How TOILETS are Made

Summary

This video provides an in-depth look at the process of manufacturing toilets at a state-of-the-art factory in Johannesburg. It details the journey from raw materials like clay and sand being mixed and molded into toilet bowls and water tanks, to the automated glazing and firing processes that give the products their signature smooth, glass-like finish. With modern high-tech machinery and skilled workers, the factory produces millions of units annually, exporting to Europe and Africa. The entire process is designed for efficiency, ensuring consistent quality and precision in every product.

Takeaways

• 😀 The Vitus Factory in Johannesburg specializes in making high-quality ceramic toilets and basins, with Vitus meaning glass-like due to its strong and shiny finish on porcelain.
• 😀 A toilet consists of two main parts: the toilet bowl and the water tank (or system). These parts are carefully manufactured to ensure efficiency and durability.
• 😀 The factory uses a mixture of clay, granite sand, and other minerals to produce the materials for both the toilet bowl and water tank.
• 😀 The clay mixture is processed in large rotating mills where it is turned into a fine liquid clay mixture, which is used for molding.
• 😀 The factory employs High Press casting technology, ensuring that toilets are consistently made with the correct size and thickness.
• 😀 During the molding process, the liquid clay is drawn into a mold, and water is forced out, leaving behind solid material that forms the toilet parts.
• 😀 The molding process is computer-controlled, allowing for precise adjustments based on different toilet designs and sizes.
• 😀 After molding, the toilet pieces are air-dried for about 10 hours, followed by 12 hours in a drying tunnel at 65°C to remove excess moisture.
• 😀 Pneumatic lifters are used to help workers move heavy toilet parts with ease, and scarring pads are used to smooth rough edges for a perfect finish.
• 😀 Toilets undergo a two-stage glazing process using robots to apply a glass-like surface, and the final appearance develops after the firing in a kiln at temperatures reaching 1200°C.

Q & A

What does the word 'Vitus' mean and how does it relate to the products made at the Better Factory?

The word 'Vitus' means 'glasslike' and describes the strength and high-gloss shine that Vitus ceramic gives to porcelain and ceramics, which is a key characteristic of the toilets and basins produced at the Better Factory.

What are the two main sections of a toilet produced at the Better Factory?

The two main sections of a toilet produced at the Better Factory are the toilet bowl and the water tank, also known as the system.

How does the flushing process work in the toilets made at this factory?

When the toilet is flushed, water flows from the tank into the toilet bowl, causing the water in the bowl to rush down the drain in a process known as 'wash down.' The toilet bowl is then refilled with clean water.

What materials are used in the production of the toilet bowl and water tank?

The toilet bowl and water tank are made from a mixture of clay, granite sand, two types of clay, and various other minerals, which are carefully mixed in controlled amounts.

How is the liquid clay mixture prepared for the molding process?

The raw materials are sent to large rotating mills where water and other components are added. As the mills turn, the particles are ground into a fine powder, resulting in a watery liquid clay mixture.

What is the role of the resin mold in the manufacturing process?

The resin mold is used to shape the toilet bowl and water tank. The liquid clay is poured into the mold, and under pressure, water is drained through the mold, leaving behind a solid ceramic layer. This process forms the required thickness of the toilet components.

How is the molding process controlled at the Better Factory?

The molding process is entirely computer-controlled, with different settings adjusted for various toilet designs and sizes. Hydraulic pressure is used to close the mold, and high-pressure air is employed to further drain water from the clay cast.

What happens to the toilet bowl and tank after they are removed from the mold?

After removal from the mold, the toilet bowl and tank are still soft, so they are left to air dry for about 10 hours. They are then placed in a drying tunnel for 12 hours at a temperature of 65°C to remove moisture from the clay.

What is the purpose of the glazing process in toilet manufacturing?

The glazing process provides the toilet with a glass-like, shiny surface. In the first stage, a robot applies glaze to the inside of the toilet, and in the second stage, another robot sprays the exterior. This process ensures a smooth, durable finish.

How is the final shiny finish achieved on the toilet components?

After glazing, the toilets are fired in a kiln at 1,200°C for 12 hours. This high-temperature firing melts the glaze and vitrifies the ceramic, giving the toilet a hard, shiny surface.

How many toilets does the Better Factory produce annually, and what is their global reach?

The Better Factory produces 2 million toilets annually. These toilets are not only sold within South Africa but are also exported to Europe and other parts of Africa, demonstrating the factory's global reach.