1. Process of Granite Manufacturing

Quarry to countertops! Granite is a rock formed below the earth’s surface from slowly cooling magma. After the quarrying process, the stone undergoes a quality check and enters the manufacturing process. This involves several stages that transform raw stone into finished products. After the block selection, the blocks are transported to the manufacturing units for cutting, shaping and finishing. The granites can be further processed based on their intended use.

2. Extraction and Block Selection

Extraction, commonly known as quarrying, is a primary step in the stone process. After obtaining the necessary permits, the extraction process commences. There are techniques to expose the stone blocks. These blocks are carefully selected based on factors like colour and texture. Each block that meets the exact size is inspected for quality specifications. Block selection is important for achieving uniformity in appearance and durability. In addition, the blocks are verified without cracks, fissures and other quality checks before moving to the further process.

3. Block Cutting

Block-cutting is an indispensable step in the process of transforming large granite blocks into usable slabs and tiles for various applications. This is a complex process that calls for precise and specialized tools. These blocks are often rough and asymmetrical in shape, and they can weigh several tons. Marking the appropriate dimensions on the block's surface is the first step in block cutting. To assure precision, this is done using CAD software or template software. Next, diamond-studded saw blades or wire saws are employed to cut the granite along the marked lines. Water is often used to cool the blades and minimise dust. No movement should be there while the process is going on. The cutting process may take several hours, depending on the block's size and complexity. Every 2-3 hours, the machine and the block are re-adjusted to ensure a steady and straight cut for the blocks. Once the block is cut into manageable pieces, it undergoes further processing to refine its shape and finish. To generate high-quality items, block cutting in granite requires both sophisticated technology and great artistry.

4. Slabs Drying and Pre-heating

Before moving further, we make the slabs dry thoroughly and hence with high-pressure hot air, we pre-heat the slab. Drying the slab is the initial step in processing stone for the intended use. This is essential to remove the excess moisture from the slabs. Excess moisture can lead to cracking, warping, or other defects during subsequent processing and usage. Typically, slabs are placed in specialised drying chambers or environments with strict environmental controls so that moisture can gradually evaporate. The stability of the stone is ensured and the possibility of structural flaws is reduced by proper drying. Every slab is processed in preheating for 2 hours. Preheating serves several purposes. It reduces the risk of thermal shock during cutting and shaping, which leads to cracks and fractures. It enhances the ability of the stone, making it easier to cut, shape and polish. Preheating can also improve the adhesion of adhesives or resins used in laminating stone pieces. This controlled heat treatment is done to optimise the stone’s characteristics, making it smoother and more precise.

5. Polishing of Granites

Polishing granite is important to elevate its appearance, and improve durability. It results in a sleek, appealing surface, enhancing the stone’s value and lifespan, and rendering it versatile for diverse uses. Once the manufacturing of tile or large slabs of granite is ready, it should be processed to Rough surface grinding , Smooth surface grinding , Polishing . All these techniques use various grades of abrasive mixtures and polishing heads. Polishing granite during the stone processing involves using specialised equipment like diamond polishing pads and a variable-speed polisher. The process begins with cleaning the granite surface and selecting the appropriate grit pad. Starting with a coarse grit, circular motions are used to remove imperfections, followed by progressively finer grits for a smoother finish. A final buffing pad or polishing compound can be employed for a high-gloss shine.

6. Waterproofing / Sealing

Waterproofing is a technique that extracts the internal moisture from the stone and makes it resistant to atmospheric moisture. Waterproofing/ sealing is an acute step to safeguard the material against moisture, stains and damage. This process involves applying exclusively formulated sealer to the surface of the stone. The liquid penetrates the pores of the stone, creating a protective barrier that fights against oil, water and others. This acts as the layer, that prevents them from seeping into the stone and causing damage. Proper sealing enhances the longevity of the stone.

