How Its Made: Ceramic Tiles

Summary

This video script details the production process of ceramic tiles, highlighting their durability and resistance to wear, stains, and odors. The factory's process involves mixing talc with secret chemicals, molding, automated painting, and a meticulous baking process in a massive kiln. The result is a high-quality, versatile tile suitable for various applications, including flooring, backsplashes, and bathroom walls.

Takeaways

• 🏠 Ceramic tiles are versatile and suitable for various surfaces including flooring, kitchen backsplashes, and bathroom walls due to their durability against humidity and resistance to liquids and odors.
• 🔥 They are fireproof, fade-resistant, and stain-resistant, making them a low-maintenance choice for home installations.
• 🛠️ The production process of floor tiles is similar to that of wall tiles but involves a different composition of ingredients.
• 🕰️ The mixing process is highly precise, with a 6% water to 94% powder ratio and a 12-minute mixing duration to prevent overheating and drying out.
• 🚂 The mixture is transported via a conveyor belt to a grinder, ensuring a uniform fine texture for tile formation.
• 🤖 The factory utilizes fully automated machinery to produce standard 10.8 cm square tiles, showcasing the efficiency of modern manufacturing techniques.
• 🔩 A press applies heat and pressure to compact the mixture into molds, creating the tile shape while maintaining the integrity of the material.
• 🧹 Tiles are cleaned with a revolving brush to ensure a dust-free surface, crucial for proper paint adhesion.
• 🎨 The factory uses a water-based paint specifically designed for ceramics, which is continuously circulated to maintain a consistent color blend.
• 🚿 The painting process is automated, with tiles passing through spray zones and drying under heating elements in seconds.
• 🔥 Tiles are baked in a gas-powered kiln, which is 58 meters long and can bake up to 50,000 wall tiles at once, highlighting the scale of production.
• ⏱️ The firing process takes 14 hours with a gradual temperature increase to 1075 degrees Celsius and a slow cool-down to avoid thermal shock and cracking.

Q & A

Why are ceramic tiles a popular choice for flooring, kitchen backsplashes, and bathroom walls?

Ceramic tiles are popular due to their ability to withstand humidity without absorbing liquids or odors, being fireproof, fade-resistant, stain-resistant, and durable as they do not wear out with use.

What is the starting ingredient used in the production of ceramic tiles?

The starting ingredient is talc, a soft, powdery mineral which is blended with four different powdered chemicals, the names of which are a company secret.

What is the water to powder ratio in the mixture used for making ceramic tiles?

The mixture has a 6 percent water to 94 percent powder ratio.

How long does the mixer run for the ceramic tile mixture?

The mixer runs for precisely 12 minutes to avoid overheating and drying out the mixture.

What is the standard size of the wall tiles produced by the factory?

The standard wall tile size produced by the factory is 10.8 centimeters square.

How does the factory ensure the tiles are formed into the correct shape?

The factory uses fully automated machinery and a press that applies heat and pressure to compact the mixture into a mold, solidifying the shape of the tiles.

What happens to the tiles after they are formed and before they are painted?

The tiles are transported on a conveyor belt, flipped right-side up without breaking, and then cleaned by a revolving brush to remove dust and contaminants for paint adhesion.

What type of paint is used for the ceramic tiles, and how is it applied?

The factory uses a water-based paint specifically designed for ceramics, which is applied through an automatic process that resembles an automatic car wash, with four spray zones and immediate drying under heating elements.

How are square border tiles different from regular wall tiles?

Square border tiles look like regular wall tiles but have two rounded edges, which produce a clean finished look when installed above the regular tiles.

Why are border tiles often more expensive than regular tiles?

Border tiles are often more expensive due to the manual labor required in their molding process, as it is more complex than the fully automated process for regular tiles.

What is the length of the kiln used for baking the tiles, and how many tiles can it bake at once?

The kiln is 58 meters in length, longer than an Olympic-sized swimming pool, and can bake approximately 50,000 wall tiles in one batch.

What is the firing process like in the kiln, and how long does it take?

The firing process takes 14 hours, starting at 200 degrees Celsius, gradually increasing to a peak of 1075 degrees, and then slowly descending back to the starting temperature, with a cooling period of about an hour.

