The process we use for manufacturing our products is called rotational molding, or roto-molding. Roto-molding makes a uniform product line using extreme precision and yielding great durability of rims, edges and corners.
Roto-molding starts with a metal mold. Each mold is made of two mirror image halves that fit together and form a hollow center in the exact shape of the product being cast.
Whether it is new or recycled resin, it starts in pellet form as little bits of Linear Low Density Polyethylene. Recycled resin comes from petroleum manufacturers, like Exxon Mobil or Dow Chemicals. The resin pellets go into the pulverizer and are made into a fine powder. This powder is the base for all of our resin products.
Depending on the color choice, we can use up to 100% post-consumer recycled material. With our darkest colors being 100% recycled, black is the new green at TerraCast®. We also use sustainable practices in our factories. Our ovens are heated with natural gas and our cooling chambers use reclaimed water. We’re so green; we qualify for LEED credits.
The powder base is put into the color blend machine. We offer all kinds of solid colors from simple black or white to our proprietary Tennessee Green. We then blend a UV inhibitor right into the resin, to make sure your color stays true for years to come.
We have six proprietary stone blends including Brazilian Terracotta, Ash Granite, Sandstone Granite, and Verde Granite. For those, we use a combination of colors mixed together into a translucent base blend. The Verde Granite blend, for example, is a green translucent with speculate added in different shades of green, black and white.
We can match or create any color you desire and even create your own unique granite blend as well.