7. Robotic Handling of Slabs

Robotic handling of slabs in the stone processing industry revolutionises efficiency and safety. Robotic systems equipped with skilled grippers can accurately move heavy stone slabs, minimising the risk of errors and injuries. These robots can precisely position slabs for all activities including cutting, polishing and other activities. All handling actions of slabs are carried out by robotic slab machines with robotic vacuum cups. This replaces manual effort, saves time, and avoids any possible damages and accidents. Advanced sensors and software enable robots to adapt to various slab sizes and shapes. Additionally, robots can work continuously, enhancing production rates and reducing labour costs. Overall, robotic handling of stone slabs streamlines operations, enhances productivity, and improves workplace safety in the stone processing industry.

8. Ensuring the Look

Stunning visual appeal Ensuring the demanded look in the stone process involves attention to detail and several key factors. Precise cutting and shaping techniques are crucial to achieving the desired dimensions and design. Additionally, expert craftsmanship in polishing, honing, or texturing the stone's surface is vital for the desired appearance.

9. Quality Inspection of Final Product

Quality in every piece!
Quality is the maximum requirement of the customer. Ensuring the high quality is every tile is our motto. In this case, quality inspection is the influential element during the stone process. The key factors that should be noted during the stone process are

• 1.Visual appeal
• 2.Dimensional accuracy
• 3.Edge quality
• 3.Surface finish
• 3.Durability

10. Stone Finishes

Stone finishing is the final and indispensable step in stone processing. This is the process of transforming the raw honed stone into an exquisite surface. It is done to expose the stone’s unique beauty while improving the smooth and long-lasting finish. There are many types of stone finishes.

Polished:
For a smooth and glossy finish, polishing is a good choice, it involves the use of abrasive materials and a machine to refine the stone’s appearance and texture. In the beginning, coarse abrasives are employed to remove imperfections and irregularities followed by progressively finer abrasives to achieve a smooth finish. This can look nice against the other styles.

Honed:
Honed finish refers to the specific texture derived by grinding and smoothing the stone’s surface. To obtain a matte or satin appearance honed finish is used. The look of the honed finish is also described as velvety. In the Honed finish, the colour of the granite is more muted and less formal. A honed finish is less prone to scratches than a polished surface.

Flamed:
Flamed or thermal finish is done to unleash the new possible designs. It is a unique treatment, a high-flamed temperature is applied directly to the surface of the stone. An acetylene torch’s white-hot flame is used to repair the granite’s surface. The roughness effectively increases the resilient property of the stone. The finish is characterised by a non-reflective, uneven, and antique appearance.

Brushed:
Stone processing with a brushed finish is a surface treatment technique used to modify the appearance and texture. In this method, the brushes and tools are used to create a textured, slightly worn, and tactile surface of the stone. The brushing removes the softer parts and it leaves a textured finish that retains the colour and character.

Leathering:
A leathered finish is a surface treatment used to enhance the texture and appearance of the stone. To create a texture that resembles the grain of leather, various brushes and tools are used. When the texturising is completed, finer abrasives are used to soften the newly textured stone. The result is a matte, slightly textured, and undulating surface with a soft sheen. Leather finishes are the popular choice because of their uniqueness.

Sandblast Finish:
Sandblast finish is a technique that alters a stone with abrasive materials such as sand or aluminium oxide, which are propelled at high velocity onto the stone surface using compressed air or water to create a textured look. This action produces a uniform surface, that is rough and weathered.

Antique Finish:
It is a meticulous technique that imparts an aged appearance to natural stone surfaces. This finish can be achieved through a combination of treatment and craftsmanship to replicate the characteristics of centuries-old work. Distressing the stone’s surface to create a worn, textured effect that renders the irregular edges and subtle colour variations. In the antique finish, the rustic aesthetics add charm and character to the surface of the stone.

Lapatto Finish :
Lappatto finish is a specialised stone processing technique that brings a distinctive semi-polished appearance. This finish is achieved with the fusion of polishing and honing. Initially, the stone surface is ground to a matte or honed finish, removing imperfections. Then a series of progressively finer abrasives are employed to attain a semi-gloss texture. This finish provides a combination of the elegance of a polished surface and the practicality of a matte one.