Sanitana began its journey over 45 years ago and it was through ceramics that it became a specialist in what remains the material of excellence for sanitary solutions.
From the selection of raw materials to the final piece, discover every step of the production process.
The production process begins in the modelling department, where the physical prototype of the product is developed. This prototype serves as the basis for creating the original mould, the Master model, usually made of resin, which is used to produce all moulds for a given model.
These moulds are made of plaster, a material chosen for its favourable properties. Each mould is composed of several parts and joined using magnetic connections.
A liquid paste is injected into the moulds through strategically placed channels to ensure even distribution. Each mould has an average lifespan of about 90 castings.
The raw materials are received in bulk and stored in industrial silos according to their nature. When production begins, they go through dilution and screening processes that give them the desired characteristics for each type of ceramic.
At Sanitana, porcelain and stoneware are used. They differ in their physical and chemical composition, but each provides the product with specific qualities depending on its design and typology. Toilets, bidets, and small washbasins are manufactured in porcelain, while shower trays and large washbasins are made of stoneware.
Up to the baking stage, all defective pieces are reused to avoid waste. They are diluted and incorporated into the slip used in the casting process.
It's in the Ceramic factory thta the pieces take on their physical form. The liquid paste is injected under controlled pressure into the moulds and remains there for 90 to 115 minutes at temperatures ranging between 26°C and 34°C. Both temperature and humidity are key factors in the process, as they directly affect shrinkage and deformation of the piece.
Once unmoulded, the pieces retain structural integrity, though they do not yet have final strength. They then proceed to the drying and finishing stage.
The pieces are transferred to drying ovens for around 11 hours. The internal temperature gradually rises from 40°C to 90°C, followed by a cooling period. This process helps reduces moisture content to below 0.6%, a necessary condition to ensure the integrity of the piece during firing. If the required moisture level isn’t reached, the pieces return to the drying oven.
Once dry and conforming to standards, the pieces undergo finishing touches to eliminate imperfections. They are treated and blown with compressed air to remove any dust or residues that could interfere with proper glaze adhesion.
In parallel with the paste production, glass is also prepared. This glaze gives each product its final functional characteristics.
The glass is made from a blend of materials such as feldspar, kaolin, silica, calcium carbonate, zirconium silicate, talc, wollastonite, and zinc oxide, mixed and treated to achieve the ideal characteristics for each piece.
Skilled workers spray the liquid glass onto the pieces in a controlled process that ensures even coverage and durability.
After this process, the pieces are stored in a temperature-controlled area for final drying, ensuring moisture content does not exceed 0.6%.
This is the final stage of the process. The glazed pieces enter a continuous kiln, with approximately 90 metres long, where they remain for 15 to 20 hours. The temperature reaches 1260°C before dropping rapidly to 600°C, inducing a critical thermal shock during the vitrification phase. The temperature then gradually decreases until the end of the cycle.
Finished pieces are carefully inspected by specialised staff. Approved products are packed with care, including, where necessary, installation kits and manuals, and are prepared for distribution.
If minor defects are found, the pieces may be reprocessed through a second firing. Pieces with major, irreparable defects are classified as waste and are either recycled internally or by industrial partners.
Because there are situations where sanitary ceramics are not the ideal option, Sanitana has also dedicated itself to creating products made from acrylic sheets, a versatile material particularly well-suited for shower trays and bathtubs.
Discover the entire production process behind our acrylic sheet products.
Our products are made from acrylic sheets that combine impact resistance, durability, and a refined finishes. Due to the nature of the material, they offer several advantages: lightweight, strong mechanical resistance, and high durability.
Easy to clean and repairable, our acrylic sheet products are also reinforced to meet the structural requirements needed for safe use in bathroom spaces.
Production begins by heating the acrylic sheet to 120°C, making it malleable and ready to be vacuum-formed into a metal mould shaped like the final product.
Once fully cooled, the formed acrylic layer is removed from the mould, revealing the initial contours of the final piece. It then proceeds to the reinforcement area, where a mixture of resin and fibreglass is applied in strategic areas.
The piece is placed in an oven at an average temperature of 50°C to allow the reinforcing materials to catalyse and give the final product the required rigidity. Once completly dry, the piece moves on to the finishing phase, which includes precise trimming and drilling as needed.
For bathtubs with hydromassage functionality, all system components are installed during this phase, including drilling, support structure, accessories, piping, motor, and all electronic components.
Each hydromassage bathtub undergoes a series of tests during assembly process, followed by a full functional test to ensure the product meets all performance and safety requirements.
Once production is complete, the products undergo quality control, including a visual inspection and specific testing in accordance with CE and EN standards to ensure compliance. Approved products are then carefully packed and made ready for shipping.
Stonex® marked Sanitana’s entry into the creation of composite material products, offering properties similar to natural stone. It is a highly resistant material with excellent cleaning, maintenance, and repair capabilities. Its unique features, combined with superior durability and water resistance, make Stonex® an outstanding choice for bathroom products.
From the selection of raw materials to the final product, explore the entire production process of Stonex® products.
Stonex® is a composite material that combines mineral fillers with polyester resin. Coated on the surface with a gel coat, it's characterised by its soft, comfortable texture similar to natural stone. This textured finish provides high slip resistance, ensuring user comfort and safety. Extremely durable, Stonex® is resistant to wear, impact, thermal shock, and UV rays. It is available in three colours, with mineral pigments integrated into the raw material mixture, ensuring a long-lasting colour stability over time.
The production process of Stonex® products begins with the Mould, a metal structure lined with a silicone finish that gives the final product its natural stone-like texture and slip-resistant surface. The mould also defines the shape and dimensions of the shower tray.
