Cultured Marble / Engineer Stone Cast Polymer Manufacturing

Transcription

1 Cultured Marble / Engineer Stone Cast Polymer Manufacturing Sunrise International Company 2018

2 Cultured Marble is a mixture of crushed limestone, resin, pigments and catalyst. This matrix is mixed together and poured over a gel coated, cultured marble mold. You will get an exact copy of the mold you are pouring on. For example, if you want to produce a bath tub you will pour the matrix over a tub mold.

3 If you want to produce a sink, you ll pour the matrix over a sink mold

4 The three most common questions are: 1. Can I make money? 2. How much does it cost to set up a cultured marble factory? 3. How do I get started? You ll find the answer to these questions and more, following.

5 72 Double Bowl Vanity Top with two end splashes (Bullnose Edge) Resin is the biggest factor in determining what your material cost will be. I ve seen resin prices range from $1.90 per kilogram to $3.50 per kilogram. There are a lot of reasons for the wide price variation. Will you buy it direct from a manufacturer or through a distributor? The same applies if you have to rely on imported resin. On the following pages we will use resin costing of US $2.70 per KG which gives us a.92 total matrix cost when we calculate our resin, filler and miscellaneous consumables like gel coat, wax, masking tape and tooling clay. If you would like a spreadsheet on Excel to see exactly how we came to this number or to include your own numbers, let us know and we ll be glad to it to you. The small chart below shows some other matrix costs based on various resin prices. Total weight: 61 KG Material Cost: $ 0.92 per KG Total Material Cost: $ X $ 4.60 per inch 183 cm X $1.81 per cm $ (Counter Top) $ (2 bowls) $12.00 (1 End Splash) Total Selling Price = $ Selling prices on this and following pages are based on an average from 3 factories in the U.S.A. A local market survey will determine what the market will bear in your area. Material cost includes cost of raw materials and does not include labor or overheard costs.

6 Bathtub/Shower Surround 32" X 61" (81cm X 155 cm) Bathtub: 100 KG 53 SF (5m2) for 3 Wall Panels weight: 93 KG Soap/Shampoo Combo weight: 4 KG 39" (1m) Window Corniced Window Sill: 5 KG Total weight: 202 KG Material Cost: (202kg X $ 0.92 per KG) Total cost of Materials: $ " X 61" (81cm X 155 cm) Bathtub: $ sf (5m2) for 3 Wall $9.40 per sf: $ Or 5m2 for 3 Wall $99.6 per m2) Soap/Shampoo Combo: $ (1m) Window Sill: + $ Total Selling Price: $1,534.20

7 Shower Pan & Surround 42" X 42 (106cm X 106cm) Shower Pan: 66 KG 73 sf (6.7 m2) Wall Panels Weight: 133 KG One 39" (1m) Window Sill: + 5 KG Total Weight: Material Cost: 204KG X $ 0.92 per KG 204 KG Total cost of Materials: $ x42" (106cm X 106cm) Shower Pan: $ sf (6.7m2) Panels at $9.40 per sf: $ Or 6.7m2) 99.6 m2 39 (1m) Window Sill: $ Total Selling Price: $

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9 Only 3 molds are needed for this elegant bathtub installation. (1) Bathtub Mold (2) Wall Panel Mold (3) Trim Mold This is a close up of the corner shelf in corner bathtub installation

10 Four molds are used for this installation. (1) Bathtub Mold (2) Shower Pan Mold (3) Wall Panel Mold (4) Soap/Shampoo Mold

11 Four molds were also used in this installation. Bathtub Mold (1) All Purpose Mold (2) Drop In Bowl Mold (3) Wall panel Mold

12 Regardless of the size of investment, our goal is to supply you with as a diverse assortment of molds to produce as many different products as possible. For example, we will show you how you can use one large counter top mold to make any size vanity tops. You ll simply select the bowl style of choice and put a divider bar on the mold to make the required length you need. Notice that we are making a single bowl and a large double bowl vanity top on the same 12 foot (3.6m) All Purpose mold. The sinks on the following pages are made using this same 3.6 meter All Purpose Mold and a selection of Floating Bowl Molds.

13 You will see a drawing of each bowl style on the Molds page of our website. Click on Floating Bowls to see the sink bowl styles available. Here is a pink two-tone Diamond Shaped Sink with an off-set bowl, utilizing he same All Purpose Mold and a Diamond Floating Bowl Mold. A two-tone sink like this is unique and nobody in your market area can make a product like this but you. The bowl and counter top are one piece so there is no joint or seam where dirt can hide or mold to grow.

14 Here is a vanity top using a Pearl Floating bowl.

15 I think you have the picture. Any size any color; all on the same mold. Only a cultured marble shop could offer your market so many choices.

