Sintered Stone Production Process
A technical breakdown of the 9-step vitrification process.
Raw Material Selection
Sintered stone is composed of 100% inorganic minerals (Quartz, Feldspar, Silica). We perform **XRF Spectroscopy** on every raw batch to ensure 99.9% purity. Unlike quartz, this material contains **zero resin binders**, ensuring complete UV stability and fire immunity.
Wet Grinding & Mixing
Minerals are refined in industrial ball mills for 12-18 hours. The target is a **particle size < 50 µm**. This microscopic powder is then mixed into a uniform slurry. The smaller the particles, the higher the flexural strength of the final slab.
Spray Drying
The slurry is atomized into spherical granules in a 400°C drying tower. We maintain a precise **6.02% moisture content**. Correct granulation is critical to ensure even distribution during the pressing phase.
30,000-Ton Pressing
Using **SACMI Continua+** technology, the granules are compressed under **30,000 metric tons** of hydraulic force. This extreme compaction evacuates air pockets, resulting in a non-porous body with ≤0.05% water absorption.
Pre-Kiln Drying
Slabs pass through a secondary dryer to extract residual moisture. The target is **< 0.5% moisture** at 160°C. This prevents internal steam fractures during the high-heat sintering stage.
SACMI DDG Surface Printing
Aesthetics are applied via **SACMI Digital Decoration & Glazing** at 1440 DPI. Inorganic inks penetrate the surface for 5D depth. This enables precise **vein matching** and batch-to-batch color consistency.
1,300°C Sintering
In a roller kiln exceeding 500 meters, slabs are heated to **1,300°C**. Particles fuse via **solid-state diffusion**. This vitrification creates a Mohs 7 hardness surface, impervious to heat and acids.
Controlled Cooling
Slabs are cooled gradually following a precise thermal curve. This **neutralizes internal tension**, ensuring the stone can be cut and fabricated without the risk of spontaneous cracking.
AI-Assisted Quality Control
Every slab undergoes AI visual scanning and ultrasonic audit. We verify **ISO 10545 compliance** and dimensional tolerance within ±0.5mm before final packaging on A-frame pallets.
Technical Performance Specifications
Standardized testing data for sintered stone physical properties based on ISO and ASTM protocols.
Mohs Hardness
High mineral compaction results in a surface harder than most stainless steel tools.
Water Absorption
Effectively non-porous structure eliminates internal staining and bacterial growth.
Fire Resistance
Inorganic material that does not burn, smoke, or release toxic fumes under extreme heat.
UV Stability
Mineral-based pigmentation ensures zero color fading in outdoor or high-sunlight areas.
How Sintered Stone Compares
A technical comparison based on chemical composition and physical performance tests.
| Material Features | Funtek Sintered Stone | Quartz (Engineered) | Natural Marble | Large Porcelain |
|---|---|---|---|---|
| Heat Resistance Direct hot pans | Immune (1300°C) | Low (Scorches) | Medium | High |
| UV Stability Outdoor use | 100% Stable | Yellows | Fades | 100% Stable |
| Porosity Stain defense | ≤ 0.05% (Zero) | 0.1% (Low) | High (Porous) | ≤ 0.5% |
| Scratch Class Mohs Scale | 6 - 7 | 7 | 3 | 5 |
Architectural Surface Finishes
Beyond the sintering kiln, specialized mechanical treatments define the final tactile and reflective properties of the slab.
Polished (Glossy)
Diamond-tipped heads progressively smooth the surface to a mirror-like clarity.
Honed (Matte)
Diamond-tipped heads progressively smooth the surface to a mirror-like clarity.
Silk (Satin)
Diamond-tipped heads progressively smooth the surface to a mirror-like clarity.