Frequently Asked Questions

Pertaining to starting a new Cultured Marble factory
Molds, Equipment, Supplies & Training
These are the most frequently asked questions asked by those investigating establishing a cultured marble factory.  I have been adding to and working on this page since I first built the website.  Many of these Frequently Asked Questions were asked by trainees during the years when I was working at Tiffany Marble and some are questions I’ve been asked recently by prospects who have found my website and are searching for answers prior to starting their own cultured marble factory.  Working independently, I am now able to be forthright and answer all questions thoroughly.

This will answer many of your questions that pertain to cultured marble molds, equipment, training, raw materials, costs, training, etc.  I don’t have these Questions and Answers in any particular order, but more or less wrote them down in the order they came to mind and in the order they were asked.  So, take the time to read the who thing since you will find many important Questions and Answers throughout.   I encourage you to come up with additional questions that I can include here.

What is cultured marble?
Webster’s Dictionary defines ‘cultured’ as ‘produced under artificial conditions’.  Cultured marble is a mixture of resin, marble dust, and  catalyst.  Pigments are added to the mixture to get the desired colors.  This matrix mix is then poured into cultured marble molds where it will harden into the shape of the mold whether it’s a sink mold or a bathtub mold, etc.  It’s about four times the tensile strength of natural marble, and more stain resistant.  Its seamless qualities make it an excellent choice for the bathrooms and kitchens since there are no grout seams for dirt to hide.
Is there more than one type of cultured marble?
There are several variations and formulas such as cultured onyx, cultured granite, spray granite, flexible marble, solid surface, and other formulas that you can view on the Formulas page.
Can I be competitive with natural marble and tile?  What are the advantages of cultured marble?
Absolutely.  Natural marble is very porous, stains easily, and is less sanitary in the kitchens.  Food products spilled on an unsealed natural marble countertop or one made with tile can seep into the pores of the natural marble creating a very unsanitary condition.  Tile requires grout, which is more porous than natural marble.  Fabricated solid surface kitchen countertop is dense, so food juices won’t penetrate or seep into the countertop.  For the same reasons, the solid surface and gel coated cultured products for the bathroom are more stain resistant and more sanitary.

Natural marble is generally limited to flat surfaces while manufactured cultured marble products are not.  Cultured marble can easily be formed to produce bathtubs, shower pans, one-piece vanity tops, large one-piece shower surrounds, one-piece bathroom flooring, and many other products made on the molds you see on the Molds page.  Your customers will never have to clean mold from grout infested showers again, and will love you for it.
What can you supply me to start my cultured marble factory?
Molds, Equipment, Supplies, Training and continuous Support.

Raw Materials: I do not sell raw materials.  I’ll line you up with closest and best source for your raw materials whether you are establishing your factory here in the U.S., or overseas.  Some overseas manufacturers may have to import resin and I have a list of overseas suppliers from which to choose from, that I will give you when you’re in for training.
What raw materials make up cultured marble?
Crushed limestone, polyester resin, gel coat, powder or liquid pigments & catalyst.
What size space do I need for a cultured marble factory?
Wow... this is really a broad question.  It really depends on how large an operation you intend to grow in to, and how much equipment you start with.  One company has a formula they use to determine how many square feet are required per every one-thousand dollars worth of molds.  But, since I’m selling the same cultured marble molds for a fraction of the price, obviously this formula won’t work.  Just as important, if you have equipment including multi-level (4 or 5 level) storage racks (see Equipment page) for your molds, you can put four times more molds into the same square footage than if you are working without any equipment.  This is another huge cost-saving benefit to having mold storage racks and conveyor equipment.

Domestically, most new cultured marble factories start out with a smaller area than a new manufacturer overseas.  The reason for this is that a domestic factory can start out with a smaller package of molds and order a single mold now and then and have it in their factory in a reasonable period of time.  Overseas, most manufacturers prefer to start out with a larger selection of molds to start with because it is not as easy to order one or two molds and have them in their factory in time to produce the product for their customer.  By the time you account for manufacturing time, shipping time, and the time it takes to clear customs, your customer may be long gone because they couldn’t wait for you to get the mold.

