Como é FABRICADO o PORCELANATO #Boravê 🔵Manual do Mundo

Summary

This video takes viewers on an insightful journey through the meticulous process of creating porcelain tiles in Cocal do Sul, Santa Catarina. It explores the various materials used, such as clay, granite powder, and limestone, which are carefully blended to form a strong, durable base. The script delves into each stage, from mixing and grinding ingredients to pressing, drying, and firing the tiles at high temperatures. It also highlights the final touches like glazing, polishing, and quality checks. The video showcases the high-tech machinery and expert techniques behind porcelain tile production, offering an engaging look at this fascinating manufacturing process.

Takeaways

• 😀 The base of porcelain tile production starts with clay, which is mixed with other materials like ground granite and limestone during the manufacturing process.
• 😀 Granulated granite, resembling sand, adds strength to the porcelain, while limestone creates porosity, allowing better adhesion when applied to walls.
• 😀 Computer-controlled systems manage the precise dosages of materials, which are then fed into large conveyors and undergo grinding in a continuous mill.
• 😀 Barbotina, a thick, well-mixed slurry, is created from these ingredients and passed through a vibrating sieve to remove impurities.
• 😀 A deflocculant is added to disperse particles in the water, ensuring the mixture remains well integrated and prevents sedimentation.
• 😀 The slurry is sprayed into a high-temperature environment to dry quickly, leaving the mixture in powder form for further shaping.
• 😀 The powder is then placed into a mold and subjected to 400 kg per square centimeter of pressure to form the tiles, making them resilient even before firing.
• 😀 A press applies intricate textures to the surface, such as a wood pattern or a rough texture for slip resistance, similar to a stamp.
• 😀 Tiles are passed through a dryer at 175°C for one hour, then coated with a thin layer of water, followed by an engobe and glaze.
• 😀 The glaze, which is a mix of powdered glass and water, is applied to the tile in a visually captivating waterfall-like process.
• 😀 After the glaze application, tiles are placed in a high-temperature oven (up to 1200°C) for 45 minutes to achieve their final form, with strict temperature control to prevent bubbles.
• 😀 The tiles are then left to cool for several days to ensure they flatten and reach the desired properties before polishing or further adjustments.
• 😀 Some tiles are polished to improve shine, using a resin and abrasive mixture, and a final sealing process with a nanoparticle-based product ensures they are impermeable.

Q & A

What are the main ingredients used in the production of porcelain tiles?

The main ingredients are clay, finely ground granite (called 'all fields pacto'), limestone, and water, along with a few other materials mixed during the production process.

Why is granite powder used in porcelain tiles and not in regular ceramic tiles?

Granite powder is important for its ability to melt and provide enhanced strength during the firing process, which contributes to the porcelain tile's durability.

What is the role of limestone in porcelain tile production?

Limestone is used to release carbon dioxide during firing, which creates porosity in the tile. This porosity helps the tile adhere to walls better.

How are the ingredients measured and mixed in the production process?

The ingredients are measured by a system called 'tremonhas,' which uses motors to pull the raw materials into a conveyor belt with a scale that controls the amount of each ingredient.

What is the function of the 'barbotina' in tile production?

Barbotina is the name for the well-mixed slurry made of the raw ingredients. It undergoes thorough mixing and screening to remove impurities before being transformed into tiles.

How is the consistency of the slurry controlled during production?

A defloculant is used to disperse the particles in the slurry, ensuring that they stay evenly distributed and prevent clumping, which is critical for creating a smooth final product.

What happens during the pressing phase of porcelain tile production?

In this phase, the powdered mixture is placed into a mold and pressed with a force of 400 kg per square centimeter, which shapes the tile and gives it structural integrity before firing.

How does the texture of porcelain tiles differ for various designs like wood imitation?

The texture of the porcelain tile is achieved through the use of presses that stamp specific patterns onto the tile, such as wood-like textures, providing realistic finishes.

What is the purpose of the glaze and its application process?

The glaze, or 'engobe,' is applied to the tile for both aesthetic purposes (such as color) and to create a smooth surface. It is poured onto the tile in a waterfall-like manner.

How is porcelain tile drying managed before it enters the kiln?

After glazing, tiles pass through a dryer where they are kept at a temperature of about 175°C for an hour, which reduces their moisture content to prepare them for the high-heat process in the kiln.

What happens during the firing process in the kiln?

The porcelain tiles enter the kiln, where they are heated gradually up to 1,200°C over 45 minutes. This controlled heating ensures the tile doesn't develop bubbles and reaches its final hardened state.

Why is it important for porcelain tiles to rest for three days after firing?

The tiles need time to cool down and settle, as they can initially be slightly curved after exiting the kiln. Resting helps them flatten out and stabilize.

What is the polishing process in porcelain tile production?

The polishing process involves using abrasives to smooth and shine the surface of the tile, removing any imperfections and giving it a glossy finish.

How are the edges of porcelain tiles treated to ensure a perfect fit?

After polishing, tiles undergo a process called rectification, where the edges are squared to create precise, sharp corners, ensuring that the tiles fit together perfectly during installation with minimal grout space.

What is the importance of the inspection process in porcelain tile production?

The inspection process ensures that each tile meets quality standards. Machines check for correct dimensions, and any defective tiles are rejected, ensuring only perfect products reach the packaging stage.

What considerations are taken during the packaging of porcelain tiles?

During packaging, the tiles are carefully arranged in pallets to avoid damage during transport. The challenge lies in properly positioning the tiles to prevent breakage while ensuring safe delivery to stores.