Publix stores and some offices feature custom-made woodwork built in our cabinet shops, where skilled associates prepare each piece with care. Go behind the scenes at our Lakeland, Florida, cabinet shop to discover how pre-laminated panels of plywood are crafted into shadow boxes. These display cases are used to merchandise and showcase items like ice cream cones and toppings.
Step 1: Planning the build
The 1st step in creating a shadow box is taking measurements. The planning team makes a list of the exact dimensions needed for each piece.
Step 2: Cutting the wood
Next, beam saw operators cut full sheets of three-fourthsinch domestic poplar plywood finished in Portico Teak laminate. This laminate has cool silver and brown tones with dark streaks and is commonly used in cabinetmaking.
“My job is to accurately, efficiently and safely cut specific parts from full-size sheets,” Production Cabinet Maker Ryan Smith Sr. said.
Ryan enters the measurements into the computer, completes each cut and places the cut boards on a cart for transfer to the edge bander.
Step 3: Edge banding
At the edge bander, 2 associates tag team to cover the raw edges with a 3-millimeter protective band. Together, Production Cabinet Makers Preston Gay and Moises Serrano guide the boards through the machine, ensuring each edge looks smooth and professional.
“We add the edge band to help prevent moisture from building up, which can cause the board to swell. It also protects our customers and associates from getting cut on the raw edge,” Preston said.
“To secure the edge banding to the raw ends of the wood, we add an adhesive to the edge banding machine,” Moises said.
The adhesive comes in the form of small rubber pellets that are melted in the machine before being added to the edge band.
As the board passes through the machine, the edges are cleaned and rounded, and the ends are snipped to prepare for the adhesive. Buffer wheels then clear away any debris that has collected on the edges, and the adhesive is applied to secure the edge band to the raw ends of the wood.
Step 4: Assembling the shadow box
Next, the pieces are moved to the assembly station.
“I’m responsible for building the shadow box,” said Production Cabinet Maker Bill Eckenrode. “I drill the holes into the boards and add the tag molding and shelf pins.”
Lastly, Bill performs quality control by checking the shadow box for any damage and making sure all of the building specifications are accurate.
Step 5: Packing and shipping
The assembled shadow box is then shrink-wrapped and stored in the warehouse until the production inventory coordinator arranges for shipment to its final destination: your local Publix.
About our cabinet shops
Publix has cabinet shops in 3 Florida locations (Jacksonville, Lakeland and Miami). These shops combined have 49 associates who produce nearly 50,000 custom-built projects each year for our stores and some offices.