To get to your question.  Domestically, you can easily start manufacturing in 3,000 square feet.  If you add equipment, you can utilize more molds and produce more pounds per day in this same 3,000 square feet.  With conveyor and storage equipment, you can grow and remain in this same 3,000 square feet, producing several thousand pounds of marble per day, so you may not out-grow this space for some time to come.  If you quadruple the quantity of your molds, you can simply add addition multi-level storage racks and still produce in the same square foot manufacturing space.  The average factory overseas is between 10,000 to 20,000 square feet, or 1,000 m² to 2,000 m² and it’s not uncommon to start with 2,000 m².
How many molds do I need to start with?
It depends on your investment and working capital and what products you want to manufacture, but what is most important is that you start out with enough molds to sustain your business through the beginning stages.  You will want to have a well rounded selection of molds to produce bathtubs, shower pans, vanity tops with bowl options, shower surrounds, and the necessary accessories like soap dishes, trims, shampoo holders, and window sills .  I also suggest including some products like columns, shower seats, and other items that make you stand out above the competition to give you every advantage with your new venture.
How can I determine how many units per day I can make on each of your mold packages?
How many ‘units’ per day each mold package produces is irrelevant.  How many ‘Pounds-Per-Day’ (or Kilograms-Per-Day) you produce is what you need to know.  There is a big difference between making 20 soap dishes totaling 100 pounds and making 20 shower surrounds totaling 4,000 pounds.  Guess which “20 units” make you money?  “Units per day” looks good on paper, (I made 200, five pound soap dishes today!) but your whole factory will revolve around how many pounds per day you produce.  E-mail or call me if you want a chart that shows how many ‘Pounds-Per-Day’ you can expect to produce on each mold package.  I also have them in ‘Kilograms-Per-Day’ so let me know which one you prefer.
What types of products should I manufacture?
I pretty much address this earlier, but a good way to find out what will be the biggest sellers is to talk to your future customers.  Contractors will be your best source for this kind of information.   They will tell you which products they prefer, and which sizes and styles would be their preference.  Look at a copy of their floor plans.  Print off the mold drawings on the Mold page and show them what their options are.  At the same time, some contractors may not have used these kinds of products in your area.  You have to show them, for example, the benefits of having one-piece shower surround wall panels vs. tile.  He benefits by a fast and easy installation.  The end user benefits from never having to clean soap scum and mold out of tile grout again. 
How many employees will I need?
With the proper equipment, it shouldn’t take too long before 4 employees will be producing 2,000 to 3,000 pounds per day.  Without the conveyor equipment, you will require additional employees to sort out the chaos and shuffle the molds around the factory.
Why does the equipment allow me to produce more parts per day?
The equipment gives your factory organization, and there is no lifting or shuffling around of molds.  All the molds are on a roller track and follow a ‘flow’ or ‘system’ through the factory making it easy to move the molds through the manufacturing process.  They molds start out in the set up area, slide down the track to the spray booth, over to the vibrating table, into the storage rack to cure.  They are then moved to the de-mold and finishing area before starting this sequence again.  Without the equipment, there will always be alot of chaos and time consuming shuffling around of molds to move them through the manufacturing process.  Also, if you don’t have an extra large space, you are limited on the quantity of molds your factory is able to accommodate, which limits production and how many pieces or pounds per day your factory can produce.  If you’re not able to start out with a conveyor system in the beginning, your first goal should be to do what needs to be done to include one in your manufacturing operation as soon as possible.  The equipment makes you money by increasing production and at the same times saves and money by producing with less labor, and in less space. 
Can I make any color of marble?
There are more colors available to you than you will probably ever use.  But, if you have all the standard colors available and want more, you can even order custom colors.  There are dry power pigments, liquid pigments and many granite colors to satisfy any customer’s needs.
