How we make sure every panel that leaves our workshop meets the standard it should.
Every MDF panel, Tongue & Groove board, Cheshire moulding, and solid pine rail we sell is manufactured or sourced against defined quality standards. This page sets out those standards — the checks we carry out, the tolerances we hold, what constitutes a genuine defect, and what is expected natural variation in wood-based products.
Last updated & effective: 25 June 2026
What this policy covers
This policy applies to all products manufactured at our Cambridgeshire workshop and all products sourced and sold through lunaireworks.com. The products fall into two distinct material categories, and the quality standards described in this document reflect the specific properties of each.
Manufactured MDF products — these are cut, shaped, and quality-checked in-house at our own workshop. They include all Shaker Wall Panel kits, Tongue & Groove MDF panels (including the V-Groove range), Cheshire Moulding Shaker panel kits, Dado & Picture Rail kits in MDF, and all Build Your Own custom-cut orders. MDF is an engineered wood product with consistent density and a uniform surface, so tolerances for this category are well-defined and strict.
Solid pine accessories — these include the Pine Decorative Panel Moulding Dado Rail (1m × 63mm × 25mm), the Solid Pine Panel Moulding (28mm × 15mm), and the Traditional Solid Dado Rail (41mm × 20mm). Solid pine is a natural sawn timber product. Its colour, grain density, and surface markings vary between individual pieces in ways that are inherent to the wood itself — not defects — and are addressed fully in the natural variation section below.
This page is not a marketing document. It is a factual description of the quality standards and processes we apply, written to give you a clear, honest picture of what to expect from the products you order from us.
Raw material standards
The quality of our finished panels depends entirely on the quality of the board and timber we begin with. Here is how we select and verify incoming materials before any cutting begins.
MDF board specification
We use FSC-certified Medium Density Fibreboard (MDF) for all of our manufactured panel products. The board is sourced from UK-based suppliers whose material meets BS EN 622-5:2009 — the British and European standard for fibre boards of the MDF type. The key material properties we specify are:
- Nominal thickness: 6mm (tolerance ±0.3mm) and 9mm (tolerance ±0.5mm) as per supplier datasheet
- Smooth, sanded face and back surfaces — no raised fibres, pitting, or surface delamination before cutting
- Moisture content between 5% and 11% on delivery — boards outside this range are returned to the supplier
- Formaldehyde emission class E1 (≤0.124 mg/m³ as per EN 717-1) — confirmed on supplier certification documentation
- Consistent fibre density throughout the board cross-section — no visible voids or internal delamination
Solid pine accessory specification
Our solid pine dado rails and panel mouldings — including the Pine Decorative Dado Rail (1m × 63mm × 25mm), the Solid Pine Panel Moulding (28mm × 15mm), and the Traditional Solid Dado Rail (41mm × 20mm) — are sourced from softwood timber merchants supplying planed, smooth softwood.
- Planed all round (PAR) softwood — smooth on all four faces, with no rough-sawn surfaces
- Moisture content between 12% and 18% — consistent with interior-grade dried softwood for UK climate
- Profiles checked against nominal stated dimensions on each delivery — rejected if measured cross-section deviates by more than ±1mm from specification
- Natural features — grain, colour, and tight sound knots — are accepted as inherent properties of solid pine and are not grounds for rejection (see Natural Variation section below)
All pine products are suitable for paint or stain finishes. They are not pre-finished. Customers apply their own chosen paint, stain, or varnish after installation.
Quality control process — stage by stage
Every MDF panel order moves through six defined quality control stages at our Cambridgeshire workshop before it is packed for dispatch. No stage is optional.
Board and timber receipt inspection
When a delivery of MDF board or pine moulding stock arrives at the workshop, it is checked against the supplier's delivery note before being accepted. The inspection at this stage covers: board thickness sampled at multiple points across each sheet using calibrated digital callipers; surface quality on both faces for scratches, indentations, or delamination that would affect the finished panel; and moisture content on pine stock using a pin-type moisture meter. Any board that fails the incoming check is refused and returned to the supplier. It never enters the cutting queue.
