Understanding the Quartz Manufacturing Process: A Behind-the-Scenes Look at LE Surfaces’ Factory

For decades, natural stones like granite and marble have been a cornerstone of beautiful and luxurious countertops. However, these materials possess inherent limitations. LE Surfaces proudly manufactures handcrafted quartz slabs, a superior alternative that offers both stunning aesthetics and exceptional performance.

The Advantages of Quartz

Natural stone surfaces are susceptible to staining, may exhibit natural fissures, and often lack a uniform texture. Additionally, achieving seamless installations with natural stone can be challenging due to variations in size. Quartz products address these concerns and provide significant benefits:

• Stain Resistance: Unlike natural stones, quartz offers exceptional resistance to staining, making it an ideal choice for high-traffic kitchens and bathrooms.

• Superior Durability: Quartz countertops are remarkably resistant to scratches, chips, and cracks, ensuring lasting beauty and functionality.

• Consistent Design: Unlike natural stone with its unique patterns and color variations, quartz offers a consistent aesthetic in terms of color, pattern, and texture throughout the entire slab and across multiple slabs.

• Seamless Beauty: Quartz is produced in larger slab sizes, minimizing seams and creating a visually uninterrupted and elegant countertop surface.

The surge in popularity of quartz countertops can be attributed to advancements in manufacturing efficiency, leading to a significant decrease in cost and availability of large quantities over time.

Handcrafting the Unexpected

Unlike mass-produced countertops, LE Surfaces takes quartz engineering to a whole new level. We don’t just source our materials – we meticulously control the supply chain, ensuring the highest quality quartz aggregates for our foundations. This commitment to raw materials allows us to innovate relentlessly. Our design team pushes the boundaries of what’s possible, crafting unique colors, and patterns that redefine the concept of quartz countertops.

But innovation isn’t enough without understanding your vision. We work hand-in-hand with our clients, staying at the forefront of trends and collaborating to create truly distinctive spaces. With LE Surfaces, your countertops won’t just be beautiful, they’ll be a statement piece that sets you apart from the ordinary.

The Journey of Quartz

The process of creating quartz countertops involves two main stages: raw quartz manufacturing and quartz slab manufacturing.

Raw Quartz Manufacturing: Extracting a Natural Wonder

1. Extraction: Quartz is primarily extracted through open-pit mining. Specialized equipment like backhoes and bulldozers remove surrounding clay and soil to expose the quartz veins. Once exposed, smaller tools are used for precise extraction.

2. Processing: The extracted quartz undergoes a thorough cleaning process to remove impurities and imperfections. It’s then crushed, screened, and ground into various sizes depending on its intended use.

3. Supplying: Processed quartz is transported in bulk using shipping containers or large trucks/trains (land).

Quartz Stone Manufacturing: Transforming Raw Material into Stunning Surfaces

1. Raw Material Selection: The process begins with selecting high-quality quartz manufactured by facilities like ours here at LE Surfaces.

2. Blending: The chosen quartz is crushed and meticulously blended with resin binders and additives to achieve the desired ratio (typically 80-90% quartz and 10-20% resin).

3. Molding: The mixture is then poured into a mold and formed into slab sizes of 63” x 126”. Super jumbo slabs are becoming more popular and are also available. Multi Step Process to create handcrafted aesthetic.

4. Slab Pressing: The mixture is compacted into slabs using a vacuum and vibration technique. This step minimizes porosity for superior stain resistance.

5. Heating and Curing: The slabs undergo a curing process in a kiln to attain essential properties like stain and impact resistance.

6. Cooling and Polishing: After curing, the slabs are cooled, calibrated and polished to a perfect finish in a wide range of colors and designs

7. Quality Verification: LE Surfaces prioritizes quality control. Our engineered quartz manufacturing process ensures consistency in color, dimension, and overall uniformity. This translates to a faster and more efficient installation process for contractors.

The Future of Countertops is Quartz

Here at LE Surfaces, we’re committed to providing our customers with the highest quality quartz countertops, along with exceptional customer service and expertise. Visit our showroom or contact us today today to explore the vast selection of quartz countertops and discover the perfect fit for your dream space.

Connect with us: https://lesurfaces.com/about-us/

Andrew Evans | VP Global Sales and Marketing

Gordon Shell | VP North and South American Sales