Can I make any shape of cultured marble?
The molds are designed to be very versatile and by using divider bars, templates and a combination of molds, you can supply any standard or custom shaped products for your customers requirements.  You can manufacturer products specific to your customers requirements that they could never buy off a shelf in a building supply store.
Is it possible to pour my molds four times per day?
You will have a very successful business if you only turn your molds once a day provided you have enough molds to start with. Whoever says it’s possible to turn your molds four times per day has never worked in a factory pouring marble or is smoking something. How many times per day your molds can be poured has nothing to do with the molds you're pouring on, but everything to do with the raw materials you are putting on the molds. Your molds could certainly handle being poured four times per day but the question is whether you are capable of setting up the molds, waxing the molds, spray them with gel coat, letting the gel coat cure, pour the marble, and have the marble cure fast enough to take it off and do this cycle four times in a day. Oh, maybe we're not talking about an eight or ten work hour day. Also refer to the piece I wrote on the Blog regarding this. 
What happens if this current building trend doesn’t continue?
Statistically, when new construction goes down, remodeling construction goes up, and the remodeling industry is usually a more ‘custom’ market where the mark-up is better than the new construction market.  You may require a larger variety of mold styles and sizes in the remodeling market, but the bigger mark-up will more than pay for itself.
What are the molds made from?
I’ll save my time and space here and simply refer you to the Molds page.  I covered this question there since it's a very important question that demanded a detailed explanation. 
What is the life expectancy of a mold?
The molds are designed to produce several thousand parts and will last you many years by using a little common sense and incorporating a maintenance plan.
Do you have a minimum mold package requirement?
No, I don’t have a minimum requirement but if I feel you’re undercapitalize, I’ll tell you so.  For starters, you have to start with enough molds to produce enough products to sustain the business.  You’ll want to be able to produce  bathtubs, shower pans, shower surrounds, vanity tops, window sills, trim moldings, soap dishes and a few other miscellaneous accessories that will go into a bathroom or kitchen.

Of course there are exceptions to the rule.  If an individual wants to manufacture a few select items and work it in conjunction with their existing business, then it may be feasible to start with a very small selection of molds, for example, a cabinet shop who wants to produce their own cultured marble, onyx, granite, and solid surface sinks and countertops. for their existing customers.
Is it hard to keep the molds in good working condition?
The molds are quite easy to work with and maintain.  You’ll learn the importance of mold maintenance in training and we’ll do some mold maintenance work.  The molds are designed to make you several thousand pieces and will last you many years with proper maintenance.  There is nothing difficult about maintaining your molds and it is more a matter of discipline and working habits.  In one sentence and a 5 minute demonstration, I’ll teach you something that, if every marble shop would do it, would save them thousands of dollars in sanding and buffing labor cost and give them several years of extra service.  Did you hear about the guy in San Francisco that put over 600,000 miles on his 1988 Toyota, and is still driving it?  That is extreme, but it shows you what maintenance will do for you.  In your case, good mold maintenance will not only save you labor cost, but will allow you to use every mold for many more years.
Will you help in laying out our factory?
Certainly!  I have quite a few factory layouts that I’ve done in the past that may work for you and if you already have a building, chances are one of them will fit your building configuration nicely.  E-mail or fax me your factory floor plan, including dimensions, door locations, and support columns, and I will send you a factory layout to fit your requirements.
Are there factors we need to keep in mind in regards to expansion when laying out the factory?
Yes, but I always do that when laying out a factory floor plan anyway.  If you don’t have equipment, simply adding equipment with multi-level storage racks will allow you to add four times more molds to your mold inventory.  That, in turn, frees up space to add even more racks so that your factory can utilize even more molds.  The equipment layout drawing that you see on the Equipment page could easily be adjusted to allow for twice the mold capacity. 

When laying out a new factory with the equipment, we would want to take ‘expansion’ into consideration when we set up the factory initially.  The most common ‘add-ons’ in a factory would be more storage racks, a gel coat heating tunnel, and more vibrating tables.