Cutting equipment verification before each production run
Our CNC router is calibrated before each production run — not just periodically. A test cut is made on a scrap offcut of the same material thickness being used for the order, and the resulting dimension is measured using a steel rule and digital callipers. If the test cut falls outside the ±1mm tolerance band, the machine is adjusted and re-tested before any customer panels are cut. This step is logged on the workshop production sheet for the order. We do not begin cutting customer panels until the calibration test passes.
First panel off the CNC measured against specification
The first panel cut from each new order is removed from the machine and measured across all four dimensions (length, width, and both diagonal measurements for squareness) before the rest of the batch is cut. If the first panel measures within tolerance and is square, the batch run proceeds. If any measurement is outside tolerance or the panel is out of square, the offset is corrected in the machine program before continuing. This catches any CNC drift or setup error before it can affect the whole order — not after.
Visual inspection of all cut faces and surfaces
Every panel is visually inspected under workshop lighting on all six faces — both flat surfaces, both long edges, and both short cut ends. Inspectors look for: chipping or break-out along the cut edge caused by a blunted router bit; delamination or fibre separation at the face; machine score marks on the surface; and any visible inclusions or voids in the MDF core. Panels with cut-edge chipping greater than 2mm deep or surface marks that would show through a finish coat are pulled from the batch, set aside, and not dispatched. Accepted panels are stacked face-to-face with a paper separator between each pair to protect their surfaces during the packaging stage.
Count verification before packaging
Before any order is packaged, the quantity of each panel size and type is counted against the order specification. For standard kits (for example, a 20-pack of 10 × 100cm and 10 × 50cm Shaker slats), the count is verified twice — once by the person who cut and inspected the panels, and a second time by whoever packs the order. For custom orders, the count is verified against the approved Design Confirmation document. Any discrepancy between the pack count and the order specification stops the packaging process until it is resolved. Orders are not dispatched short on quantity.
Protective packaging for transit
Panels are packaged to prevent movement, surface abrasion, and edge damage during courier transit. MDF panels are stacked with protective interleaving, edge-guarded with cardboard corner protectors, and wrapped or boxed depending on the size and panel count of the order. Long panels (over 100cm) are shipped in reinforced packing to prevent flexing damage during handling. Pine mouldings are wrapped and edge-protected before being placed in a shipping box with void fill. We do not compromise on packaging material — a panel that passes every quality check and then arrives damaged because of poor packaging is a failure on our part, not the courier's.
Dimensional tolerances — full specification
These are the tolerances we hold, how they are measured, and what they mean for your installation.
| Measurement | Product type | Tolerance | How it is measured | Practical meaning |
|---|---|---|---|---|
| Cut length | All MDF panels (Shaker, T&G, Dado kit) | ±1mm | Steel rule and digital callipers on the first-off panel and on a sample from the middle of each batch | A panel listed as 100cm may measure 99–101cm. Invisible to the eye after installation and decoration |
| Cut width | All MDF panels | ±1mm | Digital callipers measured at three points along the length (top, middle, bottom) | A 50cm-wide panel may measure 49–51cm. Consistent along the full length of each panel |
| Board thickness | 6mm MDF panels | ±0.3mm (per BS EN 622-5) | Incoming material check using calibrated digital callipers on the raw board before cutting | Governed by board supplier's manufacturing tolerance — not our cutting process. Covered by material certification |
| Board thickness | 9mm MDF panels | ±0.5mm (per BS EN 622-5) | As above | As above — same principle, slightly wider tolerance on the thicker board grade |
| Squareness | All rectangular MDF panels | Both diagonals within 2mm of each other | Diagonal measurement from corner to corner; panels are rejected if the two diagonal measurements differ by more than 2mm | Panels will sit flush and square against adjacent panels and rails without visible gaps at corners |
| Profile cross-section | Pine mouldings & dado rails | ±1mm on stated nominal width and thickness | Sample measurements on incoming stock; rejected batches returned to supplier | A 63mm-wide dado rail will measure 62–64mm. Differences are not visible after paint or stain is applied |
