Inside Flexiteek’s factory: how synthetic teak decking is really made
What looks like traditional teak decking on a boat is, in reality, the result of tightly controlled polymer engineering, precision tooling and continuous extrusion technology. Inside Flexiteek, synthetic marine flooring is built through a process that blends material science with industrial production at scale. The company transforms raw bio-attributed PVC into finished decking which is designed to replicate the appearance, texture and performance of timber at sea.
MIN visits Tollesbury, Essex – Flexiteek’s UK headquarters.
Shaping the product at source
The manufacturing process begins in the tool room, where production dies are designed and produced. These dies are attached to the end of extrusion lines and determine the final shape of each product. Having an in-house tool room is a significant capability, allowing the company to develop and manufacture its own tooling rather than relying on external suppliers.
Everything starts with the die. Raw material is forced through it under pressure, creating the profile required for the finished product.
Raw materials and formulation
The factory uses different grades of material depending on the product being manufactured. The base material is bio-attributed PVC, which already contains key additives including UV stabilisers.
Colour is created through carefully controlled formulations. Each colour has its own recipe, with precise percentages assigned to individual components. The manufacturing system automatically measures and controls the amount of each ingredient entering the process.
For some decking products, five different colours are combined to create a single finished product. Each colour feed system is fitted with weighing scales, allowing operators to monitor material inputs in real time and ensure accurate dosing throughout production. The scales feed information directly into the control system, giving constant visibility over the formulation process.
Extrusion
Once mixed, the material enters the extrusion line.
The PVC compound is heated to around 180°C before being pushed through the die. Immediately after extrusion, the profile enters a cold-water bath where its temperature is rapidly reduced to approximately 30°C.
A puller system then draws the profile through the line at a constant rate. Maintaining a consistent pull speed is critical, as variations would alter the dimensions of the finished product.
The line also offers printing capability, where required, allowing markings to be applied as part of the manufacturing process.
At the end of the process, the material is wound into finished lengths. Operators work to predetermined lengths and widths, with the system effectively converting output into measurable square metres of finished product. Once the required length is reached, alarms and visual indicators alert staff that the product is ready for handling.
Co-extrusion technology
One of the more technically interesting aspects of the operation is the co-extrusion process used to create the synthetic decking’s distinctive appearance.
The factory simultaneously extrudes different coloured materials through separate channels to achieve the Flexiteek grouted effect. This process also works for the Wilks fendering products made onsite. For example, white Wilks Click material travels through one path, and black material through another, before the streams meet within the die and emerge as a single Click fendering profile.
This process allows different colours to be permanently integrated into the product structure rather than applied later as a surface treatment.
When new products are developed, the steel die must be modified or redesigned to achieve the required shape. Colour adjustments can then be made through changes to the masterbatch formulations.
Creating the teak appearance
After extrusion, the material undergoes a secondary finishing process that gives the product its teak-like appearance and non-slip properties.
Profiles pass through a machine that combines an abrasive belt with a conveyor system. The abrasive process removes material from the upper surface, exposing the internal colour structure and creating the wood-grain effect.
The process simultaneously roughens the surface to improve grip and produce the decking’s non-slip characteristics. Thousands of metres of product pass through the surface-finishing machine each day. The abrasive belts require replacement roughly once a month.
While this is happening, the factory’s extraction system continuously removes the dust generated. Dust is collected through an exhaust ventilation system.
Quality control
Colour consistency is controlled through a swatch-based system.
The company maintains reference samples for each colour formulation, allowing production teams to compare current output against the original approved standard. Every production run is checked against these swatches, and products are matched on a batch-to-batch basis to ensure consistency across manufacturing runs.
The reference standards are retained so colours can be reproduced accurately long after their original development.
Warehousing and dispatch
Much of the factory space is devoted to warehousing and logistics.
Many products are manufactured to order and move directly through the production flow to dispatch. Standard stock items are stored in warehouse racking before shipment.
The final dispatch area serves as a last checkpoint before products leave the factory.
Continuous evolution
The factory layout has evolved over time rather than being designed as a fixed system from the outset.
The introduction of Flexiteek3 was a significant turning point. New machinery was installed and processes were optimised specifically around the material.
Beyond decking
The factory also produces fenders under the brand name Wilks. These include profiles designed to be fitted to the sides of boats. While manufactured using similar extrusion principles, these products involve a slower and more manual production process than decking materials.
Read more about the company’s manufacturing process on its website.
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