From Lab to Factory: How We Created a Custom Color Composite Decking Solution

At Écoplast, we often say that manufacturing our Naturodeck composite boards right here in Quebec gives us unique flexibility. Recently, we had the perfect opportunity to prove it when a client challenged us to create an exclusive color that doesn't exist anywhere else on the market.

Here is the behind-the-scenes story of this step-by-step custom composite decking production.

Why Choose Custom Composite Decking?

Opting for custom composite decking allows you to perfectly match your outdoor living space with your home's unique architecture, without compromising on material quality, performance, or durability.

Step 1: The Raw Material Test and Custom Lab Blend

Everything starts with a pure base. To validate the behavior of our recipe (made of 60% local hardwood and recycled plastic), we first sent raw material to our colorist without any pigments. From this neutral base, an initial custom blend was developed in the lab to capture the client's vision.

The initial test sample developed by our colorist in Granby for this custom composite decking project.

Once the raw material was analyzed by our expert, precision resin compounding work began to prepare for the full-scale extrusion process.

The custom blue composite compound engineered in the laboratory.

Step 2: Precision Adjustments (The Secret is in the Details)

The first sample straight out of our test production line yielded an interesting result, but the blue turned out a bit too pale under natural daylight.

Our first extruded sample board: a brushed blue shade that was slightly too light.

To achieve the rich, deep finish expected for this custom composite decking order, we adjusted the formula by adding a precise amount of carbon black. This modification darkened the shade just enough for the second sample board. This time, it was a perfect match!

The final dark blue shade (left) compared to our other standard composite colors.

Step 3: Support from Our Local Partners

Such agility would not be possible without a strong local ecosystem. To stabilize this new custom formulation and launch official production, we relied on the technical support and responsiveness of our trusted local supplier, Colorex. Thanks to their high-quality pigments, we were ready for the final step.

Step 4: Factory Approval and Secure Production Run

Because a deck project is a long-term investment, we invited the client to validate the final result directly at our Farnham factory. Nothing beats seeing and touching the product under real daylight!

Once we got the green light, we launched the final manufacturing run. Our protocol for every custom composite decking order? We always produce an **extra 15% of boards**. This ensures the client keeps a security inventory from the exact same color batch in case they want to make modifications or additions in the future.

The Local, Eco-Friendly Manufacturing Advantage

Whether you are a passionate homeowner or a general contractor looking for a unique identity for a large-scale project, circular economy and local manufacturing break down traditional barriers. Choosing custom composite decking means zero compromises, no slippery plastic cap sheets, just raw, durable composite tailored to your taste.