Manufacturing process of ceramic tiles
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The document provides an overview of the manufacturing process for standard ceramic tiles at a factory located in Gazipur, Bangladesh. It describes the key steps which include obtaining raw materials like clay and talc, grinding and mixing the materials to form a powder, shaping the powder through dry pressing, glazing and coloring/designing, firing to harden the tiles, finishing, sorting, and final packaging. The factory uses lean manufacturing principles to reduce waste and costs and continuously improve product quality.
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Manufacturing process of ceramic tiles
The document summarizes the manufacturing process of ceramic tiles. Raw materials like clay, silica, and talc are ground into a slurry using a continuous ball mill. The slurry is spray dried into a fine powder and stored in silos. The powder is pressed into tiles using hydraulic presses and dried. Tiles are glazed, printed, and fired in a roller kiln to increase strength. The finished tiles are sorted, packaged, and shipped for use in floors, walls, roofs, and ceilings.
Manufacturing Process Of Ceramic Tiles
The document outlines the 7-step manufacturing process for ceramic tiles:
1) Preparing raw materials like clay and feldspar.
2) Batching involves proportioning raw materials by mass for accuracy.
3) Mixing and grinding reduces raw materials to a uniform size.
4) Spray drying converts the body slip to granules suitable for pressing.
5) Pressing simultaneously compacts and shapes the granules in rigid dies.
6) Drying increases strength before firing and prevents warping in the kiln.
7) Firing at high temperatures transforms the shaped granules into durable ceramic tiles.
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Ceramics are inorganic, non-metallic materials made through heating and cooling processes. The document discusses the history and types of ceramics including clay products like bricks, tiles, and terracotta as well as other classes like stoneware, earthenware, and porcelain. It describes the manufacturing processes and properties of common ceramic materials and their uses in products like sanitary ware, insulators, and plates.
Manufacturing process of tiles
The document outlines the manufacturing process for porcelain tiles, which begins with mixing raw materials like sand, clay, and minerals. The dry powder is then extruded into molds and dried before being fired at high temperatures, which gives the tiles strength, stability, and resistance. Statistical process control is used throughout to monitor dimensions, density, and other parameters to ensure quality.
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Crystalline ceramics tend to be stronger and more stable at high temperatures than non-crystalline ceramics. Common crystalline ceramic examples include barium titanate, strontium zirconate, and magnesium aluminate. Non-crystalline ceramics have higher viscosity when heated and are called "glassy" at room temperature when solid. Ceramics are generally solid, inert, brittle, hard, strong under compression but weak under tension and shearing. Porcelain is made through a process involving crushing raw materials like clay and feldspar, mixing, forming, bisque firing, glazing, and final firing. Porcelain has advantages like being non-porous,
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Ceramic materials have been produced by humans for at least 24,000 years and are inorganic, nonmetallic solids formed through heating. Ceramics have a variety of properties including hardness, attractiveness, chemical inertness, and heat insulation. They are used widely in construction materials, decorative items, kitchenware, medical devices, and more. The production of ceramic tiles involves batching raw materials like clay and feldspar, grinding them, spray drying, pressing, drying, and high-temperature firing to form durable tiles.
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Ceramics are nonmetallic materials made by firing clay and other materials like silicates and metal oxides. Ceramics have been made since prehistoric times and the modern ceramics industry produces a wide range of structural materials and products. The ceramics industry relies on raw materials like clay, silica, and feldspar which are formed and fired through processes like grinding, shaping, drying, glazing, and firing to produce final ceramic goods.
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Manufacturing process of ceramic tiles
The document summarizes the manufacturing process of ceramic tiles. Raw materials like clay, silica, and talc are ground into a slurry using a continuous ball mill. The slurry is spray dried into a fine powder and stored in silos. The powder is pressed into tiles using hydraulic presses and dried. Tiles are glazed, printed, and fired in a roller kiln to increase strength. The finished tiles are sorted, packaged, and shipped for use in floors, walls, roofs, and ceilings.