Outlines

00:00

🏭 Ceramic Tile Production Process

This paragraph details the manufacturing process of ceramic tiles, which are favored for their durability and resistance to various elements. The factory specializes in both wall and floor tiles, starting with a base ingredient, talc, mixed with undisclosed powdered chemicals. The mixture undergoes hydration, grinding, and forming into tiles using automated machinery. The tiles are then cleaned, painted using a water-based paint in an automated spray process, and subjected to a gradual 14-hour baking cycle in a large kiln to ensure hardness and quality without thermal shock.

Keywords

💡Ceramic Tiles

Ceramic tiles are a type of hard, durable, and non-porous surface material commonly used for various applications such as flooring, kitchen backsplashes, and bathroom walls. In the video's context, they are highlighted for their ability to withstand humidity, not absorb liquids or odors, and for being fireproof, fade-resistant, and stain-resistant. The script emphasizes that no matter how much they are used, ceramic tiles do not wear out, showcasing their longevity and practicality in home and commercial settings.

💡Humidity

Humidity refers to the amount of water vapor present in the air. In the context of the video, ceramic tiles are noted for their ability to withstand humidity, which is crucial for areas like bathrooms and kitchens where moisture levels are typically high. This property makes them an ideal choice for such environments, as they do not deteriorate or become damaged due to moisture.

💡Fireproof

Fireproof is a term used to describe materials that are resistant to or do not easily catch fire. In the script, it is mentioned that ceramic tiles are fireproof, meaning they can resist burning or slow down the spread of fire, which is an important safety feature for any building material, especially in areas prone to fire hazards.

💡Stain-resistant

Stain-resistant refers to the ability of a material to prevent or minimize the absorption of stains. The video script highlights that ceramic tiles are stain-resistant, which means they are easier to clean and maintain, as they do not easily retain dirt or spills, making them suitable for high-traffic areas and households with children or pets.

💡Wall Tiles

Wall tiles are a specific type of ceramic tile designed for use on walls, often in areas such as kitchens and bathrooms. The script describes a factory that specializes in wall tiles, which are made using the same process as floor tiles but with a different composition of ingredients. Wall tiles are typically used for decorative purposes or to protect walls from water damage.

💡Molding Process

The molding process in the context of the video refers to the method by which ceramic tiles are formed into their final shape. The script describes a fully automated machinery that produces 10.8 centimeter square tiles, a standard wall tile size, by depositing a batch of mixture into a mold and applying heat and pressure to compact the mixture into the desired shape.

💡Automated Machinery

Automated machinery refers to mechanical equipment that operates automatically without the need for continuous human intervention. In the script, the factory uses fully automated machinery to produce its tiles, which includes a moving tray that deposits mixture into molds and a press that applies heat and pressure to shape the tiles, showcasing the efficiency and precision of modern manufacturing techniques.

💡Water-based Paint

Water-based paint is a type of paint that uses water as the primary solvent instead of organic solvents. The factory in the video uses water-based paint specifically designed for ceramics, which is continually circulated in a vat to keep the color well blended. This type of paint is environmentally friendly and is applied to the tiles through an automated process that resembles an automatic car wash, ensuring a uniform and high-quality finish.

💡Kiln

A kiln is a type of oven used for the high-temperature firing of ceramics. In the video, the factory uses a gas-powered kiln that is 58 meters in length, which is longer than an Olympic-sized swimming pool. The kiln is used to bake the tiles at a controlled temperature for 14 hours, allowing them to harden and become fully vitrified, a process critical for achieving the desired strength and durability of the ceramic tiles.

💡Vitrification

Vitrification is the process by which a material, such as ceramic, becomes non-porous and glass-like after being fired at high temperatures. The script mentions that after the tiles are taken out of the kiln, they are fully hardened and vitrified, which means they have undergone a transformation that makes them more durable, water-resistant, and suitable for various applications.

💡Border Tiles

Border tiles are a type of decorative tile used to create a border or frame around an area, often in combination with other tiles. In the video, the factory produces square border tiles that have rounded edges, which provide a clean finished look when installed above regular tiles. The production of border tiles requires some manual labor due to their complex shape, making them often more expensive than regular tiles.

Highlights

Ceramic tiles are popular for flooring, kitchen backsplashes, and bathroom walls due to their durability and resistance to humidity, liquids, odors, fire, fading, and stains.

The factory specializes in wall tiles, using a different composition of ingredients compared to floor tiles, despite the same production process.

The starting ingredient for tiles is talc, a soft powdery mineral, blended with four secret powdered chemicals.