Do I really need a spray booth?
Absolutely!  One of the first steps in producing marble, onyx, and granite is applying gel coat on the mold.  The gel coat is one of the first steps in manufacturing your marble and it is what gives your products the stain resistant qualities.  So, you will require a spray booth to apply your gel coat.
I see you stress the importance of a larger spray system rather than using a more simple cup gun.  There must be some advantage to spending the extra money.
I had a long half page explanation how a quality gel coat spray system will pay for itself in a short period of time.  To keep this FAQ as short and to the point as possible, let me simply say here that the money you save on material cost (gel coat) and time (labor), a gel coat system will pay for itself in one year.  If you start out using a cup gun, seriously consider graduating as soon as possible, to a better system.  I would not recommend your spending an extra 5K or 6K unless it was going to add to your bottom line.
Some places don’t stress equipment like you do on your website?  Why?
I think the Equipment page pretty much answers this but I will summarize it in a few short words.  The cultured marble conveyor, transfer, and storage equipment will cut your labor cost and increase your production, putting more profit in your pocket.  Why others don’t promote equipment more is a good question.  I guess if they only sold molds they might think it would take money out of your mold budget and you would buy fewer molds.  I look at the whole picture and will help you build a factory that will make you money.
What is the most basic equipment will I need to get started ?
The equipment that you will absolutely require is: a Blender/Mixer, Vibrating Table, and a Spray Booth and Gel Coat Spray system.  You could start with this and eventually grow into buying the above mentioned equipment as your profits allow.
Do I require a lot of small tools?
You biggest investment will be in molds and equipment that you see on those two pages on this site.  There are some such as a compressor and some small power tools that you will need such as skil saw, sanders, buffers, etc.
Are there other companies that sell the concept of establishing a new marble factory?
Of course!  There are companies that sell molds, there are companies that sell the equipment, and there are companies that sell cultured marble supplies.  But, there isn’t anybody that will watch out for you and bundle everything together with your benefit in mind.  Molds, Equipment, Supplies, Detailed Training, and the crucial Continued Customer Support.  I will see to it that you buy everything that is required to make you money, but at the same time make sure you are not buy unnecessary items to establish your new factory.
What are the square feet requirements?
Good question.  I must not have explained this clearly earlier, so I’ll try to be more clear.  That depends on how big of an operation and how many molds you start with and whether or not you start with the conveyor and storage equipment. The factory layout system on the Equipment page is in a small 3200 square foot building.  Notice that this factory has four multi level storage racks.  Without the multi level storage racks, you would require twice as much space and you would produce fewer parts per day since you don’t have an organized system in your factory.  If you’ll look at the drawing, you’ll notice that if you add another 20 foot of transfer cart rail, you can add another four additional multi level mold storage racks, which will double the capacity in this same 3200 square feet. So, as you can see, your square foot requirement is not based strictly on how many molds you have.  Also, this gives you an idea on how the equipment will actually pay for itself in a short period of time, by saving on manufacturing space, and increased production.
Can I buy my supplies locally?
Some supplies and shop tools you can buy locally and some you will buy from supplier specific to this industry.  When you come in for training, you will get my personal list of ‘all’ suppliers that I have been working with and collecting for the past 15 plus years.
Why are there so many sizes/depths of Vanity Top Molds?  Bathroom Vanity tops are generally 22" deep. Kitchens are 25".  Where would I use a big 30" Deep No Bowl All Purpose?
You’ve done your studying, or you’re a contractor.  You are correct in your dimensions, but to make a mold package even more versatile, this 30" No-Bowl All Purposes is a good mold to have.  It will allow you to make the various style of edges, such as the Bullnose, Ogee and other drop front edges you see in the Photos Page.
Are there any environmental issues or hazardous waste?
There is no hazardous ‘waste’ in producing cultured marble.  You will be using a flammable polyester resin to manufacture your cultured  marble products, but it’s a common raw material in manufacturing.
