Fabrication carrelage

Summary

This video outlines the meticulous process of manufacturing tiles, starting from raw materials like sand, clay, and talc, which are refined and mixed to create a slurry. The slurry is atomized into fine particles, which are then pressed into solid tiles under high pressure. These tiles undergo drying and firing in high-temperature roller kilns, where they are coated with glaze and decorated using screen printing. After cooling, the tiles are inspected for quality and imperfections. The final product is packaged and ready for shipment, ensuring durability, aesthetic appeal, and impermeability.

Takeaways

• 😀 Raw materials used in tile production are easily found in nature and include sand, white clay, talc, phosphate, and Carolina clay.
• 😀 Raw materials are transported to the factory, stored in specific areas, and categorized using a simple digital reference system.
• 😀 Raw materials are mixed in precise proportions by adjusting the speed of conveyors to achieve the intended mix.
• 😀 The mixture is transferred to large mixing tanks, where it is combined with water and ceramic beads to create a liquid slurry called 'barbotine'.
• 😀 The barbotine is atomized in a large chamber, where hot air dries it rapidly into fine particles, forming atomized powder.
• 😀 Atomized powder is stored in a tank and fed precisely into molds using a hydraulic press that applies 340 to 400 kg/cm² pressure to solidify the powder into a solid mass.
• 😀 The solidified tiles are then heated to remove moisture and ensure stability during firing in the oven, producing a homogeneous final product.
• 😀 Tiles are temporarily stored in containers at various stages of production before the next steps, which also allows for maintenance of equipment.
• 😀 The application of enamel and screen printing provides both aesthetic and functional qualities to the tiles, such as water resistance, durability, and hygiene.
• 😀 Various types of screens are used for applying color and patterns to the tile surface, with mechanical and visual quality checks ensuring precision and consistency.
• 😀 The enamel is applied to the tiles using methods like cascading, sieving, or dry varnishing, before the tiles are fired in a roller kiln that can reach temperatures up to 1,190°C.
• 😀 After firing, the tiles are inspected for defects, and their color and quality are validated before being packaged and shipped, with labeling providing information on their quality.

Q & A

What are the primary raw materials used to make tiles?

The primary raw materials include sand, white clay, talc, phosphate, and Carolina clay.

How are the raw materials stored before processing?

The raw materials are stored in warehouses and classified by type using a simple numerical reference system.

How is the mixture of raw materials prepared?

The raw materials are mixed in precise proportions by adjusting the conveyor speeds that feed the main conveyor.

What is barbotine, and how is it prepared?

Barbotine is a liquid mixture of raw materials and water, combined with ceramic balls to form a slurry.

What role does the atomizer play in the production process?

The atomizer sprays the barbotine into a large tank with hot air, which causes it to break into particles that dry quickly and form a powder.

How is the atomized powder applied to the molds?

The atomized powder is poured into a waiting tank, which releases precise amounts onto a plate, evenly distributing it into molds using a hydraulic press.

What happens after the powder is pressed in the molds?

Once pressed, the powder forms a solid mass, which is then heated to remove excess moisture, ensuring product stability during firing.

Why is the drying step important in tile production?

The drying process removes moisture, ensuring that the product remains stable during its subsequent firing in the kiln.

What are the roles of glazing and screen printing in tile production?

Glazing and screen printing add aesthetic, waterproof, durable, and hygienic properties to the tiles, with screen printing used for patterns and colors.

How are tiles tested for quality during production?

Various tests are conducted to check the accuracy of the design, color definition, and physical quality of the tiles before they are qualified for shipping.

What is the final stage of tile production before shipping?

In the final stage, the tiles are inspected for imperfections, quality is validated, and they are packaged according to specifications before being stacked on pallets and sent for shipment.