How We Manufacture
At
Revco we strictly adhere to woodworking fundamentals, from wood selection to
finish application, ensuring the delivery of an exceptional product. We
take pride in creating quality furnishings that can be enjoyed for years to
come. Below we've outlined our underlying philosophies behind every piece
of furniture we make.
The
Wood
Understanding
wood's characteristics and properties is vitally important to creating a superior
product. At Revco, we believe that quality furnishings begin with quality
lumber.
We
use Plantation Grown Mahogany due to its proven reputation in fine furniture
making. We also use local Mango wood in an effort to support the local
farmers. Some items are made of other tropical hardwoods for their aesthetic
nuances. We support wood vendors that believe in Re-Forestation; as a
tree is cut down a seedling is planted in its place in order to maintain balance
in nature. In addition, we implement processes and check-points to ensure
the lumber's quality is preserved from the point of purchase to our factory.
Quality
does not end with lumber selection. Strict guidelines must be adhered
to when drying lumber in order to preserve any product as it ages. We
kiln dry all of our lumber and use USDA / FPL (U.S. Department of Agricultural
/ Forest Product Laboratory) services to set our kiln schedules. After
it's properly dried and seasoned, we store our lumber in dry sheds to maintain
the desired MC (moisture content) level until it is ready for processing in
the plant. Our standard MC levels are equivalent to what the wood may
equalize to in an air-conditioned environment that has a RH (relative humidity)
level between 30%-52% (which means the wood has 6%-8% MC).
Engineering
Wood
has innate characteristics that must be carefully considered during engineering
to increase the product's longevity. Solid wood will dimensionally change
based on RH levels; all solid wood expands and contracts, moving with its environment.
Furniture must be designed with this in mind. In colder, dryer climates,
wood contracts (shrinks) creating slightly larger spaces between moving parts;
in warmer, humid climates the wood will expand (swell) reducing that space.
So, on a winter day a dresser drawer will work smoothly, however when the temperatures
rise, the same drawer may stick. Engineering a piece to accommodate for
expansion and contraction (ensuring the drawer moves smoothly in all temperatures)
takes a special skill set and understanding. We are constantly working
to innovate in this area, with creative thinking and strict adherence to wood
properties.
Finishing
The
finish is the first impression. As the most skilled and talented woodworkers
know, great lumber, design and engineering can be lost without a beautiful,
quality finish.
We
use a sophisticated process that begins with very intense surface preparation.
Each piece is thoroughly hand-sanded then subtly and lightly distressed; bringing
character and uniqueness to the furniture that allows it to age elegantly.
Distressing is an artistic process requiring careful planning and is done entirely
by hand; no two pieces look exactly the same.
After
distressing, the furniture moves into finishing where we use a nitro-cellulose
lacquer that is applied to all surfaces (inside and out, top and bottom); this
makes the product more stable and gives maximum protection to the wood.
Finishing the furniture completely helps to stabilize and balance moisture exchange
reducing the warping of wood.
We
build a finish like we build a piece of furniture, by following a meticulous
16-step process applying a multitude of layers with many hand-finishing techniques
along the way. We use shading and highlighting to add character and warmth,
and "build" on our top coats to promote clarity and depth. In
addition to providing a lustrous finish, this process also enhances wood grain.
Our finish is then evaluated in a special color chamber providing the ideal
inspection environment. The piece is then placed in our curing room for
24 hours, allowing the finish to harden.
Finally,
the furniture moves to our packing department where the piece is hand rubbed
to a perfect sheen.