16 Vessel Bowls are becoming increasingly popular and can be used utilizing the same All Purpose Counter Top Mold

17 Double or multiple bowl vanity tops are very popular in master bathrooms & commercial installations and are easily made on the same mold. Very unique and again, something not available in your market except by you.

18 Another double bowl installation. The counter top, bowl, front edge and backsplash are all one seamless piece. A jewel like this is easy to clean because there is no place for dirt to hide or mold to grow.

19 A variety of Pedestal Sink Molds are also available. This is one of the more popular styles.

20 Colors are important to your customers and a cultured marble factory can offer an almost unlimited assortment of colors. In fact, Color Choice is a huge reason many people will be knocking on your door. People want choices that over-the-counter type stores just don t offer. This is one way you can display your colors. You will see a small assortment of pigments in the Supply Package but there are many more colors available. Your resin supplier will also offer pigments. If cultured Granite may be a big seller in your market area, keep in mind that there are a huge variety of granite colors as well.

21 Even though white or light natural colors are the most popular in the USA, you can make any color the customer wants just as easily as making boring natural colors. The customer is always right. Regardless of color, you can make it.

22 Think Colors! If your customer wants a pink bathtub, you can make it!

23 If your customer wants a blue bathtub with some crazy waves in it, you can make it!

24 You can make majestic Grecian columns in any color.

25 Cultured Marble is all about Custom. Being the manufacturer you can manufacture about anything. This gives you a big advantage because you can produce items that are not available anywhere else in your market. This will reward you with higher profits. I know a factory that has a showroom down the street from an American Standard brand plumbing retail store. They get a lot of drive-by business from people who want more choices (color, size, shape & design) in their bathrooms and kitchens that an over-the-counter type retail store like this is not able to give them.

26 Custom: Here is an example. Where else could a customer buy a large seamless L shaped counter top with built-in bowls? This isn t any harder to make than a standard sink. You make a template, lay it out on a wall panel mold, set your divider bars and floating bowls and pour the marble/onyx/granite matrix over it.

27 Here s another simple but elegant custom vanity top / make-up table installation

28 or this commercial lavatory with multiple sink bowls

29 There is a big demand for custom commercial installations in every market.

30 You can make shower pans, shower surrounds & wall panels any size, any shape or any color. Here s a very unique installation a factory put in their showroom, just to show what they can do.

31 A custom hotel vanity top installation

32 Another elegant, unique and custom hotel vanity installation

33 You can make any size or shape table top on the wall panel mold by simply making a wooden template.

34 Tables are a cash cow. Every restaurant, coffee shop, hotel, office, fast food Establishment, etc., needs tables. You can supply them because you can make any size, shape or color. You can also make custom fitted products for their other surfaces that they may need covered, like counters, pick-up counters, reception desks, window sills, etc.

35 Here is a large 2 meter X 3.5 meter conference table being manufactured.

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37 Textured Seamless Flooring Seamless cultured marble flooring has no grout lines so it is more sanitary and easy to clean. Textured panels can also be used for wall paneling, shower surrounds and other textured flat surfaces in addition to flooring.

38 If your customer wants a tile appearance but still wants seamless flooring, you can do that as well.

39 Textured Flooring or Wall Paneling. You get the tile appearance but all one piece. Easy to clean. No grout lines!

40 Tile appearance without the grout: Some people are just so used to a tile appearance they don t want it any other way. Your customer will love you when you can show them how they can have their cake and eat it too. We ll show you how to make wall panels with a tile appearance but without the nasty, soap scum accumulating, mold growing grout lines prevalent in a ceramic tiled shower surround.

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42 Transparent Cultured Onyx table tops with circular table base using Flexible onyx. The two pictures are of the same table. The picture on the left shows it being backlit.

43 Love Table Tops

44 Every restaurant, bar, coffee shop and home needs table tops. They re easy and create fast cash flow. Read more about table tops at:

45 You can make them any color, shape or size.

46 Everything is about Ads. Google sells Ads; Facebook sells Ads, Twitter, LinkedIn, and the list goes on and on. Here s a way for both you and your customer to make money. Sell your local coffee shop, fast food establishment or bar Advertising Tables like these. You make money manufacturing the tables and they make money selling Ads that they put in the cutout you made in the table top. It s a win-win situation for both of you.

47 It s all about custom, right? Size, shape, solid colors, veined marble, transparent onyx with or without inlays like this, or even an unlimited selection of granite colors.

48 Mirror Frames can be elegant in any part of the house. Who can resist a mirror frame to match their bathroom counter top?

49 There is nothing better for window sills than a marble corniced front edge window sill. Window sills get a lot of abuse from people setting things on them and from condensation. Every shower that has a window is especially a good candidate for a cultured marble window sill but they are an elegant touch for every room in a house or office.

