Manufacturing

Based on our manufacturing expertise, access to proprietary raw materials and our skilled labor force, we produce all of our sponges in our factory in Calymnos, Greece.

Founded in 1956, the factory traces its roots back three generations to the natural sponge business. Calymnos being known internationally as the "sponge divers island", our factory had contributed in the past to the development of the natural sponge business and the successful distribution of the Greek natural sea sponges around the world. The increase in the world demand for sponges along with the limited supply of the natural ones led to the addition of the synthetic sponge to our line of products. The factory gradually became a manufacturer of synthetic sponges that are used in many areas of the industry.

  • Beautiful Downtown Calymnos

    Calymnos lies in the south eastern Aegean Sea between Kos, Leros and Asia Minor. Calymnos history, culture and folklore relate overwhelmingly to the sea and seafaring. By long tradition, Calymnians are known for harvesting sponges from the sea-bed as close as Pserimos or as far as North Africa.

  • Sponga USA Factory

    Established in 1955, the Sponga USA factory located outside downtown Calymnos, prides itself as a part of the Calymnos history of sponge production. The factory, originally built as a natural sea sponge factory, was converted and extended into a synthetic sponge factory in 1968. Operated under the direction of, resident Nick Tsangaris, the factory employs over 25 locals, making it the 3rd largest employer on the island.

  • 2 Automated Lines – 4800 sponges per hour

    Fully automated with top-of-the-line machinery, the Sponga USA factory is able to produce 4800 sponges per hour, including finishing and lamination as needed.

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Exclusive and Proprietary Base Foam Buns

Our Premium Grout Sponges are made of a high quality, exclusive polyester base material. We utilize a proprietary "gas explosion" or "thermal" reticulation process to create the optimal number of open cells, while assuring highest level of durability.

This process of reticulation involves placing a bun of foam in a very large vacuum pressure vessel. The vessel is evacuated and filled with an explosive gas mixture. The gas is ignited and a controlled flame front passes through the foam, melting the window membranes and leaving the skeletal structure intact. The benefit of this process is a smooth, clean polish cell stand which provides the sponges made of these buns with a maximum absorption, retention and release of water and sand for faster and better grout clean-up.

  • Raw Base Buns

    Our manufacturing process begins with our exclusive proprietary base foam "bun" materials that are specifically designed for the Tile and Stone Industry.

  • Proprietary "gas explosion" Reticulation

    Our Reticulation process creates maximum porosity to hold more water for better clean-up and release maximum water and sand/cement.

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Cutting Process

Regardless of the material and the reticulation process, our proprietary "buns" are cut into foam bars with our automatic vertical cutting machines.

  • Automated Cutting Process

    Base foam "buns" are loaded individually onto the automated cutting machine.

  • Sponge Milling Machines

    The foam buns then feed into our automatic sponge milling machines, which mill the different sizes and shapes of sponges.

  • Initial Cuts

    Milling machines then make the initial cuts to the sponges.

  • Precision Cuts

    Our automated cutting process allows us to create precision cuts, ensuring uniformity in the size and shape of the sponges.

Shaping Process

Both automated lines produce product to exacting specifications.

  • Shaping Machine

    Cut sponges are loaded onto the automated shaping machine.

  • Shaping Process

    Sponges are automatically shaped to specification.

  • Finished Product

    Shaped sponges, not needing lamination, are then conveyed to the shipping area to be compacted, boxed and shipped.

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Laminating Process

Available on select items, our lamination process combines two products into one.

  • Laminating Rollers

    For our laminated products ( scrubber sponges and float sponges ), we apply a strong polyurethane glue and then compress the sheets between two rolling cylinders.

  • Lamination

    Sponges are individually laminated to ensure quality control.

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Shipping

Once made, all our sponges are compacted in bales to save on transportation cost.

  • Compacting Process

    Hydraulic presses effectively compact sponges.

  • Ready for Shipping

    On site inventory ensures your product will be delivered quickly.

  • Shipping Containers

    Containers are loaded in our factory to take our sponges all over the world.

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