Brothers John and Michael Borg had developed a successful kitchen manufacturing business during the late 1980’s. During this time they could see the potential for a specialised cabinet door manufacturer in the Australian market, and had carefully investigated the emerging European process of fully thermoformed kitchen doors. In October 1990 they incorporated a new business to manufacture and distribute thermoformed doors, marketed under the brand of ‘polytec’.

The company’s showcase door manufacturing plant is located at Charmhaven on the NSW Central Coast, approximately one and a half hours drive north of Sydney. polytec pioneered automated thermoforming production methods at this facility, which now produces in excess of 5000 doors per day.

The company grew throughout the 1990’s to become the largest manufacturer of thermoformed kitchen doors in Australia. In 2000 the company accelerated its expansion by investing in the manufacture and distribution of a range of co-ordinating decorative melamine board products, with the commissioning of a 3000 x 1200 melamine press at a new factory, located in the nearby town of Somersby N.S.W.

Routing of Door Profiles	Robotic Spraying of Specialised Adhesives	Pressing of the Thermolaminated Foil

Pressing of Melamine Panels	Cutting of Melamine Panels	Square Edge Banding

The success of the Somersby melamine facility brought about a need for increased capacity to satisfy growing customer demand. In 2003 further expansion was completed at Somersby to create one of the largest melamine laminating facilities in Australia. The site is dominated by a new 7200 x 1800 melamine press, which is one of the fastest and most advanced short cycle presses in the world. This advancement allowed polytec to supply a greater variety of melamine panels, including products for the office furniture and commercial joinery markets.

In addition to the Charmhaven and Somersby manufacturing sites with their integrated distribution centres servicing Sydney and Newcastle, the company also has branches in Melbourne, Brisbane, Perth, Adelaide, Canberra, Coffs Harbour, Tamworth, Bathurst, Albury, Singapore and Malaysia.

Strategic investment in the latest machine technology and computer integrated manufacturing processes has enabled polytec to become one of the fastest growing private companies in Australia, with the company quietly and diligently emerging as a market leader in wood panel surfacing and cabinet door manufacture.

In 2004 Borg continues its commitment to manufacturing in Australia with the addition of a melamine profiling plant that produces edged and profiled melamine doors, further complimenting the existing polytec range of doors and panels. This expansion is being housed in a purpose built extension to the Charmhaven site that houses Australia’s first fully robotic door manufacturing facility.

In keeping with the company philosophy to continually bring innovation to the kitchen door market in Australia, the new Charmhaven factory also houses an Aluminium Frame door plant that produces contemporary aluminium framed doors with a variety of translucent glass inserts.

These new developments, and the addition of benchtop laminates to the polytec product range, enable polytec to supply the Australian kitchen door market with the most comprehensive panel packages in the marketplace.