How is Sintered Stone Made?

Manufacturing Process of Sintered Stone

The production of sintered stone involves a highly specialized and precise manufacturing process. The key stages include the preparation of raw materials, pressing, sintering, and finishing.

Here is a detailed overview of the entire process of making beautiful and durable sintered stone countertops:

1. Preparation of Raw Materials

The primary materials used in the creation of sintered stone are natural minerals like quartz, feldspar, clays, and oxides, mixed with recycled materials.

These raw materials are carefully selected to ensure the desired characteristics of the final product, such as color, texture, and durability. The materials are ground into fine powders and blended in specific ratios to form a homogeneous mixture.

2. Molding and Compression

Once the raw materials are mixed, the material is molded into large slabs or panels. This is typically done using advanced hydraulic presses, where the mixture is compacted at high pressure to ensure that it forms a uniform and dense structure. The compression stage also helps eliminate any air pockets, ensuring that the final product is strong and consistent.

3. Sintering (Firing)

The pressed slabs are then subjected to an intense heating process known as sintering. During sintering, the slabs are heated to temperatures ranging between 1200°C to 1300°C (2200°F to 2400°F). This heat causes the raw materials to bond at a molecular level, creating a non-porous, extremely hard surface.

The sintering process also contributes to the material’s resistance to environmental factors like UV light, temperature fluctuations, and moisture.

4. Cooling and Cutting

After sintering, the slabs are slowly cooled down to prevent thermal shock that could cause cracking. Once they reach room temperature, the slabs are cut into the desired dimensions using diamond blades or water jets. The cutting process ensures that the sintered stone can be easily customized to meet the specific requirements of any project, from small countertops to large facade panels.

5. Finishing

To achieve the desired finish, the surface of sintered stone is polished or textured. Various finishing techniques can be employed, including polishing for a glossy look, honing for a matte finish, or applying a textured surface for added grip and aesthetics. The final product is then thoroughly inspected for quality to ensure it meets the industry standards.