Equipment
Our state-of-the art equipment helps us
not only in production time, but more importantly it allows us to ensure our
customers the highest quality product EVERY time. Our shop is set up
so that different areas can focus on their specific task at hand.
Process of Production
1. First we have to choose the mold that
will be necessary for the job. We have mold storage racks with casters that
we store all the molds on so that whichever one we might need it is always
easily accessible.
2. Next the molds are moved to the set-up
area where everything is laid out, measured, taped off, and clayed per
custom order. All of the molds are treated and waxed which cuts down on
finish work allowing a faster production and a higher quality finished
product.
3. The molds then go to the spray booth
area where they are inspected again for proper measurement and then sprayed
with gel coat. To ensure even coverage, the base can tilt and rotate 360
degrees. If spray granite is requested, the tip on the spray gun is changed
and a granite/gel coat mixture is sprayed onto the mold. There is a
built-in vacuum/ventilation system so that the overspray doesn’t settle on
the molds in the storage racks and other equipment.
4. It is then guided into the heat tunnel
which drastically reduces the gel coat curing time. As the gel coat cures in
the heat tunnel it is protected from any foreign debris while simultaneously
heating the mold and gelling the top coat so it can be poured on almost
immediately. The heat tunnel is a crucial part of the process that allows us
to continue to produce no matter how hot, cold, or humid it may be outside.
5. After the gel coat is cured the mold is
guided onto a vibrating table where the marble will be poured onto it.
6. The mixing station is set up with all
of the pigment colors, catalyst, fillers, and other ingredients that are
necessary. A scale is used to measure out the exact amount every time so
that the color is always consistent. We then pour the filler in the mixing
pot, weigh the resin, turn the mixer on and add the resin and other
ingredients accordingly.
7. After it is mixed and before it starts
to catalyze, the pot is transported by the mixing cart to the vibrating
tables where it is then hand poured or thrown (depending on the type of vein
you request) onto the molds and vibrated until it covers the entire mold
evenly.
8. After the marble cures and is released
from the mold it is moved to the finish area where it is trimmed down,
ground, and polished to get that high gloss sheen. Our marble is
buffed/ground in the grinding booth which has a high suction
vacuum/ventilation system so that the dust is sucked out immediately and
doesn’t drift out into the shop.
9. After the marble is buffed/ground it is
set on our storage racks. Before it goes out to be installed the entire job
is inspected on a check list to make sure that every piece is present and
the right color, style, and size.
Quality
Control helps you – the customer, and us – the manufacturer, so that in
the end everyone can be proud of the final product!
