by Darcie Duranceau
The journey of a granite slab or marble countertop to your kitchen is an epic tale of geological wonder, intricate extraction, global logistics, and meticulous selection. Sounds like something straight from National Geographic? That’s because it is—or at least it could be. Kurren Bafna, General Manager of Mont Surfaces, acts as a guide through this extraordinary process, which reaches its peak when the pristinely polished countertop selections arrive in their showrooms.
UNCOVERING MOTHER NATURE’S BEAUTY: THE QUARRYING PROCESS
The epic odyssey of natural stone begins in the colossal heart of mountains across the globe. As Kurren reveals, “the quarrying process starts in a mountain where they are cutting blocks, sometimes from within the mountain and at others from the exterior.” With precision (and the help of massive drilling equipment, explosives, and specialized cutting tools), these huge segments are carefully guided onto cushioned beds of sand, safeguarding the beauty of the stone from the immense forces of their release.
JURYING AND JOURNEYING: FROM RAW BLOCK TO POLISHED
From the rugged quarry, these raw blocks embark on the next phase of their transformation. Factory owners, equipped with advanced manufacturing facilities, travel directly to the quarries to “mark the blocks,” selecting specific ones that meet their stringent quality criteria. Once purchased, a block is transported, often by flatbed, to a factory for further processing. If a quarry is in a region without extensive processing facilities, the blocks might be shipped to one of the three major global hubs for natural stone manufacturing, says Kurren, who has personally visited several of the manufacturers to select from their final products. Brazil, India, and Italy are hubs, which means many of these giant blocks of stone must be placed in very large containers and shipped internationally before they can be processed and polished.
At these sophisticated factories, the true artistry of transforming raw block into polished slab begins. Each stone, being a unique product of nature, demands a tailored approach. “Every stone is handled a bit differently,” Bafna notes. Depending on the material, it might undergo specialized treatments like acid washes, extensive soaking and drying, or multiple rounds of polishing and resin application to enhance its natural beauty and durability. This intricate manufacturing process readies the stone to be shipped to distributors like Mont Surfaces around the world. For highly sought-after materials like Taj Mahal quartzite, this entire process, from quarrying to arrival in the U.S., can span up to six months. Processing alone can take up to three months due to a material’s specific needs.
A COMMITMENT TO QUALITY
What truly distinguishes Mont Surfaces in this global supply chain is their unwavering commitment to quality control. “We hand-select all the material, every single slab of material that we have in our warehouse,” says Bafna. This means a dedicated team, including Bafna himself physically making visits to factories to personally inspect and choose each slab. They commit to a stone only after its final finish—whether polished, leathered, or honed—ensuring that what arrives at their eight Midwest locations meets their exacting standards.
Sustainability is a complex but vital consideration, and Mont strives to work with partners dedicated to sustainable practices.
Mont Surfaces’ unique blend of global reach, rigorous hand selection, and a deep understanding of the stone’s journey ensures that homeowners receive materials of unparalleled beauty and quality. It also means that a homeowner can truly understand the origins of the materials being installed in their homes.
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Indianapolis, Indiana 46278
