(English) Complete Guide to Ceramic Tiles Manufacturing Process

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Description:

Ceramic tiles are manufactured through a precise, multi-stage process that transforms raw materials like clay and minerals into durable flooring and wall solutions. India, a global leader in tile production, refines these steps with advanced technology for high-quality output.

1.Raw Material Selection:

High-quality clay (often from Gujarat and Rajasthan), feldspar, quartz, silica, and talc form the base. These are sourced, tested for properties like plasticity and strength, and blended in exact proportions by weight for consistency.

Water is added (around 33% by weight), and the mix goes into ball mills with alumina balls for grinding into a fine, homogeneous slurry. Impurities are screened out to ensure purity.

2.Spray Drying and Granulation:

The slurry enters a spray dryer, where hot air atomizes it into fine powder granules (uniform size, about 5-10% moisture). This powder is stored in silos, ready for pressing—key for even density in Indian factories.

3.Pressing and Shaping:

Granules feed into hydraulic presses (340-400 kg/cm² force), compacting them into “green” tiles within rigid moulds. Ceramic tiles use lower pressure; vitrified ones higher for density.

4.Drying Process:

Pressed tiles move to dryers (horizontal, vertical, or fast-firing types) at 100-200°C to remove residual moisture, preventing cracks during firing. This step boosts strength and ensures flatness.

5.Glazing and Decoration:

Dried tiles get an adhesive spray, then engobe (base coat), glaze (for shine/water resistance), and digital printing or rotary screens for designs. Each layer air-dries before the next.

6.Firing in Kilns:

Tiles enter roller kilns (145m long, up to 1200°C for ceramic, 1350°C for vitrified) across zoned temperatures for vitrification—fusing particles into hard, non-porous tiles. Cooling follows to 80-100°C.

7.Finishing and Quality Control:

Rectified edges, polishing with abrasives, and nano-coating repel stains. Automated sorting checks size, thickness, abrasion, and defects; tiles are graded, packed, and palletized for shipment.

8.India’s Manufacturing Edge:

India produces over 1.5 billion sqm annually, with Morbi (Gujarat) as the hub—home to 80% of capacity. Advanced automation and local raw materials keep costs low while meeting global standards like ISO 13006.

What are common quality control measures in ceramic tile production:

Quality control in ceramic tile production involves systematic checks at every stage to ensure durability, consistency, and compliance with standards like ISO 13006 and ASTM C1026.

1.Raw Material Checks:

Raw materials like clay, feldspar, and silica undergo lab tests for purity, particle size, and chemical composition to prevent defects downstream. Moisture content and plasticity are measured precisely before mixing.

2.In-Process Monitoring:

During milling, drying, pressing, and firing, parameters such as particle size, compaction pressure (e.g., 340-400 kg/cm²), drying temperature (100-200°C), and kiln temperatures (up to 1200°C) are charted continuously. Automated sensors detect variations in density and dimensions right after pressing.

3.Post-Firing Inspections:

Visual sorting machines scan for cracks, chips, colour uniformity, and surface flatness using cameras and AI. Key tests include thickness (±0.2-0.5 mm tolerance), glossiness via reflectometers, and size measurements with digital callipers.

4.Final Sorting and Grading:

Tiles are graded (e.g. first quality, seconds) via automated lines rejecting defects at rates over 99%. Samples match master tiles for colour and pattern consistency before packing.

What equipment is used for thickness and dimension inspections.

Ceramic tile production relies on precise thickness and dimension inspections to meet tolerances like ±0.2-0.5 mm, using both manual and automated tools integrated into quality control lines.

1.Manual Tools:

Digital callipers and micrometres provide handheld measurements for thickness (typically 6-12 mm) and length/width up to 1 meter. These tools, with resolutions down to 0.01 mm, are used for spot checks on samples post-pressing or firing.

2.Automated Systems:

Laser micro meters and optical scanners (e.g. non-contact laser triangulation systems) measures entire production lines at high speed, scanning tiles for straightness, squareness, and edge alignment. Vision systems with cameras and AI detect deviations in real-time.

3. Integration in Production:

Post-firing, tiles pass through sorting machines with these sensors for 100% inspection, rejecting outliers before rectification or packing. Standards like ISO 10545-2 guide calibration.