Polyston's technical infrastructure ensures independence in the manufacturing and processing of a wide range of large-format materials. Several technological processes combine to create goods composed of mineral and technical stone, ceramics, granite, and wood. Input materials are chopped and manufactured in large formats using CNC equipment or a waterjet with 5-axis cutting. The finished goods are assembled in a carpentry workshop at the company's headquarters, which is part of the production halls. Polyston s.r.o. also has a chemical plant and a casting unit for making boards from Polyston Solid Surface material, which is a result of Polyston's own research and development.
Polyston is constantly extending its technological foundation and technologies to increase manufacturing quality and broaden the range of materials available. The variety of materials has been expanded to include the availability of tempered printed glass, which is now available under the Kerglass brand, thanks to new digital printing technology with ceramic inks. Furthermore, surface treatment of polymers based on polyacrylates and polyesters will be possible with this approach.
At the very beginning of the production process of the POLYSTON solid surface material is the production of coloured granulate with the simultaneous preparation of the necessary moulds for casting not only flat boards but also all details of work and washbasin boards - front and rear slats, sinks, sinks or tubs. The need to cast all elements into moulds is based on the excellent mechanical properties of the POLYSTON solid surface material - its hardness does not allow any elements to be formed by pressing or heat, as competition with its significantly softer materials can do.
Polyston Solid Surface is made by carefully blending mineral filler, polyester resin, and pigments to achieve the desired colour tone. To create a unique design for each Polyston Solid Surface pattern, defined amounts of granulate are added to the masterbatch for structured patterns. The produced slurry is poured into moulds to make worktops, integrated sinks, and washbasins.
TThe acrylate-based sheet material casting line is a fully automated process with a programmed recipe for the correct proportions of the individual components. The result of the process is a continuous casting of material, which is gradually cooled and then cut to the required formats. The acrylic sheet material can be further thermoformed into moulds to create shape-demanding bath and washbasin designs.
Modern CNC machinery is used to machine sink castings composed of Polyston solid surface material. They gradually pass through the hands of skilled technicians, who give the worktop its final shape and meticulously integrate the sink into it. Our automated CNC is also utilized to cut ceramic and stone slabs from other vendors to our customers' specifications.
All types of materials such as granite, ceramics, unhardened glass, plastics, foams and sheets of various thicknesses can be cut using water jet technology. The resulting products are mainly worktops and tiles cut into atypical shapes and with various functional cutouts for mounting a hob or sink according to customer requirements. In the production of facade tiles and paving, we also offer 5-axis cutting, enabling cutting at an angle, creating marquetry and mosaics to measure. The working surface of the water jet has an effective cutting length of 4,000 x 2,000 mm.
Ceramic printing on glass replaces the existing printing technology - screen printing, by applying ceramic inks in full colour. Silica inks are then fused to the top layer of glass in the hardening process, which guarantees high mechanical resistance (abrasion resistance) of the printed image, resistance to UV radiation, moisture and commonly used chemicals and weathering. The production line consists of a fully automatic horizontal dishwasher, a special transport system, equipment for printing and cutting surface materials, a hardening furnace and a CNC centre for grinding, milling and drilling into glass.
Polyston's products focus on the demanding client and atypical production, which places high demands on the finalization of products. Every detail and connection is precisely performed by our experienced team. The carpentry workshop also grinds the surfaces of worktops and then packs finished products and prepares them for export.
Sophisticated technology is used for effective and clear storage of large-format ceramic plates, technical stone, and granite, allowing you to easily and especially quickly find the material you need. Its most notable benefit is the reduction in storage space, which can boost storage capacity by up to 225 tons of large-area material. The 90-position shifting system is powered by an automated motor. The maximum weight capacity of one stand is 2500 kg.
Each of our orders is made to measure and therefore must go through a quality process that pays attention to detail and accuracy. The vertical cutter is an efficient device that is used to machine the leading edge and cutouts. Accelerates the overall production process thanks to software control and automatic measurement.
The most modern technology for machining hard materials with the possibility of 3-D machining. It also includes a laser (projector), thanks to which the work is significantly accelerated and specified.
The most advanced automatic technology that works with amazing accuracy without the need for operator intervention. It cuts with a diamond at lightning speed in thicknesses of 4 - 19 mm. It can create different shapes.
Furnace for making multilayer safety glass with the best quality laminating foils in a variety of finishes - matt, clear, or colour pictures. There are multiple stages to the laminating process: 1. producing a vacuum, 2. heating to the ultimate temperature - initially to 80 degrees Celsius, then to 130 degrees Celsius after some time. When the glass lamination is complete, the temperature is maintained for a while before dropping to 80 ° C. Everything takes occur in a vacuum between two Teflon layers in a unique silicone container. In one process, approximately 12 m2 can be laminated.
Polyston, as one of the few companies on the Czech-Slovak market, has an innovative technology for tempering glass. Thanks to the hardening process, the glass becomes hardened, ie it has high flexural strength and impact resistance. The basic principles of this process are heating the glass to 600 ° C and its rapid, subsequent cooling with air.