The Schwapp manufacturing process conforms to the highest quality standards. Using global partnership and best practices, we are able to create an experience that will stay with you for life.
The making of a faucet has many steps and every stage of its manufacture is quality controlled in Schwapp. Every stage is as important because the quality of the final product rests on how well the basic steps have gone. So, creating the ‘chassis’ or foundation of a faucet is as crucial as the final finish.
Our faucet bodies are made of the purest possible brass. Brass, which is an alloy of copper and zinc, is resistant to soft-water corrosion and hard-water calcification. It is the perfect metal because it gives the faucet a certain ‘substantialness’ as well.
The faucet’s shape is achieved through die casting using state-of-the-art technology. We use IMR die casting machines from Italy, which are unparalleled as far as the construction quality that can be achieved is concerned. The IMR machines are used by top rated manufacturers across the world.
The body is made by melting brass at high temperatures and moulding them to the desired shape. These moulds are such that there is little aberration in the shape of a faucet. This is a must to ensure the final finish, which is a chroming process, is smooth as a mirror and reflects as dedicatedly.
The hot forging process is used since this method can produce a near-net shape in about three seconds with little waste. Forging is the process of shaping metals by deforming them in some way. In hot forging, heated metal is forced into a die that is almost the same shape as the faucet body. The pressure is slowly increased over the course of several seconds to make sure the die is completely filled with metal.
After die casting comes the process of machining. This is also computer controlled process. Our cutting-edge machining process ensures that the die casted product has all its surfaces finished to a high degree of smoothness. The internal water passage ways are also smoothened for better performance during machining.
Once the foundation of the faucet has been created, the internal areas that come in contact with water are leached off lead to ensure they are not just tough but also healthy, as it cuts off toxic contaminants. Almost all lead molecules are eliminated from the metal surface with this process. The process is highly automated and computers control most of the machines.
After the leaching process comes the crucial process of polishing the faucet. Only after the brass surfaces are polished to technical precision can the product be sent out to chrome plating. Unless the polishing is perfect the faucet will not get that shine that we look for in every high quality product.
For that perfect finish, polishing is carried out through a combination of manual and machine driven processes. For high-end and niche faucets the polishing is done by experienced artisans. Senior polishing technicians, who understand exactly how much pressure to apply at what points to ensure that a Belgian mirror-like finished surface is realized after chrome plating, work exclusively on our pride-of-place range.
In the auto polishing process, high tech Spanish machines, which can polish four faucets every minute with unforgiving precision, are put to work. The skills of our senior technicians and the efficiency of our cutting-edge polishing machines gives every Schwapp product that undeniable, perfect shine.
Every faucet and bath system created by Schwapp undergoes a chrome plating technique that enhances durability of the product greatly. The chrome finish is so fine that it ages very slowly. With bare minimum care, this finish can even serve you a lifetime.
In this process, first a base coating of electroplated nickel is applied, followed by a thin coating of electroplated chromium. The chrome layer is deposited from a plating bath containing certain additives that improve corrosion resistance.
The chrome layers are impossibly thin, less than the thickness of a human hair. In fact, thinner the layer, better your faucet.
After plating, various components of the faucet are fixed with digital precision. This is also a computerized process and ensures the faucet is solid both on the outside and the inside. Before that, the faucet and the necessary components are stored for a while to so that they ‘set’. And soon, they are sent to the assembly line. This process takes place on rotary assembly machines and is robotically controlled. The spout, if separate, is first installed, followed by the ceramic cartridge and control lever.
Our faucets are then put under the most rigorous test to eliminate all problems. They are filled with an extractant water to ensure there is no corrosion and hence no contaminants. Toxicologists review the material formulations to determine potential contaminants that may extract from the faucet and into the drinking water. Product samples are randomly selected for testing at Schwapp laboratories.
State-of-the-art test machinery turns faucet handles on and off at least 200,000 times. They are also kept submerged in various chemical solutions to ensure that the chrome finish is spot on. The faucets are also put through an unforgiving water and air testing cycle so as to ensure the product is perfect
Independent test teams look at faucets after every stage of manufacture. Right from the brass foundation to the polished product to the final assembly, independent experts take a critical look at the products. Anything that fails their test is promptly sent back. These independent experts function as teams that work on incentives. It simply means more faults they find at every stage of production, more they earn. This ensures nothing is left to chance.