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 Kalymnos, Greece.
Founded in 1956, the factory traces its roots back three generations to the natural sponge business. Kalymnos 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 Kalymnos
Kalymnos lies in the south eastern Aegean Sea between Kos, Leros and Asia Minor. Kalymnos 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 Kalymnos, prides itself as a part of the Kalymnos 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.
Exclusive and Proprietary Base Foam Buns
Our Premium Grout Sponges are made of a high quality, exclusive polyester base material designed for the Tile & Stone Industry. We utilize a proprietary "gas explosion" or "thermal" reticulation process to create the optimal number of open cells, while assuring the highest level of durability.
The reticulation process starts by placing the high quality polyester foam “bun” in a very large vacuum pressure chamber. Air is evacuated from the chamber and then filled with an explosive gas mixture. The gas is ignited and a controlled flame passes through the polyester foam, melting or opening the cell membranes while retaining a strong skeletal structure. The result of this process is sponges that are soft and smooth with maximum absorption, retention and release of water/sand/cement for the fastest and best 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.
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.
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.
Packaging Options
Depending of the specific product, sponges are available in Bales with individual sponges, 3 piece or 12 piece mesh bags and/or Corrugated boxes with 12 piece or 30 piece vacuum pack bags.
Vacuum Pack Process
Depending on the desired quantity up to thirty (30) individual sponges are placed in clear, plastic vacuum bags.
Air is evacuated, compressing the sponges down to convenient handling size bags.
Depending on the desired quantity, the compressed sponge filled bags are stacked and banded together.
The stacked, banded sponge bags are placed in SpongaUSA corrugated boxes for shipping.
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 be shipped to our US Distribution facility.