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Manufacturing Process

Manufacturing Operation at R. Rajesh Exports

The diamond manufacturing & processing facility of R.Rajesh Exports is located in Surat (India). Here we process diamonds that delight with their purity and sparkle, in a range of sizes, shapes, color and clarity to suit every desire and need. Hence, our company has invested in state-of-the-art manufacturing facility at Surat with the capacity to process more than 3 Lac carats of rough diamonds annually. It is geared with cutting-edge technology and most advanced diamond cutting & polishing machineries. This helps us to ensure that we get the best sparkle & brilliance from each stone processed. Housing nearly 2500 committed employees in superior work environment to ensure the highest quality output.

Manufacturing Process:

Rough Purchase

Rough diamonds are sourced from the mines in South Africa and from organized markets of Antwerp, Dubai, Russia; through leading mining companies like DTC, Alrosa, Petra and ODC. Processing of diamonds according to well-defined quality control criteria leading to classification and grading of the polished diamonds by our expert staff.

Rough Assortment

This department deals with the assortment of rough diamond based on final results (Polished Outcome) of rough diamond. The results include color, clarity, size, cut etc. This department deals with the rough stone checking and to determine its properties such as purity, color, & size etc. i.e. 4'C's namely color, clarity, carat & cut. In this department the rough diamonds are assorted in to small packets based on the results by our experts. The clarity of a diamond is based on the number, location, size and type of inclusions found in the stone. An inclusion is an imperfection part in the stone that is visible under the magnification of a Grader's loupe. After rough assortment the diamonds are ready for the planning and marking department.

Planning & Marking

This is also one of the most important departments of the entire manufacturing process. This is the department which finalizes the actual shape, size, weight, clarity of the diamond. Here our expert personnel doing the planning, after he plans as to what is going to be the final output, here they mark the diamonds from where the diamond is to be cleaved or to point out where top bottom table is to be kept. When the person is not able plan the diamond technology is used. We have many advanced planning machinery which is used to mark the diamond. We have Galaxy Solaris System one of most advanced planning system which can identify each and every inclusion, pin point in the diamond. Based on this system rough diamonds are planned to get the best polished diamond. The lesser the inclusions, the clearer, brilliant and expensive the diamond will be. Quality is determined by how clean the diamond is inside. Very few diamonds can be described as” ‘flawless”; most have inclusions which may be caused by carbon spots (piques), mineral inclusions (olivine), bubbles or cracks (glets). The positioning of the inclusions within the diamond influences its value, as some inclusions may be polished out during the manufacturing process. Some diamonds may be so heavily included that it is almost impossible to see into them (Boart).

Cleaving

Cleaving and sawing are simple processes by which a diamond can be divided into 2 pieces. Now in diamond there are different planes on the basis a diamond that is marked can either be cleaved or sawn. If the marking is along with or parallel to its planes then the diamond has to be cleaved. Cleaving is simply done by a chisel and hammer, wherein the hardest material available is split into 2 pieces at the blow of the hammer.

If the marking is perpendicular or against the planes then the diamond needs to be sawn i.e. 'cut'. Sawing process in the recent times has advanced a lot as far as technology is concerned. At present diamond are sawn through laser machines. We have 32 advanced laser machine systems which are used for sawing the rough diamonds. The greatest benefit of this system is that, it is very fast and precise. A number of pieces can be sawed using laser technology at the same time by single equipment to get best crafts. “Crafts” is the technical word in diamond industry which can be best described as ready to process rough diamond.

Laser System

Once the process of Cleaving / Sawing is completed the craft diamonds is sent back to the planning and marking department for checking the results of procedures and then passed on to the next process of Boiling.

Boiling Process

The rough diamonds which are processed under laser system are needed to clean. The main function of this department is to clean the diamonds which are processed in laser machine. Here crafts are washed in sulfuric and nitric acid. After boiling process the diamonds are passed on to next process of lotting.

Lotting

The term “lotting” is the technical word in diamond industries. “Lotting” means preparing small packets of diamonds based on size. The main function of this department is to allot the diamonds to the factories. Here diamonds are allotted to the various factories based on the size.

Brutting

Brutting is the process of giving shape to the rough diamond. A person doing this has to take care of many things as the rough diamond is of ' vivid ' shapes and resembles a normal stone. Bruting process includes rough blocking, top blocking, bottom blocking. The main function of this process is to give a shape to the rough diamond in such a way that its optimum effect can be achieved by the polisher, without extra weight loss than required. The brutter has to take its utmost care of the diamond at this process so that it does not break. Also in this process the brutter has to leave as much of natural skin on the piece of diamond as possible. The minimum natural left has to be in a particular way, i.e. it has to be on the table as well as the bottom of the diamond. At the bottom of the diamond it has to be in 3 positions so as to cover the circumference of the diamond. In this process all kinds of internal imperfections formed before or after crystallization of a diamond are removed through blocking. And all imperfections rising from the surface and developing into the interior of the stone are included under inclusions. They could be pin-points, crystalline objects, feathers, clouds, needle, twinning wisps, internal graining or even air bubbles trapped inside the diamond.

Polishing

After being bruited a diamond passes to the polishing department where the final work of faceting is done. Polishing is the final step in diamond cutting. Polishing means the process of giving the diamond its final look. Ideally a diamond should be free of any visible polish lines, burn marks, scratches or abrasions under 10 x magnifications. The smoother the polish, the more beautiful and brilliant the diamond will appear. Surface facets of a poorly polished diamond appear blurred or are dull in their sparkle. This process includes three steps top, bottom, and table. Here the artisan has to be very careful at all stages as even a small mistake done by him can make the diamond look poorer than what it might have looked had it been cut properly. This is the last step in the manufacturing process of the diamond from where on it goes to the grading department.

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