How Are Solid Surface Kitchen Worktops Made?

Did you know that solid surface kitchen worktops are made with nearly 75% natural material? The addition of synthetic polymer and additives, such as pigments, makes up the remaining part. Mixing natural alumina trihydrate (ATH) in the form of a powder with polymer polymethyl methacrylate (PMMA) and allowing the mixture to cool results in a solid surface material. The material exhibits strength, durability, and long-lasting properties.

The solid surface kitchen worktops are all the rage in the modern era. But have you ever wondered how it's made? This article aims to take you through the manufacturing process of solid surface kitchen worktops step by step. It will elaborate on the process, material, and quality control applied to each step, which leads to the creation of the non-porous and premium finish material.

What Are Solid Surface Kitchen Worktops?

The solid surface kitchen worktops are made with a mixture of PMMA 66% - 70% by weight and ATH 30% - 33% by weight. The other ingredients added are pigments, catalysts, initiators, and stabilizers. The pigments give them a marble-like texture or color, similar to granite. Moreover, the catalysts and initiators ensure that the mixture cures properly, while the UV stabilizers make the material resistant to degradation by sunlight.

Kitchen worktops can be constructed using different kinds of materials. So what makes solid surface the ideal choice? Let's compare:

• Quartz: Quartz is a tough material, but it doesn't join seamlessly. On the other hand, a solid surface is more flexible and allows seamless joints, which are otherwise not possible with the quartz surface.
• Granite: Granite has excellent toughness. However, its porous nature can cause staining. In comparison, the solid surface material is non-porous and can be repaired easily through simply buffing and polishing.
• Laminate: A laminate surface is susceptible to heat and can instantly melt and deform. A solid surface has high resistance to heat. In case of direct contact with a hot object heated to 212°F, it can be damaged.

The Manufacturing Process of Solid Surface Sheets

Step 1: Material Selection

The first step is the material selection. The quality of the raw material determines the final product quality. As we already know, the raw materials are mainly ATH and PMMA. The top-tier supplier for the aluminum powder with 99.9% purity is Chinalco/Chalco. For vibrant designs, LR® color paste is the most preferred.

Not using the quartz or silica-based filler leads to zero silica product, which makes the sheets safe for human health during processes like cutting, grinding, and sanding. It takes incredible research and testing to find reliable suppliers.

Step 2: Mixing and Preparation

After we have the raw materials, the process of mixing starts. The primary component, ATH, in the form of a powder, is mixed with the liquid acrylic material (PMMA). At this stage, pigments are added for the base color of the kitchen's solid surface worktops. Any chips, objects, and catalysts to homogenously mix all over the solid surface are added. The whole process of mixing is performed under vacuum. It allows any air or gases to escape the mixture during the process. At this point, quality control may take a sample to check for the consistency of the liquid.

Step 3: Casting Inside a Mold

The mixture is then poured into a mold. The mold restricts the emulsion from spreading out and remains within the defined section. These flat rectangular mold sections are where the emulsion turns solid in the form of sheets. A slight vibration is applied to the mold to allow air bubbles to escape. There are multiple ways to form a mold. It could be plastic sheets or ropes on a conveyor.

Step 4: Curing and Solidification

After there is enough confidence that the emulsion has settled inside the mold and all air is removed, the curing process can begin. The mixture of PMMA resin and the catalyst is an exothermic reaction.

• Initial Curing: The temperature needs to be controlled at 17°C to 25°C for the mixture to harden at the right pace.
• Post Curing: It is the most critical step in solid surface kitchen worktop manufacturing. Here, heat is applied to the hardened mixture. After the material is removed from the mold, it is heated from 60°C to over 100°C. It may be held at this temperature for a significant time, typically 2 to 24 hours, depending on the sheet thickness. At this step, the material attains its full mechanical properties, surface hardness, and heat resistance.

Step 5: Demolding and Initial Inspection

After the demolding and post-curing, the process of initial inspection starts. A quality control inspector may look for cracks or an uneven surface to rule out defective pieces. There is usually zero tolerance for cracks and bubbles. The dimensions are measured to ensure that the later processes will machine the rough, solid surface kitchen worktop into the correct dimensions. If there are any corrections or changes needed, they are well documented at this stage.

