The quartz stone manufacturing process begins with the selection of raw quartz materials. Since many years, natural stones such as granite and marble have always been used widely at both residential and commercial buildings for kitchens bathrooms, counters etc.
What are the disadvantages of using Natural stone?
- They are less smooth as compare to quartz stone.
- Natural stones are susceptible to stains faster than raw material for man-made stone production
- Sometimes with passage of time the natural features that appear as cracks
- Insufficient elasticity.
- Difficult to have length precision, since they are not seamless.
Though natural stones have been used for ages for their strength, durability and other such characteristics but now quartz stone provides much better alternative to these stones as they are much stronger and does not have disadvantages like natural stones.
In the last decade, the consumption of quartz countertops have increased globally. This is due to the many advantages in terms of quality, price and increased efficiency in its manufacturing Process.
The manufacturing process of quartz stone begins with selection of quality raw material for quartz stone production. These raw materials are finely selected, hereafter 90 % quartz aggregates and 10% polyester resin and other additives are crushed and blended.
Using a vacuum and vibration process the mixture is compacted into slabs.
What is the most common mineral found on the surface of Earth?
Quartz is considered to be one the most common mineral found in the earth’s surface using extreme pressure, it is a kind of mineral that can be easily processed into crystals.
Since its uses a chemical compound which consists of one-part silicon and two parts of oxygen, thus its unique properties make it very useful mineral among the rest.
Since the minerals comes in many colors and varieties and found in abundant in metamorphic, sedimentary and igneous rocks, It is also known well for its high resistance chemical and mechanical weathering properties.
It is also highly resistant to heat and due to its numerous colors and luster the quartz minerals are ideal for quartz stone making and even glass making industry.
What is Engineered or Artificial Quartz Stone?
Artificial Quartz Stone also known as engineered quartz stone are commonly available in different styles, colors and patterns. Also owing to its properties they can be easily assembled as per custom requirement and need.
Unlike granite, quartz naturally exists in clusters and itself does not form any stone blocks like granite. Although many people want to add quartz to their kitchen interiors, but the natural slate of quartz are unsuitable for countertops and need to be processed for slab applications.
To make quartz suitable for proper slab applications it can be easily converted into other forms; likely engineered stones.
Engineered quartz are also known as re-composed or reconstituted stone. These highly durable stone is achieved whilst through the manufacturing process which involves a mixture of quartz aggregated chips or pigments along with additives and resin binders.
These engineered quartz stone for slabs and countertops applications comes in abundant colors, textures and patterns. The texture can be coarse or fine, depending on the manufacturing process. Later it can be easily combined with glass or other reflective materials to get the sparkling finish and glow.
Moreover, when quartz’s being a non-porous in nature is combined with granite for durability, one can achieve a very high-end and robust applications.
Manufacturing of Raw Quartz
Due to its usefulness and essential properties, quartz is among the top B2B products being extracted and processed to be supplied locally and exported. As part of the manufacturing process, this mineral will undergo the extraction process up to the actual manufacturing processing.
1) Extraction Of Quartz
Quartz is usually extracted through open-pit mining while sometimes and very rarely exposing the deep seam of the mineral the miners use explosives.
Mining operations are carried out using of backhoes and bulldozers so the miners can effectively get rid of clay and soil surrounding the mineral. Once the crystal veins of quartz are exposed in the rock, the workers picks and chisels and uses different hand tools for extracting the quartz.
2) Processing Of Quartz
After the extraction process quartz need careful extensive cleaning. The cleaning would extract all the chemical impurities and visible flaws. Once thoroughly cleaned, the team does the screening of quartz. Later it is crushed into different sizes as per the need and usage.
The crushing process of quartz is done with a crusher while a vibrating screen is used to separate it.
Next a ball milling is used to ground the quartz. Lastly, the mineral is classified into varying sizes. Similarly, a grinder mill is used for crushing the lumpy quartz to produce a fine quartz powder.
How Quartz Stone manufacturing process works in steps;
1) Raw Material
Selection of raw material is important when it comes to the manufacturing process of engineered quartz stone, the process begins with the quartz produced; it could be any of the quartz products; quartz sand or quartz granules.
2) Blending
After the selection of raw quartz, it is then is crushed and blended under a ratio of 93% quartz aggregates to remaining 7% resin binder along with other premium additives.
3) Pressing of Slabs
After the blending process, the slabs are formed. Using the vacuum and vibration method and pressure about 100 seconds at 100 tons pressure, the blended mixture is compacted to form the slabs. Using such process decreases water absorption and can minimize porosity.
4) Heating Process
After completion of slab processing, these slabs needs extensive heating normally called curing process. A kiln at 85 degrees for about half an hour is being used to ensure the slabs attains all the necessary properties for stain and impact resistance.
Sometimes steam or oven are used to accelarte the curing process. Now the produced slabs undergoes gauging and calibrating process. Lastly sent for polishing and finally they are ready to be delivered for cooling.
5) Cooling and Trimming
After successful curing process, these slabs are held upright using clamp and cooled for 24-36 hours. Now the edges of the slabs are properly trimmed and leveled to perfection.
6) Quality Assurance
With the help of the engineered quartz manufacturing process, there will be consistency and uniformity in the shade and dimension. As a result, it saves time during the construction process. Although the engineered version resembles the natural stone’s patterns, it offers a more consistent color, pattern, and texture, and uniform appearance.
Besides, since they are man-made, they can be easily fabricated in large sizes, which can result in better aesthetics along with fewer joints.
The Extraction and Processing of Quartz
1. Quartz Extraction
Quartz is primarily extracted via open-pit mining. Bulldozers and backhoes remove surrounding soil and clay, exposing crystal veins. Hand tools like chisels are used to extract the quartz with precision.
2. Quartz Processing
After extraction, the quartz is cleaned to remove impurities. It is then crushed, screened, and ground into varying sizes using crushers and milling equipment. Fine quartz powder is produced through grinder mills, ready for manufacturing applications.
Applications of Quartz and Engineered Stone
Quartz’s versatility makes it a top choice for a variety of applications:
- Countertops: Durable and stylish, quartz countertops are ideal for kitchens and bathrooms.
- Interior Design: Quartz is used for sinks, walls, and flooring.
- Jewelry: Its vibrant colors and clarity make it popular in accessories.
- Glass Manufacturing: Quartz is a key component in high-quality glass production.
Conclusion
The mining and manufacturing process of quartz is progressing very fast due to its numerous properties and reliable features.
Its beauty is undeniable and also quartz is very flexible to be applied in many different applications. From home and commercial interiors to different pieces of jewelry and many other artistic applications, quartz has high-end use and many separate benefits in terms of production and price. Thus, quartz is for all!
At BSG Glass Chips, our unit is well equipped with state of the art machineries in which the materials are provided in required quantity.
They are polished, cut to size or shaped to any dimension, size and finish. This unit can undertake bulk orders in un-comparable time & superior quality.
Whether you are creating a cutting edge kitchen or traditional bathroom, need fabulous stone for a sink, wall or work surface whatever the job, we can design, create, polish and fit to your exact specification.