Are you a franchise?
No.  There are no continued obligations once you establish your marble factory.  You can buy from any and all the suppliers in the industry.  In fact, I give you my personal supplier list that I’ve accumulated over the years.  But, of course I will continue to give you the personal support when you need it.
Who will be my customers?
New and remodeling contractors will be your biggest customer and they will be a repeat customer for all their future projects.  But, other potential customers include bath and plumbing shops, plumbing contractors, cabinet makers, and interior designers.  Believe it or not, tile supply stores and tile setters can be a big customer for your shower pans and soap dish accessories.  Some of the local Lowe’s and Home Depot type of stores often buy their customer order products locally.  Your most lucrative market is selling retail, direct to the end user.  Consider investing in a showroom to display your products.  It will pay off handsomely.
Where/How will I find my customers?
Since contractors will be your biggest and most immediate customers, sending a personalized introduction letter is very effective.  There are many local building permit publishers that sell the weekly building permits applied for in each county.  When you get established, plan a ‘Grand Opening’ open house and get the word out by newspaper, radio and TV.  I see a local marble shop advertising on TV in the evenings.  We’ll go more into detail on this when you’re in for training.
Can I expect to go home and make quality products after training?
Yes.  I have been training for the past 15 years so I have an idea what points to concentrate on.  I always make sure everybody understands what we’re doing before moving on to the next project.  I always like see everybody taking notes so you will have all the information written in their own words and in your  own language for later reference.  You’re also free to take video and photos.
Will I be capable of training my staff after my training?
With the knowledge you’ll gain in training, in addition to your videos, photos and notes, you should be able to train others when you return home and set up your factory.  When questions come up, I’m only an e-mail or a phone call away and I try to be very prompt in replying to e-mails.  At the latest, you’ll get your question answer the following morning.
Can you come to my factory to train my employees when I get it all set up?
Set up your factory and start producing a few samples.  If you feel it’s required certainly we can discuss training in your factory to train your staff and solve any manufacturing problems you may have.  I want to give you every opportunity possible.
What are the electrical requirements in a factory?
Electrical supply varies depending on where in the world your plant is located. Most domestic (USA) electricity is 60 Hz. Internationally, 50 Hz service is the most common. In addition, electricity is available in single phase or three phase. Single phase is available almost everywhere; in homes, offices, small industrial buildings, etc. Three phase is usually available in medium to large industrial buildings. It is much more economical to operate equipment on three phase (where possible) supply due to the higher voltage. For example - a small plant with a single mixer and spray booth would need about 40 Amp, 60 Hz, single phase service or about 13 amp, 60 Hz, three phase service. A larger fully equipped factory would require three phase electrical service to efficiently operate the production equipment. This would be something on the order of 45 Amp, 60 Hz service.
What size of compressor will I need?
You will want a compressor capable of putting out 125 cfm @ 60 psi.  You can’t really buy a compressor ‘too big’, but at the same time, no use buying a lot more than you require.  But, you’ll want a compressor capable of supplying air for spraying gel coat, vibrating your tables, and using any air tools such as buffer and sanders.  
Will I need a lot of storage space for my marble products?
No.  You won’t be producing products to inventory.  Inventory does not make you money.  You will be making your products per your customer’s specifications, and they should go out the door as soon as they are ready.  
What do I need to look for in a building?
You will want to set up your factory in an industrial area.  It’s a ‘factory’.  You don’t need something classy for manufacturing especially since most of your first customers will be contractors. Often times, a showroom can be set up in the same building as the factory and many people like to buy from a ‘factory’.   They know they’re getting a ‘deal’ by purchasing directly from the factory.  After you get established, check into the feasibility of building an additional showroom offsite in a higher traffic/retail area to expand into the lucrative retail traffic.
What makes you better than another company that assists in helping individuals start a new factory?
