BallyStone Quartz Manufacturing Process | Quartz Surfaces

 

What is Ballystone and what are its competitive characteristics?

 

CHINA BALLYSTONE QUARTZ MANUFACTURING PROCESS

 

QUARTZ SLAB PRODUCTION

Hundreds of pounds of quartz crystals, resin and pigments are combined to form a single slab of quartz. After careful inspection of all raw materials- 93% of raw quartz, recycled material and 7% of resins and pigments, the compound is blended and mixed into a set mold. Then the quartz mixture enters a special vacuum and elements of vibration and pressure combine to even out the quartz slab on both the top and bottom.

BALLYSTONE QUARTZ COLLECTION

Quartz is the most common mineral on Earth and makes up 12% of the Earth’s crust by volume. Quartz crystals, naturally imbedded in dirt and clay, are washed clean with water then in a weak oxalic acid solution. After the crystals are rewashed with water, they are sorted by quality, color and size.

 

POLISH & INSPECTION

Once the quartz slabs have cured, coarse grits of diamond abrasive pass back and forth over the engineered stone slab. Typically, quartz slabs are only polished on one side; however, BallyStone Surfaces has the ability to polish both sides of the quartz slabs. Once the slabs are done polishing, each slab is inspected for defects and color consistency. Because each slab is carefully inspected, BallyStone Surfaces guarantees the quality of each slab which exits the manufac

SHIPPING

The quartz slabs are then stored on A-frame racks by color and size before shipping. Slabs can ship via flatbed trucks and containers on wooden or metal A-frames. It is most common to ship slabs on wooden A-frames when using a truck and metal A-frames on containers. Regardless, quartz slabs are never transported to the local warehouse, fabricator or consumer’s home flat but rather in an upright position.

INSTALLATION

Quartz offers a consistent pattern, requires no conditioning or polishing, is stain resistant, heat resistant, chip and scratch resistant. After the color and edge profile are selected, quartz slabs can be fabricated into countertops, backsplashes, walls, flooring, and furniture. Once installed, the quartz requires very little maintenance and cleans easily with mild soap and water.

At BallyStone Surfaces we know manufacturing a luxury product requires using a high-end process; therefore, we have invested heavily in our North American facility’s technology to ensure appearances and colors range from those that look like natural products to ones specially designed according to the requirements of architects and interior designers.

China FACILITY

In keeping with BallyStone Surfaces ongoing commitment to environmentally friendly production, the 215,000 sq. ft. state-of-the-art facility in China utilizes the most advanced, environmentally responsible manufacturing process. BallyStone’s presence in Guangdong province China as one of the leading producers of fine quartz surfaces – via its BallyStone Quartz product line.

QUALITY ASSURANCE

At BallyStone Surfaces, our team follows rigorous quality assurance procedures throughout the entire research, development and manufacturing process. Our process begins with a rigorous inspection of all incoming raw materials – color, grade and composition. These are blended at a ratio of up to 93% natural quartz aggregates with pigments and polymer resins. We have quality assurance checks throughout the process and we perform final inspection of slabs before they leave the plant.

The result – the delivery of an unequalled quality product consistent in color, texture and size.

PROCESS & TECHNOLOGY

The manufacturing facility is equipped with the most advanced Breton™ Technology, resulting in the production of the most sophisticated looks or designs of natural quartz, in an array of colors; further distancing itself from its competitors.

The compound stone produced using Breton’s patented plant and technology system has a high concentration of stone aggregates, which is manufactured under vacuum and is perfectly homogeneous in the entire mass. It is composed of stone materials of different nature bonded with organic structural resins.

The unique Breton manufacturing technology allows the combination of outstanding physical and mechanical characteristics with excellent aesthetic appeal. At the time of manufacture, quartz crystals are combined with silica and resin in a vat. The resulting mixture has the look and feel of moist sand. It is dumped into a form, where it is molded into the shape of a thick slab in preparation for entering a vibro-compactor.

It is here the elements of vibration and pressure combine to turn the mixture into a compact slab. The Breton compaction process begins as the loosely molded mixture is conveyed into the unit, which lowers itself onto the slab and begins vibrating and compacting the mixture.

The result is an engineered stone slab that lacks bonding strength. To add that bonding strength it must enter a heat press, which activates and subsequently cures the resin binder. After leaving the press, the slab is stacked vertically on a rack to finish its cure cycle before undergoing the sanding and finishing process.

The polishing line uses consecutively coarser grits of diamond abrasive that pass back and forth over the engineered stone slab as it moves down the line. The polishers are enclosed in large tubs flooded with water to keep the diamond abrasives cool and to flush off sludge. At the end of the polishing line the slabs are inspected for defects and color consistency before being loaded onto A-frame racks for shipment.

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