1. Glass sourcing/collection:
Glass is collected from Pubs/Restaurants, typically for coloured glass in the form of bottles in mint green, olive green, brown and blue, whereas for our clear and mirror glass comes in shattered or rejected sheets for the Glazing industry. Unleaded CRT screen glass and Cockle shells are bought from recycled sources.
2. Glass processing:
Upon delivery, the glass bottles are washed, sterilised and de-labelled, shells are washed and sterilised and glass sheets are wiped clean of any paint or decorative labels. Once dry, these are crushed in large batches (>1000Kgs) and then sieved in our 4 standard aggregate sizes, one colour at a time to avoid contamination, and later stored in 890L quarantined batches.
By the time an order comes through, size, shape and colour recipe has been agreed to and these details are forwarded to the factory. The mould fabricator then produces the recipient which the material is poured in. This includes a 3mm excess thickness that is later calibrated. In the meantime, the aggregate processor prepares the glass to the percentages specified in the recipe. Once both recipient and glass are prepared, the mould is treated with a release agent, resin and glass is poured in and placed in storage to cure overnight at room temperature.
The cured piece is removed from its mould and brought to a bridge calibrator, where the slab is milled down to 1mm away from the finished thickness.
Once calibrated, the slab is brought to the polishing station. The slab is lightly polished to reveal the first glass layer, so any holes can be filled and cured, before polishing the top surface through all the grades.
6. Edge polish and fabrication:
The slab then goes to the fabricators station, where the edges are polished and any specified cut-outs or features are made. Finally, the finished worktop is then stored/packaged for delivery/fitting.