| Profile length | Pine mouldings & dado rails (1m lengths) | +0mm / −5mm (cut-to-length softwood convention) | Tape measurement; no piece is dispatched shorter than 995mm for a 1m-specified product | Lengths are never over-short. A small underrun of up to 5mm is within accepted softwood trade standards |
| V-groove position | Tongue & Groove MDF panels (V-groove range) | ±1.5mm from nominal centreline | Visual check on first-off panel; the groove position is verified against the programme CNC offset file | Groove alignment is consistent across all panels within a single order. Minor offset between orders from different production dates is not a defect |
Important for tight-fit installations: If your project requires panels to fit into a precisely sized recess — for example between two fixed surfaces with no room for adjustment — please allow for the ±1mm cut tolerance in your measurements and specify slightly under-size if in doubt. For genuinely tight recesses, we recommend ordering a sample panel before committing to a full custom order. Contact us at info@lunaireworks.com to discuss.
Natural variation in wood products
Wood is a natural material. No two pieces of solid pine are identical, and even manufactured MDF can show minor appearance differences between production batches. This section explains what variation to expect, why it occurs, and why it is not a manufacturing defect.
Colour variation in solid pine mouldings and dado rails
Our solid pine dado rails and mouldings are real sawn and planed timber. Pine grows with natural variation in colour across individual trees and even within a single plank. You should expect:
- Tone variation within an order: Individual pieces in the same pack may range from pale cream-yellow to warm honey or light amber. This is determined by which part of the tree the timber came from and how recently it was milled — not by any defect in processing or storage.
- Heartwood vs sapwood colouring: Pine's sapwood (outer growth rings) is paler; its heartwood (inner rings) is darker and may have a pinkish-orange tint. Both can appear in the same piece, and this contrast is entirely natural.
- Colour change after delivery: Fresh-milled pine is lighter and will darken and warm in tone over the first weeks and months of indoor use as it oxidises and acclimatises to your home's humidity. This is expected and normal.
- Paint coverage: Colour variation in pine is effectively eliminated by applying one coat of primer followed by two coats of paint. If you intend to paint your mouldings, variation in the bare wood is irrelevant to the finished result.
Grain pattern and surface markings in pine
In addition to colour, the following surface characteristics appear in solid pine products and are accepted natural features — not defects:
- Tight, sound knots: A sound knot (one that is firmly embedded in the wood and does not move or fall out) is a natural part of pine timber and does not affect the structural integrity or paintability of the moulding. Knots up to 10mm in diameter on the face of the profile are accepted variation. A loose or dead knot (one that moves, rattles, or has a dark resinous ring suggesting it will fall out) is a defect — see the section below.
- Resin pockets and streaks: Pine naturally produces resin, which can show as small amber-coloured pockets or dark streaks in the grain. These are paintable with shellac-based primer (such as Zinsser BIN) and do not affect the finish. Resin streaks are natural, not a quality failure.
- Grain direction variation: Pine grain is not perfectly straight. Wavy or interlocked grain is a natural feature. It may cause the surface to reflect light slightly differently at different viewing angles, which is more visible before painting than after.
- Minor planing marks: Planed All Round (PAR) softwood can show very faint ridges left by the planer blades. These are not deep enough to affect the surface profile and will fill and disappear under paint. They are not sanding defects or damage marks.
Batch-to-batch variation in MDF products
Although MDF is an engineered and uniform product, there can be minor surface tone differences between panels cut from different production batches of MDF board — typically appearing as a slight difference in the base grey-beige colour of the bare board. This variation is visible in the raw, unpainted state and disappears entirely once a primer coat is applied. It is not a defect and does not indicate any difference in material quality, density, or structural performance. Customers placing repeat orders for the same project over an extended period should be aware that bare boards from separate orders may look slightly different before painting, but will be indistinguishable after decoration.