The mixture is hydrated to a 6% water and 94% powder ratio in a mixer that runs for 12 minutes to avoid overheating and drying out.

A conveyor belt transports the damp, lumpy mixture to a grinder that mills it into a fine texture for tile formation.

Automated machinery produces 10.8 cm square tiles, a standard wall tile size, using molds shaped for six upside-down tiles.

A press applies heat and pressure to compact the mixture into the mold cavity, solidifying the tile shape as it rises.

The mold automatically pops out the tiles, which roll onto a conveyor belt that flips them right-side up without breaking.

Precision-adjusted equipment handles the yet-to-be-baked tiles gently at all production phases.

A revolving brush sweeps the tiles clean, ensuring a dust-free surface for paint adhesion.

The factory uses a water-based paint specifically designed for ceramics, which circulates in a vat to maintain color consistency.

The painting process involves four spray zones applying thin coats of paint, followed by powerful heating elements that dry the paint in seconds.

The factory also produces square border tiles with rounded edges for a clean finished look when installed above regular tiles.

Border tiles require some manual labor in the molding process due to their complex shape, making them more expensive.

Tiles are stacked on wooden racks, loaded onto carts, and rolled into a gas-powered kiln for baking.

The factory's kiln is 58 meters long, capable of baking 50,000 wall tiles in one batch.

The firing process takes 14 hours, starting at 200 degrees Celsius and gradually reaching a peak of 1075 degrees to avoid thermal shock.

After a one-hour cooling period, the fully hardened tiles are ready for installation with their backs to the wall.

Transcripts

ceramic tiles are a popular choice for

flooring kitchen backsplashes and

bathroom walls they can withstand

humidity and won't absorb liquids or

odors they're also fireproof fade

resistant and stain resistant and no

matter how much you walk on them ceramic

tiles never wear out this factory

specializes in wall tiles floor tiles

are made using the same process but a

different composition of ingredients the

starting ingredient here is tall a soft

powdery mineral they blend it with four

different powdered chemicals the names

of which are a company secret the

ingredients go into a mixer where

they're hydrated until there's 6 percent

water to 94 percent powder the mixer

runs for precisely 12 minutes any longer

would heat the mixture and dry it out

the mixture is now slightly damp and

quite lumpy a conveyor belt transports

it to a grinder that Mills it to a fine

texture this mixture is now ready to be

formed into various models of tiles

the factory uses fully automated

machinery to produce its 10.8 centimeter

square tiles a standard wall tile size a

moving tray first deposits a batch of

mixture into a mold the molds cavity is

in the shape of six upside-down tiles a

press descends applying both heat and

pressure this compacts the mixture into

the cavity solidifying the shape as the

press Rises the mold automatically pops

out the tiles they roll off the machine

onto a conveyor belt the belt now flips

the tiles right-side up without breaking

them which is quite a feat considering

that these yet to be baked tiles aren't

fully hardened the equipment is

precision adjusted to handle the tiles

gently at all production phases

a revolving brush now sweeps the tiles

clean their surface must be free of dust

and other contaminants for paint to

adhere properly the factory uses a

water-based paint that's specifically

designed for ceramics it continually

circulates in the VAT keeping the color

well blended the painting process

resembles an automatic car wash the

tiles travel through four Spray zones

each of which applies a thin coat of

paint then they pass under powerful

heating elements which dry the paint in

mere seconds all that's left is to bake

the tiles which we'll see shortly the

factory uses the same ceramic mixture to

produce these square border tiles they

look just like the other wall tiles

except that two of the sides are rounded

when you install a row of these border

tiles above the regular tiles the

rounded edges produce a clean finished

look while the factory uses the same

painting process for border tiles the

molding process as you just saw is

somewhat different

rather than being fully automated it

requires some manual labor

due to the tiles complex shape that's

why border tiles are often more

expensive than regular tiles

when the tiles come out of the dryer

workers stack them on wooden racks they

load the racks onto mobile carts then

roll the carts into a gas-powered oven

called a kiln this factories kill is 58

meters in length longer than an Olympic

sized swimming pool and large enough to

bake some 50,000 wall tiles in one shot

the firing as it's called takes 14 hours

any sudden changes in temperature could

produce thermal shock and crack the

tiles so it starts out at 200 degrees

Celsius climbing gradually to a peak of

1075 degrees then descending slowly back

to the starting temperature after a

cooling period that lasts roughly an

hour

the tiles come out they're now fully

hardened and ready to have their back to

the wall