EVERYTHING ABOUT BATHS

A bath is often the most comforting, most luxurious and most eye-catching item in the bathroom. It offers deep relaxation, the perfect way to unwind after a stressful day. And for some, it's the centrepiece in a perfectly appointed design space.

Ceramic Industries' Betta Baths factory produces baths of the highest quality in a range wide enough to suit any budget, space constraints and décor preferences. In this newsletter, we'll consider the options and their applications, discuss how they're manufactured and provide some info on installation. Let's jump right in.

Bath types

Customers should consider a few factors when choosing a bath - the space available and layout of the bathroom, the design aesthetic, budget and desired function.

Freestanding baths

As the name implies, these baths stand away from the bathroom walls. They can take the form of traditional Victorian baths with decorative feet, or sleek modern baths with smooth skirts that reach down to the floor.

From a design point of view. they have real impact and often form a focal point in the room. They're luxurious and inviting while offering as much style as a fine piece of furniture. These baths require a relatively spacious bathroom.

Their tap fittings are usually attached to the wall or floor, and the waste may be located on the end or the centre.

Corner baths

A corner bath makes very clever use of space, because it doesn't require a long wall to sit against. It allows customers to place a luxurious tub in a tight bathroom. However, Ceramic Industries' range of corner baths are very attractive and look great in spacious bathrooms, too. These baths are both practical and stylish, with the look of a spa bath, and often they have ample surface space for decorative elements.

Spa baths

These baths are the ultimate in deep relaxation. Their side jets massage you with a powerful flow of water.

Some spa baths also feature jets that release air bubbles for true luxury, and have heating systems to keep the water at a constant temperature.

All Betta Baths, except the freestanding models, can be converted to spa baths with our conversion kits.

Drop-in baths

These baths are designed to be placed up against one, two or three walls. The exposed side and ends are usually tiled with the same tiles as the rest of the bathroom. Drop-in baths may have straight, oval or round shapes.

Because these baths are practical and save space, they're a popular choice for customers. Although these are very commonly seen in bathrooms, Ceramic Industries makes drop-in baths in a wide variety of shapes and styles that can add a unique look to the room.

L-shaped baths

This type combines the functionality of a shower and a bath. The extra space at end of the L-shaped bath makes it more comfortable to shower in. It's an attractive solution that gives you the best of both worids.

Materials

Over the years, baths have been produced in many materials, including enamelled cast iron, steel, copper and stone. The primary raw material used in the manufacture of Betta Baths are acrylic (polymethyl methacrylate), ABS (acrylonitrile butadiene styrene). resin and fibreglass. The materials Betta Baths use offer several advantages, including:

Good heat insulation - less electricity is used for heating water, reducing electricity bills.

Value for money.

Durable and hardwearing if cared for.

High gloss surface that will not stain, rust or corrode, if cared for.

Minor scratches or cracks in acrylic can be repaired, as the colour is constant right through the material. This also means that the baths should not wear away or flake off. (ABS baths cannot be repaired as easily.)

Acrylic is versatile and can be formed into a variety of shapes and designs.

All Betta Baths, except for the freestanding models. can be converted into spa baths with chrome jets and a heater if required.

Manufacturing processes

Acrylic cutting

Acrylic and ABS come in sheets of different sizes and colours, and are either purchased from local suppliers or imported. The cutting department provides a production plan to determine how to cut each sheet, including size and colour, for each bath model. The acrylic or ABS is then cut to the required size for each bath type.

Vacuum forming

There are two types of vacuum machines: the automatic machines that deal with entry-level, high- volume pieces, and the manual machines that handle the more high-quality pieces. The sheet is heated in the furnace for the required amount of time (usually +/- 20 minutes). For manual vacuuming the furnace temperature is set at 185 degrees Celsius, while for the automatic vacuum process, the furnace temperature differs depending on the type of bath. Once heated the sheet is pliable. It's placed into the correct mould and clamped. It's then vacuumed into shape and kept in the mould for about 10 minutes to cool.

Trimming

In the trimming department, the outlet and overflow holes are drilled, as well as holes for handles, if the bath requires them. Excess resin and fibre are then trimmed off to give the bath a smooth edge.

Mixing

The mixing department combines the correct quantities of resin, fillers and other raw material required for the production of the baths. There are two types of resin mixes - one used by the spray line, and the other by the casting department.

Casting - freestanding baths

This department deals with freestanding baths. The vacuum-formed acrylic shell is placed into a mould and clamped. It is then pumped full of casting resin, weighing between 30 and 50kg, depending on the type of bath. The moulded bath is then left to stand for 2 - 3 hours for the resin to harden. Once the resin has set, the bath is checked for imperfections. and sanded to a smooth finish.

Wood cutting

The wood-cutting department prepares the base boards that are used at the bottom of the baths. These baseboards strengthen the bath.

Spray line

There are 3 spray lines: two automatic and one manual. The automatic lines deal with the contractor and entry-level baths while the manual line deals with the luxury baths. The substance sprayed onto the bath is a combination of resin and fibreglass. The bath is coated with one layer, the wood base board is attached, then a second layer is applied. The automated programme is 2 minutes long, and once spraying is complete, the bath stands for 45 minutes inside a curing tunnel at 50 degrees Celsius.

Conversion

This department converts standard baths into spa baths. Stock required includes the bath frames and pumps.

Final inspection

This is a quality control inspection. Imperfect stock is classified as B-grade.

Packaging

The various baths are packed in a manner to minimise damage during transportation.

Warehouse

Once all required processes have been completed, the finished stock is booked in and loaded onto the system as ready to sell. Available stock is allocated to open orders. Once allocated, the stock is picked by warehouse staff, and loaded when a truck arrives.