How TILES are Made

Summary

This video explores the production process of modern floor tiles, showcasing two factories specializing in ceramic and porcelain tiles. Raw materials are mined, crushed, and ground into fine particles, mixed with water and additives. Porcelain tiles involve the addition of andesite and extrusion, while ceramics are pressed into shape. Both undergo drying, printing, and glazing before being fired in a kiln at high temperatures. The process concludes with quality checks and sorting, highlighting the factories' 24/7 operation and the use of advanced automation for efficiency in the South African market.

Takeaways

• 🛠️ Modern floor tiles are crafted in various shapes and sizes to customize the personality of a room.
• 🏭 Two primary types of tiles are mentioned: ceramic and porcelain, both made from a mixture of different clays and sand.
• ⛏️ Raw materials for tiles are sourced from quarries and then processed in factories.
• 🔨 The initial stage of tile production involves crushing and milling the raw materials into fine particles.
• 💧 Water and other additives are mixed with the ground materials to form a suitable mixture for tile creation.
• 🌐 At the Vitro factory, porcelain tiles are made with the addition of andesite, and the clay is processed using a screen feeder and extrusion machine.
• 🔄 The Pegasus factory's process for ceramic tiles involves pressing the fine powder mix into tile shapes.
• 🔥 Both types of tiles undergo a drying process to strengthen them before further treatment.
• 🖨️ Tiles are prepared for printing with a primer coating, followed by either screen printing or modern inkjet printing techniques.
• 🔧 A protective glaze is applied, which becomes transparent after the firing process in a kiln.
• ♨️ Tiles are fired in a kiln at high temperatures to bake the clay and other materials, followed by a cooling process to prevent warping or cracking.
• 🔍 Quality control checks for strength, size, and precision, with tiles sorted into different quality grades by a computerized system.
• 🤖 Automation and robotics, such as laser-guided forklifts, are used to maintain high efficiency in the production process.
• 🏡 Both ceramic and porcelain tiles are designed for durability and aesthetics in various home settings, responding to modern design demands.
• 🌏 The factories cater to both local South African and international markets with their high-quality floor tiles.

Q & A

What are the two main types of modern floor tiles mentioned in the script?

The two main types of modern floor tiles mentioned in the script are ceramic tiles and porcelain tiles.

What materials are used to make both ceramic and porcelain tiles?

Both ceramic and porcelain tiles are made from a mixture of different clays and sand, with the addition of cement in the form of andesite for porcelain tiles.

How are the raw materials for tiles initially processed?

The raw materials are mined in a quarry and then put into a crusher machine to break up the larger pieces. They are then sent to huge milling machines where they are ground to very tiny particles and mixed with water and other additives.

What is the purpose of the screen feeder in the production of porcelain tiles?

The screen feeder, which is like a cheese grater, presses chunks of the clay through holes at the bottom, preparing the clay for extrusion.

What is the extrusion process in tile production?

The extrusion process involves a vacuum removing all air from the clay mix and a large screw pressing the clay through a metal die, punching out a sheet of material that will form the tiles.

How do the factories produce tiles of different sizes?

Tiles are cut to size after the extrusion process, and both porcelain and ceramic tiles can be produced up to 600 millimeters square.

What is the purpose of the drying process in tile production?

The drying process removes some of the moisture from the material, making the clay more supple and giving the tile more strength.

What are the two methods of printing used on the tiles?

The two methods of printing used on the tiles are screen printing, where different colors are applied through a screen, and inkjet printing, which can print any design entered into the computer.

What is the role of the glaze in the production of tiles?

A protective top coating of glaze is sprayed onto each tile, which turns white shortly after coming out of the spray tunnel but becomes transparent during the firing process in the kiln.

What happens during the firing process in the kiln?

During the firing process, the tiles are first dried at a low temperature to remove water. Then, the temperature is raised to 1185 degrees Celsius to bake the clay and other materials in the body of the tile.

How do the factories ensure the quality and precision of the tiles?

Each tile passes tests of strength, size, and geometrical precision, and a computer sorts each tile into its own quality grading, with A-grade tiles and V-grade tiles being sorted automatically at high speed.

How do the factories maintain high efficiency without the need for breaks?

The factories utilize highly automated processes and robotic forklifts guided by a system of lasers reflected around the factory, ensuring efficient movement of boxes of tiles to the next stage of production.