CERAMIC TILE PRODUCTION PROCESS My Duc Ceramics Limited Company INTRODUCTION Ceramics market overview General about the whole business process Production process Raw materials Body preparation Glaze preparation Forming Glazing Tile firing Sorting and packaging CERAMICS MARKET OVERVIEW Why ceramic tiles can occupy and hold a large market for a long time? Thin, light, strong Durable Easy to use and installing Diversified BUSINESS PROCESS 1 2 3 4 5 6 7 • Take customers’ order and information • Designing sample • Planning sale forecast • Master production schedule • Material requirement planning • Line production schedule • Logistic sale Finance TILE MANUFACTURING PROCESS FLOWCHART CERAMIC TILE STRUCTURE Glaze Body Glaze Use raw materials to create tiles' body From the materials' storage Raw materials grinding Spray drying (to make the clay slip into powder granules) Body Pressing (forming tiles' body) Drying (to create stiffness for tiles) Glaze preparation: (wet glaze milling) Glaze, Engobe and Printing paste Printing preparation: Apply by silicon or digital printer Glazing and pattern printing PRODUCTION PROCESS BODY RAW MATERIALS Include: kaolin, ball clay and feldspar along with some other materials such as CaCO3 and dolomite. Raw materials are sourced from local suppliers Unfired and fired rejects are being recycled Clay Sand Feldspar BODY RAW MATERIALS Raw materials warehouse in My Duc factory CHARGING MATERIALS ON SCALE AND GRINDING MILL Before being used, the quality of the raw materials for making tile body must be checked and compared with controlled standard. Following the specific formula, each raw material will be put into the weighing scales individually. Charging materials on scale Scale close-up view GRINDING MILL • After weighing, the raw materials will be loaded into the grinding mill – this machine contains grinding balls or stones, with various sizes, to grind the materials effectively to become soft and smooth. • The raw materials will be grinded together with a suitable amount of water and some additives to form a slurry mixture. GRINDING MILL Ball Mill machines in My Duc factory FILTERING IMPURITIES • Underground tanks made from concrete are equipped with paddles to prevent underneath settling and to maintain uniformity of the clay slip. • Clay slip is then pumped from underground tank to go through two-layer vibrating sieves to remove impurities, magnetic iron and big particle sizes. • Then, it comes to the final tank to be prepared for the spray drying process. Underground tank FILTERING IMPURITIES Discharge clay slip from Ball Mill down to underground tank FILTERING IMPURITIES Paddle systems will prevent underneath settling and maintain uniformity FILTERING IMPURITIES Filtering impurities and magnet system SPRAY DRYING • The clay slip from tank will be distributed by high capacity piston pump to inject into the small jets to the pray drying tower to counter flow. • The heat in the upper part of the spray-drying tower is 4500C 6000C to dry the clay slip to become power granules • The powder must be kept and aged in Silo for 24 hours to achieve the stability in humidity before using in the Pressing Section. Spray dyer Silo SPRAY DRYING Powder is moved into Silos after drying Pump and spray clay slip to the drying-tower Powder fall down into the bottom Spray dryer Powder is moved into the Silos FORMING AND DRYING • After achieve the stability in temperature and humidity • The spray dried powder will be conveyed to the press hopper. • The green tiles will move to the drying machine tiles after formed. • Temperature of tiles after drying should be about 80 - 1100C with a residual humidity < 0.5%. Drying Forming FORMING AND DRYING Pressing/forming machine FORMING AND DRYING Forming spray dried powder to become green tiles FORMING AND DRYING After formed, green tiles will be moved into dryer FORMING AND DRYING Dryer GLAZE PREPARATION LAYER OF GLAZE: • Engobe • Base Glaze • Printing paste GLAZE EFFECTS: Increase durability Make the tile surface more beautiful Resistant to harmful chemicals and dirt Enhance aesthetic value of products Easy to clean GRINDING AND GLAZING GRINDING • Compared glaze raw materilas with standard sample • Weigh raw materials base on the standard formula • Grind original glaze with water to make glaze watery. • Ingredient facts: Frit Kaolin Ballclay Al2O3 Feldspar ZrSiO4, Other additives GRINDING AND GLAZING GLAZING • The body of tiles after drying will be continuously processed through glazing step: Engobe base glaze printing paste • Cleaning dust on the body’s tile surface by brushing system • A thin layer of water spray will be applied to condition the surface • The glaze is continuously stirred to avoid settling and to keep the glaze homogeized. • Depending on the product requirement, glaze and engobe can be applied by spray nozzles, bell, vella or disc spray. • Go through silicon drum printing or digital printing to create tiles’ patterns. GLAZE PREPARATION AND GLAZING Glaze preparation area GLAZE PREPARATION AND GLAZING Glaze preparation area GLAZE PREPARATION AND GLAZING Glaze preparation area GLAZE PREPARATION AND GLAZING Checking and clean dust on the body’s tile surface by brushing system GLAZE PREPARATION AND GLAZING Installing paddles in order to constantly stir glaze well GLAZE PREPARATION AND GLAZING Glazing GLAZE PREPARATION AND GLAZING Glazing by spraying dew GLAZE PREPARATION AND GLAZING Roto-color Printer GLAZE PREPARATION AND GLAZING Roto-color Printer GLAZE PREPARATION AND GLAZING Digital printer TILE FIRING • Moving tiles after glazing to kiln by Box Car • Tiles are fired at the temperature of approximately in the range of 1100-12000C depending on the finished product • The firing temperature and firing time must be set to meet the finished product requirement • Before going inside the kiln, all tiles are visually checked to ensure the products’ quality and avoid any untoward incident to damage the kiln • The kiln is being operated and controlled by automatic control system to keep track of the firing temperature and kiln operating condition. TILE FIRING STAGES OF THE FIRING PROCESS Pre-heating Stage Remove residual moisture and organic impurities Firing at high temperature Glaze is melted entirely, body of tiles shrinks Cooling Quick cooling, then slow cooling until tiles coming out of the furnace TILE FIRING CONTROL AFTER FIRING Due to being fired at high temperature, ceramics tiles have changed: • Size • Curvature • Tonality Random quality check is being done at the exit of the kiln in order to predict finished products quality or make decision if there is a need for kiln adjustment to satisfy product requirement TILE FIRING The kiln TILE FIRING Technical and controlling room at the end of the kiln TILE FIRING Box Car SORTING AND PACKAGING CHECKED BY HUMAN Visual Checks: • Tonality: Standard tonality is12 Darker will be from13, 14, 15, … Lighter are11, 10, 9 ,… • Surface faults: Cracks Tiny Holes Dent Pattern printing errors Rough surface SORTING AND PACKAGING CHECKED BY MACHINE • Caliber: Standard caliber is 5 and 6 Higher will be from 7, 8, ..; Smaller are 4, 3, … • Curvature: Convex Concave The machine will automatic destroy defective products that completely out of the standard. SORTING AND PACKAGING Products after packaged DISPATCH TO THE MARKET • After packaged, goods will be moved to warehouse. • Products are now ready to distribute to the market and serving consumers THANK FOR WATCHING THE PRESENTATION
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