided in Europe due to its tendency to swell, which can severely compromise the door’s durability, visual appeal, and long-term performance.

Since 2007, Sauerland has been supplying its tubular infill boards to the Indian market, helping reduce dependency on solid timber in door manufacturing. Despite its global use in over 90 countries for more than 70 years, and with an estimated 100,000 doors produced daily using the product worldwide, the Indian door industry remains in transition-still largely reliant on traditional timber infill specifications.

Key Advantages of Sauerland Tubular Boards

• Sound Insulation: Available in both extruded tubular and solid core formats, offering reliable acoustic control across various door systems.
• Fire Resistance: Vertical particle alignment through extrusion slows flame spread. Full technical support is provided for compliant fire door construction.
• Structural Strength: The arch-based core structure and ≥500 kg/m³ wall density ensure outstanding mechanical strength and impact resistance.
• Precision Thickness Tolerance: Manufactured to ±0.1mm tolerance for excellent surface quality, no telegraphing, and superior skin bonding.
• Weight Reduction: Lighter than timber cores, easing door handling and installation without compromising structural integrity.
• Low Emission: Certified to E0.5 standards for formal-dehyde, promoting safer, healthier indoor environments.
• Dimensional Stability: Tubular design maintains door straightness and form under varied climatic conditions—ideal for India’s diverse weather zones.
• Sustainability Certifications: PEFC-certified, with FSC options available-supporting global forestry conservation and responsible material sourcing.
• Zero Swelling: Near-zero thickness swelling under moisture exposure, unlike flat-pressed boards and timber infills-ensuring long-term door performance.
• ISI Compliance: Suitable for manufacturing doors per IS 2191 Part 1:2022 and IS 2191 Part 2:2022, meeting key infill criteria such as <5% thickness swelling in 2-hour General Absorption.

This educational exchange reflects Sauerland’s ongoing commitment to empowering the Indian door industry with globally proven, eco-conscious technologies. The company continues to support a shift toward modern, high-performance, and sustainable door systems that meet both international and Indian regulatory standards.

The visit was a of great learning and education for the several door manufacturers and their comments post visit:
Mr. Gaurav Singhal – Director JB Glass
My recent factory visit experience to Sauerland, which was truly insightful and impressive. The visit provided valuable exposure to the manufacturing process, quality control measures, and the company’s commitment to innovation and sustainability.

Key takeaways from the visit:

• State-of-the-art facilities: The factory’s modern infrastructure and equipment showcased the company’s investment in technology and efficiency.
• Quality control: The rigorous quality control processes ensured the highest standards of products.
  Innovation: The company’s focus on research and development was evident in the innovative products and solutions on display.
• Collaborative culture: The factory’s open workspace and collaborative environment encourage idea-sharing and creativity among employees. same was reflected in door manufacturing company as well.

I appreciated the hospitality and openness of the third generation of Sauerland, who were eager to share knowledge and answer questions.

Mr. NK Raghavendra – Pensare Solutions LLP
It was a truly enriching experience for me and the entire group of customers from India. The opportunity to witness the complete manufacturing process of the Sauerland infill and visit the fully automated Garant door manufacturing facility was extremely valuable. The live fire testing demonstration of the 30-minute fire-rated door, along with other rigorous tests on sound, moisture, and performance, added immense depth to our understanding of product reliability and technical excellence. The professionalism and attention to detail with which the entire tour was conducted reflect the commitment of both Sleek Boards and Sauerland towards sharing knowledge and building strong industry relationships. Thank you once again for your hospitality, meticulous arrangements, and the invaluable experience. We look forward to many more such engagements in the future.

Mr. Tanishq Kukreja – CEO Kalpine Industries Pvt. Ltd.
I would like to thank each one of you for organising this mind blowing trip to Sauerland Spanplatte – Gotha unit and the door manufacturer factory.
Your hospitality was heartwarming and we would love to come back with our family and management team next time.
The visit has helped us in understanding the detailed back end working from Sauerland to offer the consistent high level of quality and the extra lengths they go to make sure the complete service is offered to their customers for facilitating the best quality door manufacturing.
Visit to Door manufacturer’s factory has helped to understand the high volumes of production that are possible in this product line using engineered materials and we go back to India with the goals set to reach such volumes on earliest basis.
Thank you to the entire team in the technical insights shared for normal doors as well as Fire Rated and Acoustic Rated Door-sets.
Mr. Abhishek D. Agarwal – Manging Director Linea Designs Pvt. Ltd.
Our recent visit to the Sauerland factory in Germany was an incredibly informative experience that provided us with valuable insights and a deep understanding of the product and its manufacturing process. The opportunity to see the operations up close was both educational and eye-opening. It made us believe further in the genuinity of the product and this would help us recommend this product better.