Next is the paste preparation, which originates from a raw materials that are processed to obtain the appropriate grain size. These are then combined into a homogeneous mix of mineral fillers, polyester resin, and mineral pigments.
The first production step is the application of liquid Gel Coat, which creates a uniform first layer over the mould. Then, the paste ijection follows, through a vertical injection structure until the desired height is reached, typically around 30 mm, allowing a ultra-flat, stable shower trays.
The filled mould is then moved to a controlled-temperature curing oven, where a chemical reaction occurs to harden the material. This step is crucial for achieving the product’s final strength.
After curing, the product undergoes demoulding. Given the size and weight of each piece, this stage is assisted by mechanical structure that inverts the position of the mould, allowing gravity to aid in the release.
In the final stage of production, specialised technicians remove any excess material and correct imperfections while inspecting each piece to ensure it meets the required quality parameters.
Once approved, the product is carefully packed with all necessary accessories and installation manuals, ready for market distribution.
At Sanitana, Surfex® is used in the production of washbasins and bathtubs.
Its stone-like appearance, combined with a smooth, homogeneous, slip-resistant, and naturally antibacterial surface, makes it ideal for bathroom environments. These products are also known for their strength, durability, and maintainability.
From the selection of raw materials to the final product, discover the entire production process of Surfex® products.
Surfex® is a composite material made of polyester resin with alumina fillers. It offers a smooth and comfortable texture to the touch, similar to natural stone, with a matte finish.
Highly resistant and inherently hygienic, Surfex® is non-porous and compact, preventing the growth or spread of bacteria and fungi.
Surfex®is a material that remains unchanged under natural and artificial light. Common stains or superficial burns can be removed following proper care instructions, allowing the product to maintain its original appearance, as long as the instructions are followed.
The production process for Surfex® products begins with the creation of a physical model of the product, which serves as the basis for creating the Master, the original mold that will give rise to all the molds used in the production of a product. Masters and molds are made of metallic elements and resin and feature a smooth finish, the same one intended for the final product.
The next step is the preparation of the Paste, which is based on raw materials that are carefully prepared and combined until they result in a high density liquid paste. In Molding, the paste is injected into the molds and the chemical curing process begins, which is responsible for the progressive solidification of the material. After 15 minutes, the pieces are removed from the mold and at this stage they have partial flexibility because curing is not yet complete. This is followed by a resting phase with controlled temperature and in supports designed for this purpose, until full curing, a process that takes about 45 minutes.
The pieces move on to Cutting where they are trimmed, cut and drilled using precision equipment and in situations where it is necessary to join components, Bonding is carried out using the same paste used in injection, ensuring perfection in the finish.
After bonding, the product remains at rest until total consolidation of the joints.
With the product in the Finishing stage, grinding and polishing tools are used to remove burrs or excess material to ensure a homogeneous and smooth surface.
All Surfex® products undergo rigorous quality control. Inspections include visual and tactile evaluations, functional tests for water drainage, and impact tests to ensure mechanical resistance.
Any imperfections found are corrected, and only after passing a second inspection is the product approved.
Once approved, the final product is carefully packaged along with installation kits and manuals, ready to be shipped.
At Sanitana, Vitreous Enamelled Steel is used in the production of bathtubs and shower trays.
It combines the strength of steel with the protection of enamel, resulting in a durable, hygienic surface that is corrosion-resistant and easy to maintain. An ideal choice for ensuring robustness, safety, and a high-quality finishes.
From the selection of raw materials to the final product, discover the entire production process of Vitreous Enamelled Steel products
We use materials sourced directly from the world’s leading suppliers, allowing our team to continuously develop specialized steels and enamels that provide our customers with the best solutions. Raw materials are received both qualitatively and quantitatively, with laboratory testing carried out on the steel and the raw materials used for enamel preparation.
According to the model to be produced, each steel coil is placed on the line to start the cutting process, producing flat sheets with the desired dimensions. At the end of this operation, the flat sheets are temporarily stored until they pass the laboratory tests, after which they proceed to the stamping lines.
Stamping is one of the main stages in the entire manufacturing process of vitrified steel and takes place on different lines, depending on the product.
On the bathtub line, the process begins with lubricating the sheets for the first press, where the tub shape is formed. Then, a transfer feeds the second press, which cuts off the excess material. The bathtub moves to the flanging machine with the help of a transfer, and after trimming, it's sent to the finishing line, where holes are drilled and brackets are mechanically welded. At the end of this operation, the piece undergoes automatic inspection.
On the shower base stamping line, the process also starts with lubricating the sheets, where the tub shape is formed and the excess material is cut. This press also performs the drawing and cutting operations. Next, come the flanging and final finishing operations. After stamping, the shower bases undergo a manual inspection.
This stage, prior to enamelling, involves spraying all stamped pieces to clean off impurities and the lubrication oils used during stamping, as well as applying an anti-corrosion surface treatment.
At this stage, the enamel is prepared according to specific formulas for each type of piece. The enamel is produced in mills, stored, and then applied wet onto the surface of the degreased pieces.
The pieces are suspended on dedicated enamel lines where the line speed is programmable. They pass through cabins operated by programmed robots that apply the enamel.
The enamelling process used is called “3 coats, 2 firings” (3c/2f), which consists of two vitrification stages. During the process, the pieces undergo strict quality control in two phases: the first when the piece has two coats and one firing (first coat), and the second after the third coat and second firing (final coat).
Conforming pieces after inspection are packaged, generally using cardboard protection with reinforcements on corners and mounting brackets. After packaging, the pieces are placed on pallets and are ready for shipment.