50 You can get creative and build things like this decorative stand, or sell to those who can. Furniture manufacturers often use cultured marble in their products.

51 Hotels are big users of cultured marble; In the guests rooms, (tub, shower & sink) Lobby (coffee tables and other flat surfaces) front desk, breakfast area, business center, bar, restaurant, etc.

52 Many hotels have a breakfast buffet area.

53 Another hotel breakfast bar

54 Cultured marble can be used for Signs. You ll see this at the Birmingham Alabama Airport.

55 Phone Banks (for those few places that still have pay phones)

56 Fast food establishments are big users of your product. The front counter, condiment tables, dining tables, and of course in the restrooms.

57 There is nothing more sanitary than cultured marble in food areas. Almost every restaurant, bar, coffee shop and fast food establishment in America uses some sort of cultured product, whether it be marble, onyx, granite, spray granite or one of the other decorative formulas. Since the table or counter is seamless there is no place for dirt or food to hide.

58 Dining Table for Restaurants Or For Home

59 Look for other areas in the house or commercial establishment where you can suggest your product, like this buffet shelf. If you see a flat surface, it needs a nice finished surface. These flat surfaces are simple to make and very financially rewarding.

60 A sink like this is commonly used for laundry rooms, but clinics, hospitals and laboratories are big users of cultured marble and solid surface products because again, they are seamless so there is no place for dirt, mold or germs to hide.

61 Reception Desks

62 Look for areas in the home or business that require a countertop or marble surface. A study, storage area, laundry table, etc

63 Another small lab or bar sink. Again, seamless so it s sanitary and easy to keep clean.

64 Laundry Rooms. It s just a small little surface here but they have to put something there. It may as well be your product.

65 Bar, restaurant and fast food counters

66 Fast Food Establishments

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68 Profit margins per KG are often bigger on small accessories items than on some of the bigger products you ll manufacture.

69 You can increase your margins even more by doing some very custom things.

70 There are many styles and sizes of accessory molds to choose from. Here is a Double Wide Recessed Soap & Shampoo Combo

71 A single wide Recessed Soap/Shampoo Combo

72 Maybe a simple Corner Shelf suits your customer better.

73 Decorative Trim molding offers big returns. Long narrow trims use a small amount of material so material cost vs sales price for unique high-ticket items equals high profit margins. Trim pieces can be used as baseboards along the floor, to trim out shower installation, around bathtubs, ceilings, and doorways or any other place you commonly see trim molding. There are many styles to choose from.

74 Shower Seats are a luxury everybody wants in their shower.

75 Another style of shower seat

76 Browse the MOLD page to see Misc. Accessory Molds

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78 1. Set Up Mold

79 2. Spray Gel Coat On Mold

80 3. Prepare Raw Materials & Mix Matrix. Resin, Limestone, Hardener, Colors

81 4. Pour the matrix over the mold.

82 De-mold

83 Ready for pick up.

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89 Bathtubs are big money makers and come in a variety of style and sizes. There is no type of bathtub on the market that is more elegant and luxurious than a marble, onyx or granite tub. They are resistant to mold and mildew, require little maintenance and retain the heat which is important when a jetted system is installed. Whether you produce large corner bathtubs like the one on the front cover or standard size bathtubs with shower surrounds like you see in the picture below, you ll find that every home has a bathtub drawn in their floor plans. You can add a jetted system to any tub, which will increase your profit margins even more.

90 This is one of the most popular tubs. It s a 30 X 60 tub with built-in arm rest. Very elegant and very comfortable. You can install a Jacuzzi system on any bathtub for additional profits.

91 This is a standard bathtub but notice the added touch by adding a bullnose tub deck and a marble decorative trim molding at the base of the bathtub.

92 Here is a large two-tone bathtub

93 You ll see all the Bathtub mold styles on the Mold Page of the Website.

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95 We will train you how to make everything from simple straight edges like this to more elegant custom edges that will bring you even more profit. This banjo sink has a simple straight edge.

96 These counter tops have an extra thick Bullnose Edge

97 Ogee Edges are very popular

98 You can also make the popular banjo style with a Bullnose Edge. By the way, do you know why contractors like to use Banjo vanity tops? It gives them an excuse to install a larger/wider mirror by extending it over the toilet to make a small bathroom look bigger, giving the home extra value. As a manufacturer, we like banjos because we use a small amount of matrix (raw materials) but the return on this custom sink can be greater than a standard sink.

99 Custom edges mean higher profits. We have molds for every edge style but since we know not everyone has the budget to buy molds with every edge style, we will show you how to use divider bars to make these edge style, saving you thousands of dollars in your initial mold investment.