Step 6: Trimming and Sanding

After the solid surface piece passes the initial inspection process, specialized tools start to trim away the edges. The trimming process brings the uneven edges to square edges that form a slab. It is a process of removing flash or excess material. These are usually CNC machines that ensure a precise cut for an exact slab or sheet-like shape. High-end and premium category brands like KingKonree (KKR) use infrared bridge cutting, water-jet, CNC, and 45° cutting for ultimate precision.

To further ensure that the material has a homogeneous thickness, the surface is progressively sanded using abrasive disks or sandpaper. The abrasive numbers could start from 120, 180, 220, and go up to around 500-800. At the end of the sanding process, the solid surface kitchen worktop will have a rough surface or matte finish.

Step 7: Finishing and Polishing

After the sanding process, the finishing process starts. High-end brands like KKR use 3M Perfect-It polishing compounds to remove the microscopic scratches. Typically, polishing compounds contain extremely fine, suspended abrasive particles. These mimic the 1000-grit or 8000-grit sandpaper. The process is only applied if a glossy mirror-like finish is desired. In the end, any residue of the compound is cleaned.

Note: Sanding is essential, while polishing is optional depending on the surface finish requirement.

Step 8: Quality Assurance and Testing

After the sanding and polishing, the solid surface kitchen worktop is complete and ready to ship. However, it needs a final visual inspection to look for defects. A sample set from the final material would undergo:

• Scratch test
• Heat Resistance Test
• Visual Inspection
• Dimensional Accuracy Test
• Chemical Test (Toxicity)

Fabrication of Solid Surface Kitchen Worktops

After the manufacturing process is complete, the solid surface kitchen worktops are ready to be transported to the consumer's location. That is where skilled labor will convert the plain slabs into worktops.

The process starts with taking measurements of the kitchen worktop requirements. Typically, an L-shaped counter is preferred. However, there can also be a kitchen island. The measurement should accommodate overhangs from the cabinets. Try creating a template before actually cutting the solid surface kitchen worktop material. Ensure that the seams are away from sinks and corners. Moreover, take into account any expansion of the material in case of heating.

For edges, cut the sheets into strips that run along underneath the side of the kitchen worktop. Join the strips to the edge using adhesive, and then use precision tools to create shapes out of the edges. It can be a bullnose or a bevel design.

The solid surface kitchen worktop would need a sink hole and other similar features integrated into the material. The backsplash needs to be cut precisely with the same height along the edge between the wall and the solid surface top.

Final Quality Control

Before starting the fabrication process, it's vital to ensure that the solid surface kitchen worktop slabs have the proper certifications. These ensure that the material is safe, high quality, and complies with the regulations:

• CE — Conformité Européenne
• Prop 65 — California Proposition 65
• CSA — Canadian Standards Association
• UL — Underwriters Laboratories
• cUPC — Canadian/Uniform Plumbing Code
• SGS — Société Générale de Surveillance

Conclusion

Overall, the manufacturing process of solid surface kitchen worktops requires years of experience and strict quality control. The aesthetic appeal and dimensional integrity of the final product depend on each step of the manufacturing process. From raw material selection, proper mixing, casting, curing, to demolding, trimming, sanding, and finishing, all require attention to detail and quality control. Following these steps leads to an ideal product for use in the kitchen. It's resistant, non-toxic, eco-friendly, repairable, seamless, and luxurious in aesthetics.

Consider going for a reputable manufacturer like KingKonree (KKR) that uses only the highest grade raw material and utilizes the best techniques to form solid surface kitchen worktops.

Frequently Asked Questions (FAQs)

• How are solid surface kitchen worktops manufactured?

The manufacturing process of solid surface kitchen worktops starts with the selection of raw materials, which include ATH, PMMA, catalysts, pigments, and stabilizers. They are mixed into an emulsion, spread on a mold, allowed to cure, demolded, trimmed, sanded, and then polished into final form.

• What are solid surface kitchen countertops made of?

The solid surface kitchen worktops are made using two primary components, ATH and PMMA. These are blended together along with catalyst, stabilizers, and pigments to produce the non-porous, fire-retardant, UV-stable, and low-maintenance surface.

• How long does the manufacturing process take?

It typically requires several hours to create a single slab. However, the process is continuous, and slabs come off the production line without the need for a break. The main time is taken during the curing process, which takes around 6 hours.