What is a defect and what is normal variation
This is the most important distinction on this page. Read both columns carefully before contacting us about a quality concern.
- MDF surface tone variation between panels from different production batches — disappears under primer
- Cut dimension within ±1mm of the stated nominal size
- MDF board thickness within the BS EN 622-5 material tolerance (±0.3mm at 6mm, ±0.5mm at 9mm)
- Very fine sanding dust residue on the panel surface — wipe with a dry cloth before painting
- Colour variation in solid pine pieces within the same pack — lighter and darker pieces are both expected
- Tight, sound knots up to 10mm diameter on the face of pine mouldings
- Resin pockets or amber streaks in pine grain — seal with shellac primer before painting
- Faint planer ridges on PAR pine surface — fill and disappear under paint
- Grain direction variation and subtle surface texture variation in pine
- Minor cut-edge roughness on MDF that disappears under a light sand and primer coat
- V-groove centreline position within ±1.5mm of nominal on Tongue & Groove panels
- Pine moulding length between 995mm and 1000mm on a 1m-specified product
- Cut dimension more than ±1mm outside the stated nominal size (confirmed by measurement)
- Panel visibly out of square — diagonal measurements differ by more than 2mm
- Deep chipping or break-out on cut edges greater than 2mm deep into the face surface
- Surface delamination — the face layer of MDF peeling away from the core
- Visible deep score marks across the panel face caused by the CNC process
- Internal voids or hollow areas in MDF core visible at the cut edge
- Wrong panel size supplied — different from the product description or approved Design Confirmation
- Wrong panel style supplied (e.g. Tongue & Groove delivered instead of Shaker)
- Order delivered short — fewer panels than the quantity stated in the order
- Loose or dead knots in pine mouldings — knots that move, rattle, or show signs of falling out
- Significant physical damage sustained during transit — panels split, badly bent, or deformed on arrival
- Pine moulding length below 995mm on a 1m-specified product
If you are unsure whether what you have received is a defect or normal variation, email us at info@lunaireworks.com with photographs of the panel(s) in question, showing the area of concern against a flat surface with good lighting. We will review your photographs and respond within one business day with a clear decision — it is either a defect we will replace, or we will explain what you are seeing and why it is within normal specification.
Certifications and standards
We are clear about what is certified and what is not, because overstating certification status is misleading. Here is an accurate picture.
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FSC-certified MDF board
The MDF board we use is sourced from suppliers who hold Forest Stewardship Council (FSC) chain of custody certification. FSC certification confirms that the wood fibre used to make the board comes from responsibly managed forests. We can provide supplier certification documentation on request.
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BS EN 622-5:2009 — MDF material standard
Our MDF board is purchased to meet the requirements of BS EN 622-5:2009, the British Standard for MDF fibre boards. This governs material density, moisture resistance, internal bond strength, and formaldehyde emission limits. The board meets this standard at the supplier level; it is not a standard we apply to the cutting process.
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Formaldehyde emission class E1
All MDF board we use is specified to Formaldehyde Emission Class E1 (≤0.124 mg/m³ per EN 717-1). This is the standard required for interior use of MDF in UK and EU buildings. If you require confirmation of emission class for a building regulations submission, contact us and we will obtain the relevant technical datasheet from our board supplier.
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UK REACH compliance — MDF dust hazard awareness
MDF generates fine wood dust when cut or sanded. Fine wood dust is classified as a hazardous substance under COSHH (Control of Substances Hazardous to Health) Regulations 2002. Our workshop operates under appropriate dust extraction controls. If you are cutting or sanding our panels at home during installation, we strongly recommend wearing an FFP2 or FFP3 dust mask and working in a well-ventilated space. Our panels arrive pre-cut; most domestic installations require no further cutting.
