Raw material
Clay bodies, feldspar and quartz are milled to a slip, spray-dried to a powder and held to a fixed moisture before any of it reaches the press.
Manufacturing
One Line.
Architectural Scale.
Every slab NexStone ships is pressed, fired, ground and finished on our own line in Morbi, Gujarat - a single site running large-format porcelain at a scale most facilities are not built for.
Pressing, firing, grinding and finishing happen under one roof rather than across separate suppliers. A slab does not leave the building between stages, and nothing about it is subcontracted out of our sight.
Calibration is held to tenths of a millimetre - thickness, flatness and edge, checked against the same tolerance on every slab that comes off the line.
That tolerance matters across a batch, not for one slab in isolation. A single piece can always be finished by hand; a hundred that have to lay flush against each other on a wall or a floor cannot.
Continua Plus
Continua Plus presses by continuous compaction rather than a static plate. The body is laid and compacted as the belt moves, so the sheet is not limited by the footprint of a platen - which is what makes a slab as large as 1200 × 3200 mm possible at all.
A static press stamps one slab at a time inside a fixed frame. A moving belt has no such edge, so the length of a sheet becomes a question of line speed rather than tooling.
- 01 Raw material
- 02 Press
- 03 Digital print
- 04 Kiln
- 05 Finishing
- 06 Loading
Press
The body is laid and compacted in a continuous pass rather than a single stamp. Density is even across the full sheet, corner to corner.
Digital print
Decoration is applied before firing, so the design is fixed into the glaze by the kiln rather than sitting on top of a finished surface.
Kiln
The sheet is fired to full vitrification, the stage that fixes its strength and its low water absorption. Nothing after firing can correct what happens here.
Finishing
Grinding and calibration bring every slab to the same thickness and edge before it is polished, honed or left structured. This is where a batch becomes consistent, not just individually correct.
Loading
Slabs are racked on A-frames, crated and loaded against an export schedule. Packing is specified with the order, not decided at the door.
One slab, 1200 × 3200 mm, end to end.
Skip the line