Raw Material
The raw materials used to form tile consist of clay minerals mined from the earth’s crust, natural minerals such as feldspar that are used to lower the firing temperature, and chemical additives required for the shaping process. The minerals are often refined or beneficial near the mine before transport to the ceramic plant.
Ball mill machine
The initial step in ceramic tile manufacture involves mixing the ingredients. Sometimes, water is then added and the ingredients are wet milled or ground in a ball mill
Pressing-machine
Most tile is formed by dry pressing. In this method, the free flowing powder—containing organic binder or a low percentage of moisture—flows from a hopper into the forming die. The material is compressed in a steel cavity by steel plungers and is then ejected by the bottom plunger. Automated presses are used with operating pressures as high as 2,500 tons.
Ceramic tile usually must be dried (at high relative humidity) after forming, especially if a wet method is used.
Tiles in Conveyor Belt
Glazing
Similar methods are used as for the tile body. After a batch formulation is calculated, the raw materials are weighed, mixed and dry or wet milled. The milled glazes are then applied using one of the many methods available. In centrifugal glazing or discing, the glaze is fed through a rotating disc that flings or throws the glaze onto the tile. In the bell/waterfall method, a stream of glaze falls onto the tile as it passes on a conveyor underneath. Sometimes, the glaze is simply sprayed on. For multiple glaze applications, screen printing on, under, or between tile that have been wet glazed is used. In this process, glaze is forced through a screen by a rubber squeegee or other device.
Kiln
kilns, are used for firing tile. Usually requires a two-step process. In this process, the tile goes through a low-temperature firing called bisque firing before glazing. Firing processes take place in a tunnel or continuous kiln, which consists of a chamber through which the ware is slowly moved on a conveyor on refractory batts —shelves built of materials that are resistant to high temperatures—or in containers called saggers. Firing in a tunnel kiln can take two to three days, with firing temperatures around 2,372 degrees Fahrenheit (1,300 degrees Celsius).
Surface flatness checking
Anti-Fouling Testing
Testing of Degree
After Packing/Ready for Shipping