Experience, prices, training, dedication, and the hands-on guidance and support to see that you get your factory up and running with the dedication and expertise required to build a profitable business.  I have been setting up marble factories for many years so I have a sound knowledge of everything involved with this business;   molds, equipment, supplies, suppliers, manufacturing the products, training techniques, everything.  I am principled, pay to attention to detail, and have the sincere desire to help make your factory successful.
Do you have a standard training schedule you follow?
Yes, I do, but I also realize that everybody has different needs.  I cover all the principles and formulas that you see on the training page, but just as your customer requires custom fit pieces, every training class is ‘custom fit’ to meet the needs of the markets that each student is pursuing.
What is the delivery time of your molds and equipment?
It varies, but generally I can get them out the door in 6 to 8 weeks.  If you’re targeting a certain date, be sure to take into account shipping times and the estimated time it will take you to clear customs if you are overseas.  This varies from country to country, and you have a better idea than I would for your particular country.
How long will you guarantee the molds?
I personally select the molds that are the best in the industry.  You will not find better quality molds anywhere.  As I mentioned above, how you take care of your molds and how well you maintain them will determine how long a mold will last and how many parts you will be able to pull off that mold during the course its life.  It’s not uncommon to see molds being used for over 20 years.  Proper care, maintenance, and storage as well as some simple mold maintenance techniques will do more for you than a warranty.  I know a company who offers a long mold warrantee but they charge 2 or 3 times more for their molds.  These are the same molds.  Read more about molds on the Molds page. 
Why do you not recommend glass molds?
Glass breaks.  I know three factories overseas who's glass wall panel molds broke.  They were an ocean away and were without a wall panel mold for a few months.  This cost them a lot of money.   Only buy the standard style wall panel mold.
Do most factories start out making solid surface in addition to cultured marble and onyx and granite?
Solid surface is great.  There is a great market for solid surface kitchen sinks and for hotel vanity tops. Solid surface has become the choice of materials in the hotel industry because they are so easy to maintain.   Kitchen sinks give you great profit margins.  
Can I use the same equipment to produce solid surface if I buy one of your cultured marble factory equipment packages?
You can produce solid surface using your same conveyor equipment system and vibrating tables, but will require some additional equipment such as a vacuum blender, sander, and post curing oven.
How long is the training classes?
Regularly scheduled training classes are one week long and if language is an issue we can certainly extend this into the second week.  The main objective is that you go home knowing you can produce excellent quality products.
What all is included in the training classes?
The training page will explain how important training is and the formula page will explain all the different formulas that are covered in a training class.  It’s important that you go home capable of producing quality marble, so I make sure everybody follows along in training before moving on to the next phase.
Do most factories deliver their products?
Every factory is different and what is expected of every factory is different.  Some factories prefer to simply sell their products out the door and others require the customer to pick up.  Some factories feel they can sell more products and do more justice to their products if they do the installations themselves.
How much marble can I produce per day?
This will depend on how many molds you have, whether or not you have a conveyor system, how many employees you have, and how organized you are.  For example, using that little 3200 square feet factory with equipment, utilizing 4 or 5 employees, should be capable of producing over 2,000 to 3,000 pounds per day relatively easy.  Obviously, your goal is to increase your pounds-per-day, per person, as much as possible.  If you produce 3,000 pounds per day with 4 employees, you are averaging 750# per person per day.  Basically, the more equipment you have the higher your pounds-per-person, per day you will average.
How many molds will I need to start a new factory?
For starters, you have to start with enough molds to sustain a factory but molds alone will now make a factory.  You'll need Molds, Equipment, Supplies, Training and Customer Support.  The best place to start is to let me know how much capital you want to invest in molds and equipment and we’ll put together your factory based on those facts.
How will I know what molds to buy for my new factory?
After you determine what you want to invest in molds, we will sit down and discuss mold selection in detail.  I have helped establish factories in many parts of the world and you may have an idea which items would sell best in your area, so we can pool our ideas together to build a perfect package that is right for you.  Spend some time browsing the various categories on the lefthand side of the Molds page.  You will see hundreds of styles and sizes of molds there.  Don’t let the selection overwhelm you.  There are many molds that are very versatile that will make many different configurations.  You will learn a lot about the molds in training and we can make your final selection at that time.