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The document outlines the 7-step manufacturing process for ceramic tiles:
1) Preparing raw materials like clay and feldspar.
2) Batching involves proportioning raw materials by mass for accuracy.
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4) Spray drying converts the body slip to granules suitable for pressing.
5) Pressing simultaneously compacts and shapes the granules in rigid dies.
6) Drying increases strength before firing and prevents warping in the kiln.
7) Firing at high temperatures transforms the shaped granules into durable ceramic tiles.
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The document outlines the manufacturing process for porcelain tiles, which begins with mixing raw materials like sand, clay, and minerals. The dry powder is then extruded into molds and dried before being fired at high temperatures, which gives the tiles strength, stability, and resistance. Statistical process control is used throughout to monitor dimensions, density, and other parameters to ensure quality.
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Crystalline ceramics tend to be stronger and more stable at high temperatures than non-crystalline ceramics. Common crystalline ceramic examples include barium titanate, strontium zirconate, and magnesium aluminate. Non-crystalline ceramics have higher viscosity when heated and are called "glassy" at room temperature when solid. Ceramics are generally solid, inert, brittle, hard, strong under compression but weak under tension and shearing. Porcelain is made through a process involving crushing raw materials like clay and feldspar, mixing, forming, bisque firing, glazing, and final firing. Porcelain has advantages like being non-porous,
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Ceramic materials have been produced by humans for at least 24,000 years and are inorganic, nonmetallic solids formed through heating. Ceramics have a variety of properties including hardness, attractiveness, chemical inertness, and heat insulation. They are used widely in construction materials, decorative items, kitchenware, medical devices, and more. The production of ceramic tiles involves batching raw materials like clay and feldspar, grinding them, spray drying, pressing, drying, and high-temperature firing to form durable tiles.
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Tiles
Tiles are used for roofing and paving. They are classified based on material (common, encaustic) and use (roofing, flooring, drain). Roofing tiles include plain, pan, pot, Allahabad, Mangalore, and concrete tiles. Flooring tiles vary in thickness and shape. Tiles are manufactured by selecting clay, preparing and molding it, drying and shaping, burning in a kiln at 2200°F for 3 hours, and cooling for 3-5 days.
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Vitrified tile(2)
Vitrified tiles are made from clay that undergoes a vitrification process where it is fired at a very high temperature, becoming non-porous and water resistant. This makes vitrified tiles very durable and able to withstand harsh conditions. Glazed vitrified tiles offer a wide variety of design and color options to mimic natural stone or wood looks. Their water resistance and low maintenance needs make them suitable for use in bathrooms and kitchens.
Ceramic tile industry and market 2008
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Thanking you.............
2 the ceramic process
The ceramic process involves 12 steps: 1) selecting and manipulating raw clay, 2) wedging to remove air, 3) shaping using hand-building or wheel throwing techniques, 4) preventing cracking when clay becomes short, 5) allowing clay to reach a leather-hard state for joining, 6) recycling excess clay, 7) allowing clay to air dry until bone dry, 8) firing pieces to bisqueware in the first kiln firing, 9) applying glaze and 10) firing glaze in a second kiln firing, 11) which produces a finished glazed piece that is 12) ready to be taken home.
Ceramic molding process
The ceramic molding process involves making a mold from refractory ceramic materials that can withstand high temperatures. To make the mold, a slurry of silica grains, ethyl silicate, water, alcohol and a gelling agent is poured around a pattern. The mold is then fired to harden it and burn off unwanted materials, producing microcracks that allow permeability and collapsibility. Once assembled, the mold can be preheated and used to cast molten metals. Compared to investment casting, ceramic molds provide similar surface finish and intricacy but with reduced machining needs, shorter lead times, and ability to cast at various sizes and metals.
Metal working
This document discusses various bulk deformation metalworking processes including rolling, forging, extrusion, and wire/bar drawing. It provides details on rolling processes like flat rolling and shape rolling. The key bulk deformation processes are described as rolling, forging, extrusion, and wire/bar drawing. Specific rolling techniques like thread rolling and ring rolling are also summarized.
