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Back in the early 90's when I first began training, Solid Surface was becoming the latest craze in countertop materials so I included Solid Surface in the training program. Even though solid surface has been around for many years I still get questions from individuals who are interested in establishing a cultured marble factory who who are not clear of the differences between cultured marble and solid surface products.
If you are planning on establishing a new cultured marble factory, you may be debating on whether to also manufacture solid surface densified material. I'm hoping this article can explain the differences between Solid Surface and Cultured Marble, to both the end users as well as potential manufacturers. This will explain their applications and what is required to produce each.
Solid surface was initially used for kitchen counter tops but now it is commonly used for commercial installations such as hotel guest rooms, hotel lobbies, fast food counters, hospital counters, restaurant tables, public restrooms, etc., so there is certainly a huge market for it. Solid Surface has become a popular choice because the product looks great, is very durable, available in a large variety of solid and granite colors, and is easy to maintanin. When someone mentions Solid Surface most people think of Corian, Avonite, or Fountainhead to name a few of the first competitors in the industry, but with the addition of some flat molds and some equipment, you can produce solid surface as well.
Cultured marble is a mixture of polyester resin and crushed limestone. This ‘matrix' mixture is poured over molds (forms) that have been sprayed with a clear gel coat. This clear gel coat is what seals the cultured marble product and gives it, its the stain resistant qualities. For example, to make a shower pan (shower tray), you would wax and spray gel coat on the shower pan mold and pour your matrix mix into the mold. It is the mold which gives your cultured marble (or onyx or granite) the shape of the product. The same process is applied to manufacturing bathtubs, wall paneling, vanity tops, pedestal sinks, window sills, trim moldings, etc. Simply put, the mold is what produces the shape and size of your products, and the gel coat is what gives your products the protection from any stains that may otherwise penetrate a stone product.
Solid surface requires a different formula and technique. Unlike Cultured Marble, Solid surface is generally poured in flat sheets and ‘fabricated' (cut, seamed together, routed) to fit each particular project. A solid surface fabricator will work with Solid Surface similar to how they would work with a piece of wood, cutting the flat solid surface sheets, seaming them together, and routing various styles of edges on them. These are qualities you would not have in your cultured marble products, which are made out of crushed limestone or marble dust and simply poured into the molds. One can be very creative using Solid Surface but would require ‘fabrication' skills. Fabricating the solid surface requires fewer molds, but would require more small hand tools and installation skills than installing cultured marble products.
Solid Surface does not require gel coat since the stain resistant qualities are in the matrix mix formula. Also, gel coat would not allow you to bond them together and achieve an indistinguishable seam or allow the customer to sand it to achieve a new finish. The hardness of your Solid Surface will be enhanced by post curing your Solid Surface products in a post curing oven.
Since you will be cutting the solid surface during fabrication, you will want a truly ‘dense' part with no air bubbles in your solid surface sheets. A vacuum blender would be required to remove these air bubbles from the matrix mix prior to pouring the matrix on the mold. It does not matter that there are air bubbles inside your cultured marble products since you will be producing made-to-fit items on molds that will not require cutting, seaming, and routing.
The 36" (these come in various widths) belt sander should be used to sand your flat Solid Surface sheets to a uniform thickness. This is crucial when you are fabricating your solid surface products.
Facts: Cultured Marble: (1) Cultured Marble does not require a special vacuum blender. A standard matrix blender is sufficient.
(2) Cultured Marble does not require any post curing equipment. (3) Cultured Marble does not require the 36" belt sander which is required for Solid Surface. (4) Crushed limestone to produce cultured marble is are going to be available almost anywhere in the worldwide, whereas the raw materials to produce solid surface may not be as readily available in some areas, making less competitive.
(5) Cultured Marble does requires more molds since you will be ‘forming' a wide variety of cultured marble, onyx, and granite products. If your customer requires a 36" X 72" Bathtub, you will require a 36" X 72" Bathtub Mold. If they require a 42" X 42" Shower Pan, you will require a 42" X 42" Shower Pan mold, etc.
(6) Cultured Marble is more simple to deliver to your customer since most of the work is done by the molds. You pour your matrix in the molds, let it cure, sand around the edges, buff it if required, and it is ready to send to market. No additional fabrication is required.
Fact: Solid Surface: (1) Solid Surface is more versatile in that you can ‘fabricate' many creative counter tops from the flat sheets you produce. You are not limited to only manufacturing items in the shape of a particular mold.
(2) Solid Surface requires more expensive raw materials which may not be available in some places. (3) Solid Surface requires more equipment: vacuum blender, post curing ovens, large belt sander. (4) Solid Surface requires more installation tools and fabrication skills.
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