"With more than 60 years experience in product development, we can confidently say we know sponges and have the best built and most effective sponges in the market."
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.
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.
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.
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.
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.
Our manufacturing process begins with our exclusive proprietary base foam "bun" materials that are specifically designed for the Tile and Stone Industry.
Our Reticulation process creates maximum porosity to hold more water for better clean-up and release maximum water and sand/cement.
Regardless of the material and the reticulation process, our proprietary "buns" are cut into foam bars with our automatic vertical cutting machines.
Base foam "buns" are loaded individually onto the automated cutting machine.
The foam buns then feed into our automatic sponge milling machines, which mill the different sizes and shapes of sponges.
Milling machines then make the initial cuts to the sponges.
Our automated cutting process allows us to create precision cuts, ensuring uniformity in the size and shape of the sponges.
Both automated lines produce product to exacting specifications.
Cut sponges are loaded onto the automated shaping machine.
Sponges are automatically shaped to specification.
Shaped sponges, not needing lamination, are then conveyed to the shipping area to be compacted, boxed and shipped.
Available on select items, our lamination process combines two products into one.
For our laminated products ( scrubber sponges and float sponges ), we apply a strong polyurethane glue and then compress the sheets between two rolling cylinders.
Sponges are individually laminated to ensure quality control.
Once made, all our sponges are compacted in bales to save on transportation cost.
Hydraulic presses effectively compact sponges.
On site inventory ensures your product will be delivered quickly.
Containers are loaded in our factory to take our sponges all over the world.