Solid surface production and machinery
Solid surface production and machinery must ensure correct mixing and degassing of the raw materials. You must remember that EN ISO 19712:2003 European standard defines solid surface as a pigmented and uniform mass throughout its thickness without pores on its surface. Depending on the size of our project and the type of product profile to be manufactured (bathtubs, shower trays, wash basins, etc…), you will choose the most suitable machinery for your project. Based on the extensive experience and know-how acquired in projects related to the production of solid surfaces, AITANA CHEMICALS has developed specific production lines for this type of technology.
If you are thinking of starting a project to manufacture this type of composites, you will find below everything you need to know about solid surface production and machinery.
Solid surface production process
Solid surface manufacturing requires a very clean working environment and a constant temperature according to our formulation. A perfectly clean work environment is a basic requirement. Any polluting particle can be added to the mixture and contaminate the finished product surface.
The process of producing solid surface consists of the following phases:
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- addition of basic raw materials (resin, mineral fillers, pigment pastes and if any additives) for subsequent mixing in the chosen agitation system. It is advisable that the stirring speed is adjustable to ensure a good dispersion of the mixture. This way we will achieve a homogeneous and perfectly pigmented mass.
- degasification of the pigmented mixture. In this way, we will avoid the appearance of pores on the finished product surface.
- Proceed to fill the mould with the degassed mixture using the chosen injection system. It is recommended to add the catalyst just before the injection of the mixture into the mould. The mould will be clean and treated previously with the appropriate release agent.
- after curing the parts will be demoulded
- to avoid further tensions in the solid surface parts, it is advisable to make a proper post-curing process.
- at the end, surface finishing works and packing the manufactured pieces will be carried out.
Much of the success in achieving a high quality solid surface part is in the control of the catalyzing process. We will never allow the catalyst to begin before the complete filling of the mould.
Solid surface production machinery
Depending on our production forecasts and the type of product to be manufactured (bathtubs, shower trays, wash basins, etc…), we will have to choose the most suitable machinery for our project. Basically, we can differentiate between two types of machinery for the production of solid surface:
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- continuous production lines. They are designed to manufacture large quantities of a certain type of product. On the one hand, their high cost means that their amortisation only makes sense in the case of large productions. On the other hand, they are designed for the production of large series of the same product. Most of the production process is automated, which allows for a considerable reduction in the amount of manpower required.
- flexible production lines. Although they do not achieve the large quantities that ensure the continuous production lines, their big advantage is that they allow us to change quickly the productive profile. They are especially indicated for companies:
- that want to get into solid surface
- with medium-sized productions
- with a wide variety of product that require quick changes in production
Customized production line control panel
AITANA CHEMICALS - solid surface manufacture
AITANA CHEMICALS is a company specialised in the technical assistance and supply of raw materials for the manufacture of solid surface products. Building on our close collaboration with our strategic partners over recent years, we offer a business model combining ‘supply, support and R&D’. We supply and assist companies all over the world that are developing or want to start a solid surface manufacturing project or other similar polymeric root composite materials.
Conclusion
The dimension of our solid surface project will determine very much the machinery to choose. In most cases, flexible production lines are the best option. This is especially true for new companies that want to start a solid surface project and do not know exactly what their target market will be. This kind of production lines allow adjusting both the amounts to manufacture and quickly change the product profile. Regarding solid surface production process, much of the success in achieving a high quality product is in the control of the catalysing process while keeping the working temperature stable.
Thanks to the close collaboration with our strategic partners we can offer our clients advice and technical assistance for the implementation and development of SOLID SURFACE and COMPOSITES projects. AITANA CHEMICALS has participated in numerous projects of this type. If you have any specific needs in this field, please do not hesitate to contact us.
If you are interested in knowing all about solid surface, we recommend you read our extensive article dedicated to this topic.