Clay is imported and tested in a laboratory before being transferred to a production line or discarded. It is weighed then milled and mixed with water, potash, and chemicals in large tanks for 8 hours. The viscous material is purified as it moves to a stirring chamber and underground storage tank. It is then dried and purified into powder in a spray dryer before being compressed into tiles at high pressure. The tiles are glazed and fired at 1200 degrees Celsius in a kiln, then cooled and packaged. Common ceramic tile failures include diagonal size variations, uneven surfaces, and insufficient glossiness. Tiles are priced between Rs. 24-40 per square foot depending on type and taxes.

1. Import of clay in factory

2. Taking sample of the clay for the laboratory
test
if clay passes the laboratory test then it will
take to the production line otherwise
It will dump out out outside of the factory

3. Weighing machine:- weighing of material
before it transfer to boil mill.
transferring material to ball mill
through this belt

4. Mixing of clay with water, potash and other soluble chemical solution this operation
carried out in giant tanks called ballers capacity of tank is 60 tons which rotates along
horizontal axis continuously for 8 hours.

5. This narrow line carried the viscos material to the stirring chamber in the way between the
baller and the stirring chamber the solution passes through iron rods (which are not visible in
the picture) for the purification of material from iron and other metal impurities

6. After mixing all the necessary components the viscos solution transferred to the underground
chamber where it store under stirring condition all the time because if the solution not stir
after mixing process it will eventually get hard and become useless

7. Storage of viscous solution in tank and at 95 degree celsius.

8. Spray dryer operates with coal and produce heat within it
make the solution into slurry powder and this slurry powder
transfer to the hydraulic compression line .

9. In between the spray dryer and hydraulic compression line the slurry powder again go through
from magnetics bars for the purification of powder from metallic impurities

10. The fine powder is compressed with automated hydraulics operating pressure as high as 2500
tons. After the compression the powder turn into solid tiles but it is not bind very strong at this

11. Glazing of baked tile with barium layering.

12. After glazing, The tiles get heat in kiln about 1200 degree Celsius but Before the final heating
tiles has to travel in pre kiln in which the 1% of moisture has to remove.

13. Final product after baking in kiln the temperature of tiles is
80 degree Celsius. That’s why the worker has to handle it
with gloved hands.

14. Packaging.

15. Failures of ceramic Tiles
• Diagonal variation :- Diagonal variation is a variation due to
improper Diagonal size of tile get embossed from the center
or showing contours diagonally.
• Uneven surface :- uneven surface is the problem rises after
getting final product the tile is not flat enough for the use
and cannot use anywhere or we can say that uneven
surface tiles consider as waste.
• Glossiness factor :- The market is depend on this factor
higher the value of glossiness of the tiles the more it looks
goods. That’s why company tries to make the tiles with high
value of gloss.

16. Costing
Soluble salt tiles:- 24 rupess/square-feet
Glazed vitrified tiles :- 32 rupees /square-feet
After including all taxes it will be around 40
rupees square feet
Note:- This is factory price.