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Fabricator Profile
A Visioneer in solid surface

view of kitchen
What began as a laminate cutting station has grown into a full fledged producer and fabricator of post-formed laminate tops, as well as solid surface veneer, 1⁄2-in. solid surface and solid surface accesories.
From left: Steve Aldridge, Travis Aldridge and John Aldridge
President Steve Aldridge, wth the help of his son, Travis Aldridge, as vice president, and his brother, John Aldridge, as vice president of sales and marketing, grew his business from a one-man laminate cutting station to a full-fleged manufacturer of a variety of products, including an inventive solid surface veneer that is poured and fabricated in-house.
Figure 1
Figure 1 - Sta-Care offers a hybrid of laminate and 1⁄4-in. solid surface that has many features of both products.
Figure 2
Figure 2 - Using the special grade of contact cement, the solid surface veneer is laminated to a particle board substrate, fitted with a balance sheet and moves onto a company-built core building machine that squares the sheet, applies build-down strips, creates an expansion joint and applies hinge tape for v-grooving.
Figure 3
Figure 3 - Once they have been laminated, the solid surface veneer slabs move into a nonconventional v-grooving machine, which the company built, to undergo v-grooving, glue-up and clamping as part of the same process.
Figure 4
Figure 4 - While the company still batch mixes its solid surface, it recently switched to a “continuous curing” line in which the material is conveyed through a curing oven and comes out the other side near-ready to fabricate.
Figure 5
Figure 5 - Since switching over to a continuous curing line Sta-Care has found it very easy to get into the production of standard 1⁄2-in. solid surface.
Figure 6
Figure 6 - Sta-Care now molds a number of specialty products, including 32 colors of sinks, vanities, shower pans and shower caddies.

"We have no intention of fabricating [1⁄2-in. material] at this point," said Steve. "If you want to fabricate 1⁄2-in., you have to install, and we cover too large of a market area to be able to install a product. So, I've made the decision all along, and I keep making it year after year, and that's to stay as a furnish-only company and not get into the installation."

However, they are working to establish a distributor network and drive a lot of growth through providing their ½-in. solid surface to other fabricators, according to John. Additionally they are handling a number of molded products.

"We've gotten into a number of specialty applications," said John. "We're manufacturing quite a bit of material for commercial applications. We're large enough to handle the volume and small enough to want to do it."

These specialty products include a variety of different thicknesses of material, but also 20 matching aggregate sinks as well as 12 solid colors and numerous prefabricated accessories, such as shower pans, wall cladding and shower caddies, all of which can be made to match a particular color of vanity or countertop (see Figure 6).

Looking Ahead
While the company continues to produce approximately five miles of laminate tops a week, customizing the majority of them, and customizes most of its solid surface veneer product, it is looking toward a future where more and more material is supplied to outside fabricators.

John said the company is continuing to develop its network of fabricators and that the door is wide open for numerous potentials.

Because the solid surface veneer does not require any expensive or specialized tools, many laminate companies can add it to their lineups easily. Additionally, its price point is attractive in that it will give solid surface fabricators wanting a less expensive alternative an opportunity to provide it without entering the laminate market. Finally, hard surface fabricators wanting to be able to offer a solid surface option can buy into the product with a relatively low investment, all of which spells out growth for the company.

"You could set up a shop to do this very easily," added Steve. "It could be a really easy way for fabricators to enter the solid surface market without the huge expenses."

Whether this happens or not remains to be seen, but there is little doubt that the innovation the company has based its foundation on will continue to drive the business well beyond its current boundaries.