Meeting the Managing Director and hearing her perspective on the company and the broader sector was a highlight of the visit. Her vision and clarity added great depth to our understanding of the business.

We were fortunate to be hosted by Mr. Amit Vaze and Nitin Uncle, who were exceptional throughout the tour. Their warmth, attentiveness, and willingness to explain every detail made us feel extremely comfortable and welcome. Their hospitality truly enhanced the entire experience.

Overall, the visit was not only insightful but also left us with a strong appreciation for the passion and professionalism behind the brand.

Mr. Ashok A Kuriakose – Director Kelveneers Pvt Ltd
As part of the Indian contingent of door manufacturers who visited Sauerland factory I am very happy to have experienced firsthand large scale manufacturing incorporating automation and technology. The Family run business of Sauerland also emphasized the importance of putting people and family first and we are honoured to be part of that Ethos.

Mr. Vidit Kedia – Director AMIT DENSIFIED DOORS PVT. LTD.
We recently had the opportunity to visit the tubular board manufacturing unit at Sauerland and the complete door set manufacturing facility at Garrant, along with a memorable city tour of Erfurt, Germany. It was an insightful and enriching experience that offered us a deep understanding of advanced door manufacturing processes and technologies.

A special thanks to the entire team at Sleek Boards, and especially Vaze Ji, for their exceptional hospitality and meticulous coordination throughout the trip. Every aspect of the visit-from the technical demonstrations to the local arrangements-was thoughtfully planned and executed. The fire and acoustic testing sessions were particularly impressive and gave us a firsthand look at the precision and quality that go into the products.

We are also deeply grateful to Sauerland for opening their doors to us and giving us the opportunity to explore their state-of-the-art manufacturing unit. It was a privilege to witness the innovation and expertise that drive their operations.

This visit has left us with valuable insights and a stronger sense of collaboration for the future. Thank you once again to everyone involved for making this experience so rewarding.

Mr. Tarun Nichani – Managing Director Shivani Interior Solutions Private Limited
On behalf of our entire team, we wish to sincerely thank the Sauerland team for welcoming us to their facilities and for making us feel so at home during our visit.

A special thanks to Mr. Amit Vaze and the entire Sleek Boards and Sauerland team for organizing the tour. We were absolutely blown away by how impressive the factory is. The level of precision, efficiency, and innovation in operations was truly eye-opening. It’s clear that so much time, effort, and expertise have gone into getting to this point, and it really shows. We were particularly impressed by both the fire testing and acoustical testing of the doors—it’s not every day you get to see these tests in action. What made it even more impactful was the detailed analysis following the fire test. The thorough explanation of why the door performed so well and the critical factors to keep in mind when manufacturing fire doors was incredibly insightful. It’s rare to see such a deep dive into the nuances that make a product both safe and effective.

I also want to commend the care you take in ensuring that your products and processes are truly best-in-class. It’s rare to see such a perfect balance of cutting-edge technology and attention to detail. You’ve built something really special, and we feel lucky to have gotten a first-hand look at that level of commitment to quality.

Of course, we’re also very grateful to the Garant team for their warm welcome and for sharing insights into their operations. Seeing the approach to manufacturing and quality control gave us even more perspective on what we need to do as we plan out our own facility. It was incredibly inspiring to see how both of your teams operate with such precision and passion.

As we move forward with setting up our own door manufacturing facility, we’ll be looking back at the lessons we learned from both of you. The knowledge and insights you’ve shared with us will undoubtedly play a huge role in helping us get it right.

We thank Sauerland for their time, hospitality, and generosity. We’re excited to stay in touch and work together in the future.

Mr. Jaikaran Singh – Antico Veneers
Trip to visit Sauerland in Germany was one of the most enriching experiences in wood work & aligning the need for updated application of their product in the Indian door making industry. The technical advancement & know how we experienced at Sauerland is of cutting edge & provided clarity at best for futuristic growth in India. We cheer to our long standing relationship with Sauerland to bring the best in the world back to our homes.

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