Floor plank modification system

A composite flooring plank modification apparatus comprising:

• an automatic loader having a plurality of pneumatic suction cups constructed and arranged to hold a composite flooring plank workpiece;
• a motorized heating station coupled to said workpiece loader having an upper heat source and a lower heat source and motorized rollers to heat a portion of said workpiece to at least 90 degrees Centigrade;
• a rotary positive and negative embossing station coupled to said motorized heating station having a plurality of rollers to exert pressure onto said workpiece to form said workpiece into a desired shape;
• a motorized cooling station for receipt of said workpiece comprising a system of upper rollers and lower rollers with at least one fan to cool said workpiece, said upper rollers are adjustable and free spinning and said lower rollers are driven by a motor to transfer said workpiece at a required rate to maintain said workpiece in the desired shape;
• a first unloading station having carrier rollers and a plurality of alignment supports constructed and arranged to move and position each said workpiece from said motorized cooling station and combine like workpieces together into a single nested workpiece, wherein said nested workpiece are grouped in a position to be stacked on a pallet;
• a second unloading station having a conveyor belt with a plurality of vertical rollers positioned perpendicular to and disposed along said conveyor belt defining slots therebetween, said conveyor belt disposed between said first unloading station and said pallet;
• wherein said automatic plank loader, said motorized heat station, said rotary positive and negative embossing station, said motorized cooling station, said first unloading station and said second unloading station are interconnected to fold said workpieces into stair noses and other trim elements.