manufacturing process of ceramic tiles

Welcome To The Presentation on

“Manufacturing Process

of

Standard Ceramic Tiles”

Presented by

Shamima HossainRoll- 1983Md. Rasel Mia Roll- 1984

Presented to

Mrinmoy Mitra LecturerDepartment of Business AdministrationWorld University of Bangladesh

World University of Bangladesh

Location facilities of Standard Ceramic

The factory locating in Gazipur, only 30 KM distance from capital city of Dhaka. Therefore they get following facilities-

1. Available of labors

2. Easy for transportation and communication

3. Low cost delivery

Manufacturing System of Standard Ceramic

Standard ceramic follow the lean manufacturing system. Which means their main aim is to-

• Reducing Waste

• Reducing cost

• Continuous Improvement of product quality.

Production Process of Standard Ceramic Tiles

Raw material

Weighing Ball Milling

Vibrating Screen and Homo Tank

Spray DryerDry Pressing

Glazing Coloring & Designing Firing process

Finishing Shorting and Packaging

Raw Materials for Ceramic Tiles

Clay

Talc

The traditional ceramics industry is largely based on various combinations of clay minerals, feldspar and silica.

The mineral raw materials used in the ceramic industry are mainly inorganic, nonmetallic, crystalline solids formed by complex geologic processes.

Clays have the ability to form clay-water composition and to maintain their shape and strength during drying and firing

Silica

Preparation of PowderRaw Materials

Continuous Ball Mill

Slip Tank

Service Tanks

Spray Drier

Preparation of Powder (Continuous ball mills)

The mixing of raw materials takes place with the help of alumina pebbles.

This ball mill continuously rotates.

This rotation helps the pebbles to grind the raw materials.

The grinded raw materials are mixed with water to obtain slurry

Preparation of Powder (Service Tanks & Slip tanks)

Service TanksThe service tank rotates continuously so that it won’t allow highly viscous slurry to set.

In the vibration chamber filtration of sand and stone takes place with the help of huge vibrators.

The slurry free from sand and stone enters into slip tank.

SLIP TANK

The Slurry in the slip tank is continuously rotated in order to prevent setting of slurry as it is highly viscous.

Preparation of Powder (Spray Dryer)

The slip flows from tanks to spray nozzles and the slip is sprayed in the upward direction from the nozzles.

Slip sprays in the downward direction and hot air will pass upwards.

The temperature in the spray drier is maintained at 720 degree C.

The moisture content is around (4.5-5.5%)

Shaping Process (Dry Pressing)

Dry Pressing

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Glazing Process

Glazing Glazing is a layer or coating of a vitreous substance which has been fired to fuse to a ceramic object to ColorDecoratestrengthen or waterproof it.

Colouring & Designing

World University of Bangladesh

Coloring & Designing

To form required size of tiles, the floor tiles are colored and designed using silk screening (located in the printing machine), and then stored in transfer cars for a while before firing.

Firing Process The firing process is to harden the tiles. These tiles are heated in a roller kiln for about 40-45 minutes, depending on the size and type of the tiles. As a general rule, the more color and design involved, the longer the tiles are heated.

Typical firing temperatures for alumina, mullite, and zirconia reach 2850 °F - 3100 °F.

Typical firing cycles can range from 12 - 120 hours depending upon the kiln type and product.

Ceramics shrink approximately 20% during the sintering process.

Finishing

Parts made of ceramics sometimes require finishing. In general, these operations have of the following purposes, to-

(1) Increase dimensional accuracy

(2) Improve surface finish

Shorting

The tiles are sorted by sorting machines to separate the good tiles from the defective ones. The company also uses computerized machine to ensure the exact size of tiles.

Packaging

The final process is where tiles are packed according to the specific size and quality, stored in a warehouse as finished goods ready for sale

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