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How Porcelain Tiles Produced ?

Sun Power porcelain tiles produced product renowned for their high density in both residential and commercial settings.

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Inspiration

2TH April 2024

Step 1: Batching

Preparing the body ceramic tiles porcelain tiles produced begins with proportioning or batching the correct amounts of raw material. The body composition of most ceramic products consists of several materials employed, influencing both the color and hardness of the tile. Precision in mixing is important to give the desired properties.

Batching process

Mixing and Grinding Process

Step 2: Mixing & Grinding

Once all materials are ready in correct amounts. then charged into ball mills together with known amount of water. Ball stone also added to help mixing process to gain finer article. The result is fine grained water filled mixture is called slip.

Step 4: Spray Drying

Mixture water in the slip is removed via spray dryer. The process involves pumping the slip into an atomizer consisting of nozzles. Moisture of the slip droplets are dried as they are heated by rising hot air. The liquid slip will then turn into powder form.

Spray Drying Process

Pressing Process

Step 5: Creating the Tile

The subsequent step involves forming the tiles by dry pressing the dried slip powder in a forming die. Using a hydraulic press, the material is compressed at an immense pressure exceeding 7,500 tons to form rigid shape of tile. Pressing slip powder is followed by determines size and geometry porcelain tiles produced.

Step 6: Drying

Drying of the ceramic tile is carried out between the pressing stage and the firing process. The drying process is employed to gradually eliminate excess moisture in a high-humidity environment, preventing the occurrence of shrinkage cracks this tile called green tiles.

Drying process

Printing process

Step 7: Print

Printing on green tiles is utilized to porcelain tiles produced create intricate patterns and motifs with digital inkjet printing machine. The ink is used for tiles printing is formulated for heat resistant to sustain high temperature during firing process.

Step 8: Glazing

A layer of liquid glass is coated on the surface of the tile before firing as they can also be coloured or use to produce special texture.

Glazing process

Firing process

Step 9: Firing

The next step is the firing of the tile at an high temperature of 1200°C in a roller kiln. Through this intense heat leading to make the solidification of the clay body into finished tiles with desired attributes like strength, durability, and visual appeal.

Step 10: Selection & Packing

Lastly before the tiles sending to you, all tiles will be quality check and graded in accordance defects, dimension, size and shade then will be grouped and labeled on the box then stored in the warehouse.

Ball stones or alumina pebbles are added into the ball mill to help the mixing process to grind the material into a finer particle. The result of this water-filled mixture is called slip.

Selection & Packaging process

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