For centuries, ceramic tiles have been used. They’ve adorned innumerable homes and other structures throughout the world. While the premise remains the same, the actual production process has changed dramatically as technology has advanced. Furthermore, the information provided below will help you understand how ceramic tiles are created.
Step 1. Raw Materials For Ceramic Tiles
The maker begins by gathering a variety of raw materials. White clay, talc, sand, feldspar, illicit and kaolinitic clay, dolomite, and calcite are common ingredients used to make Ceramic Bathroom Wall Tiles. They will be quarried and refined by the maker. They’ll also transport the materials to the factory and store them separately.
Step 2. Mixing And Forming
The maker then weighs the raw components and blends them in exact amounts. Before the master conveyor gathers all materials for the next operation, the producer varies the speed of each conveyor to achieve the desired blend. The mixture is subsequently dumped into a storage tank by the conveyor. The water and ceramic pellets are then fed into a series of mixing tanks. The slurry is the result of this process.
The slurry is then temporarily stored in big tanks. They then put it through an atomizer. The atomizer is equipped with a nozzle that sprays the slurry into the center. The slurry is helped to become airborne by a current of hot air, and it dries quickly to create an atomized powder.
The atomized powder is then released in precise amounts into a tray, which evenly distributes the material into a mold. After that, a massive hydraulic press exerts a force of 300-400kg/cm2. This technique converts the powder into a solid mass using high pressure and residual moisture. They dry the created pieces even more to remove the majority of the moisture. This ensures that the product will be of constant quality and devoid of physical flaws or imperfections when it emerges from the kiln.
Step 3. Glazing
Both practical and artistic reasons are served by glazing and screening. These provide the tile with its aesthetic appeal, water resistance, and durability. Glazing and screening have hygienic benefits as well. To begin, the manufacturer applies a design and color using roller screens. A manufacturer can add an extra roller screen to the line to achieve more design variety.
Step 4. Firing
The tile is burnt in a kiln after the glaze has been applied. Although there are other types of kilns, the Roller Hearth Kiln is by far the most efficient. The temperature homogeneity, cleanliness, and heat efficiency of this kiln are exceptional. This type of kiln can reach temperatures of up to 1190 degrees Celsius. Kilning hardens the glaze and removes any remaining moisture from the pottery. This completes the Kitchen Countertop tile production process.
Step 5. Quality Check
To assure quality, the finished product is subjected to inspections that look for flaws. The caliber, shade, and quality of the tiles are checked using both mechanical and human means. The information about each tile is then used to sort and box the ceramic tiles in the appropriate order. The quality, shade, and caliber requirements are then labeled on these boxes by the maker. They then load them onto the appropriate pallet and prepare them for dispatch.
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