How Tiles Are Made In Factory? Tiles कैसे बनती है?

Contact details +91 95125 68680

Saans Vitrified LLP
Lakaddhar Village, Matel Road, 8-A National Highway, Wankaner 363621, Gujarat, India
[email protected]

How Tiles Are Made In Factory? Tiles कैसे बनती है?
Production Process

Steps...

Production Line 1
Quality Testing of Raw materials
Loading list of Raw materials in precise quantities as per Recipe into Mixer.

Transfer the mixer into ball mill add water. Them mix them well to 5-15 hours to achieve viscosity and particle size. Now it becomes Slurry with desired properties.

Slurry is transferred to storage tanks.
Slurry is brought to Spray Dryer. As name suggests it sprays slurry on to chamber full of hot gas. Here temperature is around 250 degrees Celsius. This process converts slurry into fine powder with desired moisture content.

This powder is transferred to Press. This machine stuff powder into mold with extreme pressure. Now they have taken shape of tile. Technically here they are called “Unbacked Biscuit”.

These biscuits are transferred to Oven (Pre Kiln) called 5 layered Dryer. This machine dries them with 300 degrees of temperature.



Production Line 2, 3, 4

Same way line one, after quality testing. Glaze Engobe is prepared by mixing glazing components in to Ball mills. Where they are mixed 5-7 hours based on required quality parameters. Same way Opeque (Glaze) and TR (Upper Layer) are made.

Merged Production Line
From 5 Layer dryer biscuits are strong enough to hold its weight. They are brought on Glaze line on a conveyer line.

Here Engobe (Glaze) layer is coated. Then Opeque Glaze is coated. Then it is it is transferred to printing area where state of the art Italian machine equipped with 10 colours do its magic to print any design you through at it.
Then it is transferred back to glaze line.

3rd and last layer of TR is coated. This is glass like substance with gives tiles it shine.

Now it goes to pre kiln for initial baking.
Then it goes to our latest 300 meter kiln. Biscuits move slowly through each section of kiln one by one. It starts with 350 degrees Celsius temperature in first section by the time it reaches to middle part temperature reached to whopping 1500 degrees Celsius.

This ensures vitrification process. Now each consecutive section decreases temperature.

When tiles comes out of kiln they are around 150 to 200 degrees Celsius. Here we have automatic machine which stakes all the tiles into Iron rack.
Person drives the iron rack to cooling place where they are cooled down for 6-12 hours.

Person loads tiles to sizing machine which makes sure that tiles are exactly 600 mm wide and 1200 mm long. 2 sides are done at a time.

Then tiles are they are polished with abrasive to make surface smooth
Last step is to coat tiles with nano chemicals to make tiles stain resistance.

Final Quality inspection. A skilled person keep on checking tiles every 10 minutes.

Sorting. Skilled persons sit inside a well-lit cabin to sort tiles in to quality grades. Mark all the tiles which doesn’t qualify as 1st quality (Premium) so that packaging person packs in appropriate boxes.
If Material is exported. They are packaged into desired pallets.

Loaded into truck or container
These is very simplified process. There are many minor stages those make sure that all the operation goes smoothly. And quality of tiles are best possible. Thanks.


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