What about producing novelty items with cultured marble and granite?
I like to keep some novelty types of molds around for fun and to pour some left-over marble matrix into, but if you want to make money, stick to producing the bath and kitchen building materials.
Since I am overseas, will I be able to contact you easily if and when I have manufacturing questions?
If you have e-mail or a phone, no problem.  The best way to reach me is by e-mail since I can read my e-mails regardless where I am.  When I’m home, I check my e-mails several times a day.  When I’m traveling, I check them at least once a day or more.
What are the biggest sellers for a cultured marble factory?
Shower surrounds/Wall Paneling, bathroom vanity tops with decorative edges, pedestal sinks, bathtubs, shower pans, columns, all-one-piece textured flooring, double and triple bowl kitchen sinks, window sills, trim moldings, recessed and corner soap dishes and combos.  Gaining popularity are undermount bowls for vanity tops.  The big question is what style you prefer.  Again, refer to the Mold page and check out the drawings in the categories on the left.
What are the most profitable products for a cultured marble business?
Tubs, pans, and wall paneling/shower surrounds.
Can I make marble columns?
Certainly.  You can make them two different ways, depending on the mold.  You can see a couple styles on the Columns page.  You can manufacture them in an open face mold in two separate pieces and bond them together, or you can make them as one unit, using a rotational mold.  There are advantages and disadvantages to both, which we’ll discuss more thoroughly in training.
How will I determine my prices?
You’ll want to do a market survey in your area to determine what the market is demanding for your or similar products.  Don’t cut prices simply to get a job.  It is better to do excellent quality work and get paid well for them.
Can I make exterior marble and granite?
Yes, you can.  You will need to add an additional product to your marble though.  There is a huge market in the bathrooms and kitchens, I’d concentrate on these first.
Are large building supply stores a good potential customer?
They wouldn’t be my main target, but some of the Lowe’s / Home Depot’s oftentimes work with local custom manufacturers like yourself for custom vanity tops.
Do I need a showroom?  Should I sell direct to the public?  Retail?
Yes! I’m all for it.  Pound-for-pound, retail gives you your biggest return.  Building a small showroom at your factory is an excellent investment.  If you show it, you’ll sell it, but you have to show it.  The product will sell itself.
What formulas that I see on your formulas page are the best sellers?
What is more important is what products will give you the best return.  The answer to that is cultured marble, onyx, and granite.  Spray granite is becoming a hot item and very profitable as well.  And you thought all those different formulas were so cool, didn’t you?  Well, they are, but do what makes you money, not what you think looks cool.
Do most factories make all these formulas?
No, because they are doing what makes them the most money.
Are the two tone sinks I see on your site hard to make?
No, they’re a ‘piece of cake’, and you can demand more for them than an ‘ordinary’ sink.  Plus, they’re great to show since it’s something not found in any other kind of bath or kitchen display room.  When was the last time you saw a two-tone sink at your local Kohler or American Standard store?  It is something unique that you can make that is very custom.  There are a lot of things you can do that you can’t buy ‘over the counter’ in other outlets.
I live overseas in a small developing country?  Do you think it’s feasible to start a marble factory in my market?
Yes, of course!  I’ve seen some markets overseas which are even more lucrative than here in the U.S.  Everybody needs these bathroom and kitchen building materials.  If you’re in a developing country, look around at what is on the market.  There is a chance that many of those building materials are imported.  You can be making these bath and kitchen items locally.  We’ll work together and build a package to fit your budget and the building needs of your area.  Every place is unique in what is required in bathrooms and kitchens so we’ll put together a factory that if perfect for you.
What is the difference between solid surface granite or cultured granite?
