Quartz worktops are made by combining crushed natural quartz (around 93% of the mix) with polymer resin and pigment, compacting the mixture under vacuum and vibration to remove air, then curing it at high temperature to form a dense, hard slab. The process, known as vacuum-vibrocompression, was developed by the Italian company Breton in 1963 and remains the basis of how quality engineered quartz is produced today.
Step 1: Quality control of raw materials
Before production begins, the raw quartz is inspected for quality and consistency. At our factory in A Coruña, Spain, every batch of material is checked before it enters the manufacturing process, ensuring the finished slab meets a consistent standard.
Step 2: Crushing and blending
Raw quartz is crushed to the required particle size and blended with polymer resin using industrial mixers. Pigments are added at this stage to achieve the target colour, and for multi-tone designs, the mixture may pass through several mixing stages to build up the pattern.
Step 3: Vacuum-vibrocompression
The blended mixture is poured into a mould in the shape of the finished slab. It is then vacuumed to remove trapped air and compacted under significant pressure, around 100 tonnes, while being vibrated. This vacuum-vibrocompression process is what gives engineered quartz its density and structural strength, eliminating the air pockets that would otherwise weaken the slab.
Step 4: Curing
The compacted slab is cured in a kiln at high temperature. Curing hardens the resin fully, increasing the slab’s strength and its resistance to staining: this is the stage that transforms the raw mixture into a genuinely durable, stone-like material.
Step 5: Polishing and finishing
Once cured, the slab surface is calibrated and polished (or given a matt, silk or honed finish, depending on the design) to achieve the final glossy or textured surface. This is also where any final quality checks take place.
Step 6: Quality inspection and packaging
Every finished slab is inspected for quality before being packaged for shipping. Slabs are typically produced at standard sizes, our range is mostly 3200 × 1600 mm, with some designs at 3300 × 1650 mm, and in 20 mm or 30 mm thicknesses.
Why the manufacturing ratio matters
The ratio of quartz to resin has a direct effect on the finished slab’s performance. Higher-quality quartz worktops, including ours, use around 93% natural quartz to roughly 7% resin. Lower-quality material can use as much resin as 12%, which makes the slab more porous, less scratch-resistant and more prone to discolouration over time. See our guide on what “composite stone” actually means for more on why this ratio matters.
Frequently asked questions
Who invented the process for making quartz worktops?
The vacuum-vibrocompression process was developed by Breton, an Italian company, in 1963, and has since been licensed to manufacturers worldwide.
What percentage of a quartz worktop is real quartz?
Typically 90–95%, with high-quality worktops, including ours, towards the top of that range at around 93%, and the remainder made up of resin and pigment.
Does the manufacturing process affect durability?
Yes, the compaction, quartz-to-resin ratio and curing temperature all directly affect the finished slab’s hardness, porosity and stain resistance.
Explore more
Read about the benefits of quartz worktops, browse the full range of 47 designs, or see our guide to 20mm vs 30mm thickness. Questions? Contact us.