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.

1. MANUFACTURING PROCESS OF
PROCELAIN TILES
NISHANT SINHA

2. WHAT IS A PROCELAIN TILES?
▪ Ceramic tiles with a water absorption rate of less than 0.5% .
▪ Used to cover floors and walls.

3. OVERALL MANUFACTURING PROCESS
▪ Preparation of raw materials.
▪ Pressing and drying.
▪ Firing process with or without glaze.
▪ Additional refinements.
▪ Packaging process.

4. Raw Material Supply Mixing Extrusion Pre-CureCoating Racking and Derecking
CuringDepalletingPost-cure Coating
& Drying
Inspection
Yard Stacking Loading & Dispatch
Collecting
& Packing

5. RAW MATERIALS
▪ Sand
▪ White clay
▪ Talc
▪ Feldspar
▪ Calcite
▪ Dolomite

6. MIXING
▪ All the Raw Materials are crushed in an uniform size.
▪ Sometimes, water is added and the ingredients are wet milled or
ground in a ball mill.
▪ Excess water is removed using filter pressing followed by spray
drying.

7. EXTRUSION
▪ The dry powder is
mechanically placed into
moulds of the required size.
▪ The body of the tile is
pressed to that size in a
hydraulic press.
▪ The pressure applied ranges
from 3,500 to 7,200 tons

8. DRYING
▪ The moisture content in the
body is reduced to the
required levels by placing the
tiles in dryers.
▪ Here heat is applied by
convection from hot gases
applied to the surface of the
tiles.

9. RACKING AND DERACKING
▪ Temporary storage further
process.
▪ Helps in removing excess
moisture, if present.
▪ Also helps in the products to
get stable.

10. GLAZING
▪ Unglazed, extruded tiles are fired
after the drying stage.
▪ Ceramic tiles have a single or multiple
coats of glaze applied.
▪ The glaze adds protection texture and
enhances chemical resistance.
▪ Silica is the prime component of
glaze.

11. FIRING
▪ Most important part of the
process because it will
determine:
– Mechanical strength
– Dimensional
– Stability
– Chemical resistance
– Ease of maintenance
– Fire resistance.
▪ Fired at temperatures of
around 1220 Celsius in
approximately 40 minute
process.

12. BYPRODUCTS
▪ A variety of pollutants are generated during the various manufacturing steps, such as:
– Fluorine
– Lead compounds.
▪ Lead compounds have been significantly reduced with the recent development of no-lead or
low-lead glazes.
▪ Fluorine emissions can be controlled with scrubbers, devices that basically spray the gases with
water to remove harmful pollutants.
▪ The tile industry is also developing processes to recycle wastewater and sludge produced during
milling, glazing, and spray-drying.

13. QUALITY CONTROL
▪ Most tile manufacturers now use statistical process control (SPC) for each step of the
manufacturing process.
▪ Statistical process control consists of charts that are used to monitor various
processing parameters, such as :
– particle size
– milling time
– drying temperature and time
– compaction pressure
– dimensions after pressing
– Density
– firing temperature and time
▪ These charts identify problems with equipment, out of spec conditions, and help to
improve yields before the final product is finished.
▪ Work closely with their raw material suppliers to ensure that specifications are met
before the material is used.