Solid surface, sometimes referred to as “Densified”, is more dense than any of the other cultured products you will be producing.  The density of this densified product prevents anything from penetrating it, giving it it’s stain resistance qualities and gel coat is not required.  This allows solid surface products to be cut, joined together, and routed, similar to what you can do with wood.  Cultured granite is produced using gel coat to resistance.   I’m writing an article on Solid Surface vs Cultured Stone, so when I finish it, I will post the link here.
What is best for kitchens?  Solid surface or cultured marble or granite?
You definitely want to use the solid surface for kitchen counter tops and kitchen sinks.  In the bathrooms, you can use either solid surface or cultured marble, onyx, or granite.
Is there any advantage of solid surface over natural marble or granite?
Everybody says I’m biased (wonder why?) but I prefer solid surface over natural marble.  Solid surface is “dense” and is much more stain resistant than natural marble.  Natural marble is very porous, therefore will stain easily.  Natural marble can be sealed, but who is going to do that process every few months for the rest of their lives.  You will get many phone calls asking how to get stains out of their marble.  You’ll already know they’re talking about natural marble, so you can tell them to call their local natural marble sales representative..... or sell them solid surface.
I am in a cold climate?  Will this affect manufacturing?
Yes.  The cooler the weather the slower your cure time.  Simply adding more catalyst won’t suffice.  There is some equipment that will speed up your cure time, and is something you’ll have to look in to.  With a small investment, you can double your production in the winter time by adding a gel coat curing tunnel.  I received an e-mail from a factory overseas.  They told me that they pretty much shut things down in the winter.
Can I make toilets?
Sure you can, but you probably won’t want to.  There are a lot of parts to a toilet, and a lot of labor involved in producing and assembling the pieces.  So, you won’t find them profitable.  Some individuals have said that selling a matching toilet would be a requirement in their market but I have found a good alternative was simply producing toilet ‘seats’ like the ones you see on the Photos page.   This is simply the “toilet seat and cover mold”.
Can I make floor tiles?
Yes, you can make floor tiles for the bathroom, but a better alternative is to try to make the bathroom floor in one single piece.  There is a large textured slate finished panel mold on the Wall Panel page that you will find on the Molds page.  This allows you to have the slate finish without all the groute lines you would have if you used 12 inch floor tile.  “Seamless” is one of your big selling points.  Why do you want to turn around now, and sell your customers ‘seams’?
A company wanted to sell me just molds?  You have a lot of other stuff on your website?  Are all these other items required, like equipment and supplies?
Read the Equipment page and then you decide.  It gets down to choosing Equipment or more employees.  The equipment shows up for work every day, never questions your advice, doesn’t require workmans comp, will work three shifts a day if asked, and never asks for a raise.
I live in a small town in the midwest.  How big a city does it take to support a cultured marble factory?
It depends on your expectations.  Also keep in mind that your customer base won’t only be from the town where you are located. Chances are, you’ll draw from a large county wide area or more.  Chances are, if you drive thirty minutes to an hour in any direction, you’d have plenty of market potential.
I am quite a distance from a big city?  Will I be able to get raw materials?
Sure, but they may not deliver as often as if you were near a larger city, but keep an eye on your inventory and just plan ahead!  If you are overseas and have to import your resins, the same applies but you just need to look ahead a couple additional weeks to allow for shipping time.
What is the Material Costs to produce marble.
Material costs will vary depending on whether you’re producing marble, onyx, granite or one of the other formulas.  E-mail me and I will send you some information on this.
Can cultured marble be repaired?
Yes, you can repair most scratches, dings, and chips.  You’ll learn how to do this detailing in training.
Is there any place where you can’t help establish a cultured marble shop?
As far as I know, I am only restricted doing business in North Korea, Cuba, and Iran.  Sanctions were recently lifted for Libya, so I’m looking forward to establishing a factory there, simply because I can.
You stress on your website the importance of the mold selection but there are so many options to choose from I don’t know where to start.  How can I determine what molds I should start with.
Don’t be overwhelmed with all the molds to choose from.  We’ll go over molds in detail when you are in for training and put together the best mold package to fit your budget.