Sintering

Sintering

Sintering entails the process of forming solid stones by applying high pressure and heat.

Definition

Sintering, or ultra-compaction, forms a robust surface using significant pressure levels and high heat (1000-1500 Celsius) without melting the material.

Applications

Used in manufacturing processes with porcelain and ceramic surfaces.

Key Process

Nanoparticles in the material diffuse across the boundaries of the particles, fusing them into a solid piece. It differs from engineered stones such as quartz and composite marble because it closes the surface’s pores at a molecular rather than granular level, resulting in non-porous and ultra-compact materials.

Thicknesses

Available in 3mm, 5mm, 6mm, 8mm, 12mm, 20mm, 30mm.

Energy Consumption and Potential Emissions

1. 1. Sintering demands substantial energy due to high temperatures during sintering contribute to elevated energy consumption
2.  2. Sintered stone brands minimise the production impact by using up to 100% rainwater and solar energy.
3.  3. Advancements in sintering technology focus on reducing energy consumption during manufacturing.
4.  4. These eco-friendly materials use natural minerals such as sand, glass, quartz, marble and granite remnants.
5.  5. The release of pollutants might arise from the combustion of fossil fuels for energy generation.

Waste Generation

• • Sintering can generate waste materials such as stone dust, including by-products from the stone processing plant 
• • Brands utilising sintering technology use up to 100% recycled materials and produce recyclable surfaces.

Eco-Friendly Materials

• • Sintering technology integrates environmentally sustainable materials to lessen resource depletion and environmental harm.
• • Material sourcing and recycling innovations reduce waste and promote the circular economy principle.

Emerging Trends

The latest advancements in sintering technology encompass various aspects, including developing novel materials, enhanced processing techniques, and applications across diverse industries.

Full Body Sintered Stone Worktops

One notable trend is the arrival of full-body porcelain worktops and ceramics with full-body veining. These innovative surfaces offer a seamless aesthetic appeal, mimicking the natural beauty of marble and other high-end materials.

Furthermore, advancements in sintering techniques enable the creation of intricate veining patterns throughout the entire thickness of the material, enhancing its visual depth and authenticity. This trend reflects the ongoing pursuit of realism and sophistication in surface design.

Top sintered stone brands in the United Kingdom

Sintered Porcelain Brands

• • Dekton
• • Neolith
• • Porcelanosa Xtone
• • The Top by Marazzi
• • Laminam
• • Caesarstone Porcelain
• • Infinity Surfaces
• • Ceralsio by CRL Stone
• • Inalco
• • Atlas Plan by Concorde
• • Florim Stone

Sintered Ceramic Brands

• Sapienstone
• Ascale by Tau
• Arklam by Supersize.

Future Prospects

Continued research and innovation will likely drive further enhancements in material properties, processing efficiency, and sustainability practices, thereby expanding the scope and applications of sintering technology in various industries.