Method for manufacturing a floor or wall panel

A method for making a floor or wall panel comprising a foamed polymer core, said method comprising providing a double belt press comprising two conveyor belts defined by an upper conveyor belt and a lower conveyor belt, the upper and lower conveyor belts being formed from polymeric material, the upper and lower conveyor belts forming a product gap therebetween;

• the method further comprising a steel belt press defining a forming zone by an opening formed between an upper steel belt and a lower steel belt;
• wherein the upper and lower conveyor belts extend between said upper and lower steel belts with said product gap formed in between;
• wherein at least two layers of the polymer powder comprising at least one layer of foamable polymer powder are provided on the lower conveyor belt, wherein said at least one layer of foamable polymer powder is foamed at least partially into a substrate between the upper and lower conveyor belts of the double belt press in the forming zone of the steel belt press, wherein a sum of thicknesses of the two conveyor belts and a total thickness of the layers at an entrance of the steel belt press is less than or equal to the opening of the steel belt press at the entrance of the steel belt press, and wherein the sum of the thicknesses of the upper and lower conveyor belts and the total thickness of the substrate formed at an outlet of the steel belt press
• is equal to the opening of the steel belt press at the outlet of the steel belt press and
• is greater than the sum of the thicknesses of the upper and lower conveyor belts and the total thickness of the layers at the entrance of the steel belt press.