Bulk forming
This document provides information on various bulk deformation processes used to shape metals, including forging, rolling, extrusion, drawing, and swaging. It discusses the general characteristics, applications, advantages/disadvantages, and costs associated with each process. Diagrams are also included to illustrate stages of specific processes like impression die forging, thread rolling, and shape rolling. The document contains a comprehensive overview of common bulk deformation techniques for metalworking.
Sheet metal processing
This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.
Extrusion blow molding
Extrusion blow molding is a manufacturing process used to make hollow plastic parts like bottles. It begins by melting plastic and extruding it into a tube-like parison. The parison is clamped into a mold and compressed air is injected to push the plastic out against the mold walls. As the plastic cools and hardens, the mold opens and the final part is ejected. Common materials for extrusion blow molding include polyethylene, polypropylene, and PET which must have good melt strength. The process offers low costs due to simple molds but is limited to hollow shapes.
Processing polymer
This document discusses various polymer processing techniques. It begins by outlining three general phases of plastics processes: heating, shaping/forming under constraint, and cooling. It then describes specific processes like thermoforming, compression and transfer molding, rotational molding, extrusion and extrusion-based processes, injection molding, and blow molding. For each process, it provides details on how it works, its advantages and disadvantages, and common applications.
Composite materials
Composite materials are composed of two or more physically distinct phases that produce properties different from the individual components. Composites can be very strong yet light weight. Examples include fiberglass, carbon fiber reinforced plastics, and cemented carbides. Composites find applications in aerospace, automotive, sports equipment due to their high strength to weight ratio and other advantageous properties. They are classified based on matrix material (polymer, metal, ceramic) and type of reinforcement (particles, fibers).
Composite material
Composite materials are made by combining two or more materials with different properties. They have a matrix phase that forms the bulk of the material and a dispersed reinforcement phase that improves the matrix's properties. Common composite materials include particle-reinforced composites like concrete and fiber-reinforced composites. Composites provide advantages like higher strength and stiffness than monolithic materials, lower density, improved corrosion and fatigue resistance, and controlled electrical conductivity. They are used widely in applications like transportation, marine, aerospace, electronics and safety equipment. Composite materials can fail due to fiber breakage, matrix cracking, debonding between fibers and matrix, or delamination between layers in laminated composites.
Composite materials 1
1. Composite materials are made of two or more materials that combine to produce overall properties that are better than the individual components. Composites have high strength and stiffness but are also lightweight.
2. Composites have two main constituents - a reinforcement and a matrix. Reinforcements include fibers and particles that provide strength and stiffness. Fibers have a high length-to-diameter ratio. The matrix holds the reinforcements together and can be a polymer, metal, or ceramic.
3. Composites have advantages over metals including lighter weight, high strength and stiffness, corrosion resistance, and reduced maintenance needs. However, composites also have higher costs and can be susceptible to impacts.
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Manufacturing process of ceramic tiles
- 1. Welcome To The Presentation on “Manufacturing Process of Standard Ceramic Tiles”
- 2. Presented by Shamima Hossain Roll- 1983 Md. Rasel Mia Roll- 1984 Presented to Mrinmoy Mitra Lecturer Department of Business Administration World University of Bangladesh World University of Bangladesh
- 3. 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
- 4. 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.
- 5. 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
- 6. 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
- 7. Preparation of Powder Raw Materials Continuous Ball Mill Slip Tank Service Tanks Spray Drier
- 8. 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
- 9. Preparation of Powder (Service Tanks & Slip tanks) Service Tanks The 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.
- 10. 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%)
- 11. Shaping Process (Dry Pressing) Dry Pressing Pow deris deposited into a tray and hydraulically pressed.Bidderand lubricants added keep to the m old
- 12. Glazing Process Glazing Glazing is a layer or coating of a vitreous substance which has been fired to fuse to a ceramic object to Color Decorate strengthen or waterproof it.
- 13. 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.
- 14. 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.
- 15. 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
- 16. 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.
- 17. 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
- 18. US