INTRODUCTION TO THE STONE INDUSTRY

USA and global market
from the quarry to the jobsite, the care and maintenance before and after install.

INSTALLATIONS
Interior/exterior ,applications ,what stones to use or not to use when and where. , stone composition, how to select the right stone for the application.

QUARRIES
Extraction of blocks, processing from block to slab and block to tile.

USE ALL THE STONE LIBRARY INFORMATION
Offering seminars and tours of quarries world wide.

FABRICATION
The mechanics of a successful stone shop, from hand fabrication to fully automated production facility; procedures; shop layout; proper material flow, production capabilities, maximize existing shop equipment.

START UP SHOPS OR EXISTING SHOPS
Shop organization and proper product flow ,efficiency.

TRAINING CENTER
Programs offered, saw cutting, slab layout ,cnc operators ,programmers ,technical support, proper material handling in shop, warehouse and jobsite's, hand fabrication, dry cutting shaping, edge polishing ,surface polishing core drilling, lamination, rodding.

SHOP EQUIPMENT ,RECOMMENDATIONS
Based on production needs and future expansions.

MATERIAL ACQUISITIONS
Save money on stone; consumables;[ shop and install ] tools adhesives sealers.

MACHINERY, VEHICLES
Reduce and or eliminate the learning curve weather you’re a start up shop or existing shop, marketing how to, where to invest your valuable hard earned dollars,, ,book matching slabs floors walls countertops a lost art, I can train you to become a real stone man.

ABOUT LEN MALAVE

When Len Malave talks about marrying Old World craftsmanship with modern technology, he’s thoroughly acquainted with both sides of the partnership. .

Even before CNC manufacturers had successfully adapted their machines from glass production to stone, however, Malave saw a vision of the future; and when he opened the doors of his own business in 1996, the shop had one of the first CNC STONE ROUTERS by Z. Bavelloni S.p.A. and ZONATO bridge saws in the United States.

Malave jokes about having stone in his veins; his father owns a restoration business, and his brother is a fabricator. “I really got into the business as a kid helping my father and people like my grandfather,” he says. “ they took me under their wing and taught me how to work with natural stone initially making our own tooling and fabricating our own jobs .” However, Malave didn't build his career strictly on those youthful experiences. A native of Cherry Hill, N.J., he joined the union at 18 years age and worked for a couple different locals, eventually signing on with D’Ambrosio Ecclesiastical Art Studios in New York. “ I’ve had incredible role models,” he says. “Some of the people that Mr. D’Ambrosio brought from overseas were master craftsmen– real artisans, were brought in from Europe to do the work, stonemasons ,painters, carpenters, iron workers,, I had the opportunity to work with some of the finest craftsmen in the world.”

Today, Malave runs three CNCs and two Zonato S.p.A. bridge saws, but the company is about much more than speedy output. Malave enjoys educating people about all aspects of his trade, whether it’s through seminars for his customers, the creation of a stone library or consulting with people much newer to the industry. “It’s important, with the growth of people interested in the industry, that they go to someone who’s had the
Experience,” he says. “We’ve been there and done that.”

When Malave talks about bringing stone from the mountain, he’s done that, too. He imports his own slabs from both Brazil and Italy, and visits to the quarries and factories of those countries help feed his love of travel. It also guarantees the quality of every stone offered by Granite and Marble by Malave. “I’ve been at this so long, and know so many great companies in both countries, that I’m able to get a selection of stone that’s just unbelievable,” he says. “We stock about 2,000 slabs, and I don’t just go for exotic stuff. There are a lot of types of Uba Tuba, for instance, and I find the best of the best, or something that’s a bit unusual. It might be a basic stone, but it’s just a really good quality.”

That quest for top-quality stones fits well with the company’s customer mix, since Malave definitely isn’t interested in turning out a cookie-cutter product. He says the company does work with some homebuilders – even those building tract homes – but only those building higher-end homes with custom kitchens. It’s an approach that’s also taken Malave’s reputation well beyond his North Carolina market. He says many of his customers have multiple homes that have taken his crews to places as far away as Washington DC, New York, Florida Colorado and the Caribbean. “We’ll go anywhere and do just about anything,” he says. “We’ve done a lot of real high end projects, when someone said well this may not be able to be done, or we cant do that, we got the call. One of the things I grew up doing is exterior panel systems and wall-hung panels. We also do exterior staircases, pool coping and decking.” Selling his products has never been a problem for Malave. He believes the quality speaks for itself – he estimates 80 percent of his jobs are either repeat customers or referrals – and he relies a great deal on his showrooms. (The one at the Greensboro facility includes two full kitchens, and a slab bathroom with an illuminated shower lined with translucent stone). Granite and Marble by Malave also takes its show on the road. The company does a number of home shows around North Carolina, and shows off its capabilities through a booth with a puzzle floor, backlit onyx walls and waterjet inlays.
Just as he was an early adapter of CNC technology, Malave also recognizes the power of the Internet, although he says initially he saw the company’s Website as nothing more than a necessary evil. “Now, I don’t know how people do without it,” he says. “It’s a marketing tool and a great reference for somebody to go in and learn more about the business. We’ve had quite a few people who were just surfing the Internet, found us and ended up calling us.”

Today, Malave employs about 50 people, although only 10 of them are actively involved in fabrication, working two shifts. “Our standard turnaround is seven-to-10 days,” he says. “When you have the CNC machines and some of the best shop personnel, it’s easy to do.” If anything, Malave would like to be doing more work. , and he’s looking at other locations along the Eastern Seaboard. “My goal is to get the company back to working 24 hours a day, then open several other locations, he says. “I want to be able to produce a minimum of 20 kitchens a day. Per location ”

Not surprisingly, Malave has raised some of his own workforce with his three sons. Shawn is a templater, installer while Jason works in the shop and Justin does installations. after school And, his five-year-old daughter, Anica, is – for now – helping in “customer service” and even has cards to that effect. “I had to put a desk in my office for her,” says her proud father. “She tells me her job is to make sure everything’s okay."

Testimonial

The counter top business can be a confusing and arduous endeavor. There are a number opinions associated with the proper way to fabricate, machinery procurements, shop layouts, and many other aspects.

In 1999 I was transitioning from a flooring company and venturing into the Granite Counter top business. We initially started with a hand rail saw and a sector edge machine to fabricated counter tops.

Late in the year of 1999 I read an article about Len Malave’ in Stone World Magazine which described a well run shop with automated equipment. I contacted Mr. Malave’ and he welcomed my questions and invited me to see his shop in Greensboro, North Carolina.

I flew to North Carolina the next day and discovered a shop which included all of the attributes I was aspiring for my company. Len guided me with proper decisions on equipment purchases and numerous consultations on proper production flow. The learning curve of transitioning a hand tool shop to a fully automated fabrication facility is tremendous and financially challenging.

The implementation of improper machinery or shop design can become a production and financial disaster. Len Malave’ consulted and assisted in contract negotiations with both machinery suppliers and large commercial customer contracts in order to help facilitate our success in the counter top industry.

Cutting Edge Granite has become a leader in the central Florida area and is continuing to refine and implement new technology in the organization with the guidance of Len Malave’. Cutting Edge Granite is forever grateful for Len’s invaluable consultations and friendship throughout the years.  

Larry Crowley
President / Cutting Edge Granite