100 Cultured Marble vs Ceramic Tile Shower Surrounds If you know anyone who suffers from allergies, sinus or respiratory problems, inspecting the shower is a good place to look for a remedy. A ceramic tiled shower has grout which absorbs moisture like a sponge and may never dry out in between uses. This constant source source of moisture is the perfect breeding ground for mold and mildew to grow. If left unchecked, respiratory problems can lead to serious health problems. A tiled shower floor is the most nasty place in a house. A cultured marble shower pan is one solid piece of rock formed over a shower pan mold. It has absolutely no grout lines so it s easy to keep clean and sanitary. A cultured marble shower surround consists of 3 large wall panels and again, there is no grout lines so there is no place for mold to grow, soap scum to accumulate or dirt to hide.

101 On the left is a tiled shower surround where each piece of tile is surrounded by hard-to-clean grout On the right, is a cultured marble (granite) shower pan and surround. No grout, therefore no unsanitary conditions.

102 Here are some clean and more-or-less maintenance free Cultured marble shower pan and shower surround installations

103 So clean and solid as a rock.

104 Being the manufacturer, you can enjoy the profits from many custom shower installations like this shower with a built-in bench.

105 Here is a cultured marble shower surround over a bathtub. A nice clean installation. Notice the trim that is installed at the top of the shower. It goes to show that if you show it you ll sell it A jetted whirlpool system like in the bathtub below can be added to any bathtub you manufacture.

106 Another clean installation. This is a Neo Angle (Corner) shower pan that is designed to fit into corners to save space. Neo Angle Shower Pan molds come in 4 sizes.

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108 Regardless of the size of the factory, each factory is designed to follow this path through the manufacturing process.

109 1. Set Up Lines

110 2. Spray Booth and Gel Coat Spray Cart

111 4. Matrix Blenders

112 4. Vibrating Tables

113 The Scissor Lift moves the molds in and out of the Mold Storage Racks

114 5. Mold Storage Racks

115 6. De-mold & Transfer Line

116 7. Dust Collector / Grinding Booth

117 8. Vanity Top Buffing Line

118 8a. Buffing Line for flat stock

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120 Choose the size of package that best suits your budget.

121 1. Fill out the Purchase Agreement specifying package size, and send us a copy. 2. Make bank wire transfer. 3. We will ship the factory by ocean container(s) between 14 and 20 weeks after we have completed manufacturing all of the molds and equipment for your factory. 4. After the containers have arrived we will come to your factory and supervise the installation of the manufacturing equipment and train you and your staff how to manufacture the bath and kitchen products for your market. We will also show you how to sell your products, bid jobs and work with your customers.

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123 Once the equipment is installed and everything is set up and in working order, we will start preparing the molds and start training on how to manufacture all the exquisite cultured marble, onyx, granite and other cultured marble / cast polymer bath and kitchen building materials that we ve showed you during our correspondence. Our comprehensive training program guarantees that you will learn the formulas and techniques to produce world-class bath and kitchen fixtures that are unmatched in your market and products your market has never seen before. Allow approximately one week, depending on size of factory purchased, to install the equipment and have it operational and another two weeks for training.

124 This group has just been fully trained and are ready to manufacture. The following pages show photos taken during some of our training classes.

125 Every formula is written on a board so you can take notes, video, or photos. If you will be using metric in your factory, we will conduct your training class using metric. Learning Mixing & Veining Techniques Proudly showing off 1 st piece Learning Detailing Procedures

126 It s all in the details

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128 After training we will sit down with you and make any changes you want in your package

129 Preparing your package for shipment: After your training is completed and your final mold and equipment selection is completed, we will start preparing your package for shipment.

130 Here is a factory ready to ship. Everything has been carefully crated and packaged for ocean container. Molds are carefully loaded into the container

131 The container is then trucked to the port

132 The container is on the way. During this time, you can make any final preparations to your building to have it ready to set up your factory when your container(s) arrives.

133 After you have received your shipment, it s time to set up your factory. We will do a layout of your factory based on your building details like door locations, columns, office areas, elevations, etc., that you provided us. Each piece of equipment will come with a drawing and detailed assembly instructions. You should find it quite simple to install but if you have any questions, don t hesitate to call us. If you would like us to come to your factory to help with the installation, let us know.

134 Here s a brief glimpse of setting up a factory.

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137 Completed. Ready for Production. An 800 M 2 factory installation.

138 Complete ready for production A 2000 M 2 factory

139 Regardless of the size of factory you want to establish or how many different products you want to produce, the important thing is to simply Get Started. Tel: Fax: Website: Viber & Whatsapp on telephone number above. Sunrise International Company All Rights Reserved