What we do not claim
We believe it is as important to be clear about what we do not certify as about what we do. Honest product representation is a core part of how we operate.
- We do not hold an ISO 9001:2015 quality management system certification as a business. Our QC process is internal and workshop-managed.
- Our panels are not fire-rated. Standard MDF is a combustible material. If fire-rated MDF is required for your project (for example, a commercial installation with specific building regulation requirements), please consult your architect or building control officer before ordering.
- The Tongue & Groove panels labelled "moisture-resistant" in product listings refers to an enhanced MDF board grade with improved resistance to moderate humidity — not a waterproof product. They are not suitable for direct water contact or consistently wet environments.
- We do not hold FSC chain of custody certification as a retailer. FSC certification is held at the board supplier level. Our products are manufactured from FSC-certified board, but we are not FSC-certified as a business.
How to report a quality issue
If you believe you have received a panel or moulding that is defective — not simply showing normal variation — follow these steps. The sooner you contact us, the more quickly we can resolve it.
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Step 1 — Photograph the issue clearly
Take clear photographs of the defective panel on a flat, well-lit surface. Include a photograph of the full panel showing where the defect is located, a close-up of the defect itself, and — for dimensional issues — a photograph showing a steel rule or tape measure against the measurement you are querying. Poor-quality photos may delay our assessment.
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Step 2 — Email us within 48 hours of delivery
Contact us at info@lunaireworks.com within 48 hours of receiving your order. Include your order number, your name, a description of the issue, and the photographs from Step 1. The 48-hour window is important for transit damage claims — courier damage must be reported promptly.
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Step 3 — We respond within 1 business day
We will review your photographs and respond in writing within one business day of receiving your report. Our response will either confirm that a replacement will be sent and provide a dispatch timeline, or explain what you are seeing and why it falls within specification. If we determine it is a defect, we cover the replacement cost and collection of the defective item where applicable.
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Step 4 — Do not install panels you believe are defective
If you install a panel that you have already identified as potentially defective, it becomes significantly harder to assess whether the issue existed before installation or was caused during the installation process itself. Keep any panels you are querying aside, uninstalled and flat, until you have received our written confirmation of next steps.
Your statutory rights
Everything in this quality policy works alongside your rights under UK consumer law — it does not replace them.
- Under the Consumer Rights Act 2015, all goods must be of satisfactory quality, as described, and fit for purpose. If a product we supply is defective, you are entitled to a repair, replacement, or refund.
- For faults discovered within the first 30 days of delivery, you may request a full refund rather than a repair or replacement. After 30 days and within six months, we have one opportunity to repair or replace before you are entitled to request a refund.
- Our internal 48-hour reporting window is a practical guideline for efficient handling — it does not override your statutory rights, which remain in force regardless of when you report a fault.
- If you are not satisfied with our response to a quality complaint, you may seek further advice from Citizens Advice or contact the UK Trading Standards service in your local authority area.
Contact us about a quality concern
Our team is in the workshop and available during business hours. Quality enquiries always reach a person — not an automated response queue.
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Email — preferred for quality reports info@lunaireworks.com
Attach photographs of the issue. Responses within 1 business day.
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Registered business address STERZEAL HATS LIMITED, 126 Newark Avenue, Peterborough, PE1 4NP England, United Kingdom
Legal identity
STERZEAL HATS LIMITED
Company No. 13249070
VAT No. GB433989551
EORI No. GB084160128000
info@lunaireworks.com
+44 33 0043 9923
Made in the UK, inspected at every stage, shipped to your door.
Every panel that leaves our Cambridgeshire workshop has been through six quality control stages. If something isn't right, we will fix it.
Lunaire Works is a trading name of STERZEAL HATS LIMITED — Company No. 13249070 — VAT No. GB433989551 — EORI No. GB084160128000
126 Newark Avenue, Peterborough, PE1 4NP England, United Kingdom
Last updated & effective: 25 June 2026
