TECHNOLOGIES
How Agglomerate Slabs Are Made
Manufacturing Process and Technology
The production process involves mixing selected aggregates (quartz, marble, and minerals) of varying particle sizes—ranging from powder to gravel of approximately 5–6 mm—along with organic pigments and a structural polyester resin (comprising about 7% of the mixture).
The latter not only serves as a binder but is also a key engineering component of the material: in the finished product, it enables optimal values of flexural strength, impact resistance, and energy absorption, and, more generally, allows the composite to be formulated with physical properties and mechanical performance superior to those of the natural source material.
The polyester resin, which contains 21% plant-based bio-component, is heat-cured and, through a computerized industrial process of high-pressure vacuum vibro-compression, allows for the compaction of large-format sheets (120×120 cm and 140×305 cm) in various thicknesses (1 / 1.2 / 2 / 3 cm).
This technology makes it possible to tailor the product to meet a variety of application needs—from wall coverings to furniture to countertops—ensuring structural uniformity, dimensional stability, and long-term reliability.
The production cycle also employs single-slab compaction, overcoming the technical and economic limitations of block sawing typical of natural stone, with benefits in terms of both consistent quality and resource optimization.
The mixture is first blended and homogenized using computerized control units that ensure precise control over the dosing and distribution of the components. It is then dispensed—according to the required thicknesses—between two sheets of paper onto a conveyor belt, which transports the material, while still malleable, to the slab-pressing stage.
Curing takes place in the catalytic chamber, which consists of a multi-story heated tower maintained at a temperature of 80–85 °C, capable of bringing the mixture to complete solidification within approximately 30–40 minutes—roughly half the total time of the entire production cycle for a single sheet. This process ensures controlled polymerization, which is essential for achieving the material’s stability, strength, and durability.
The slabs produced in this way are then subjected to finishing operations, which include grinding the two main faces, sizing, polishing, cutting, beveling, and any edge processing required based on their specific intended use.
Once finished, Stone Italiana slabs can also be supplied in large quantities while maintaining controlled and certified characteristics: consistent weight, thickness, density, and uniformity of pattern and color tone on the visible surface. This allows designers and contractors to work with a reliable, reproducible material that integrates seamlessly into even the most complex architectural and interior design projects.