How Its Made: Ceramic Tiles
Summary
TLDRThis 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
- π 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.
- π₯ They are fireproof, fade-resistant, and stain-resistant, making them a low-maintenance choice for home installations.
- π οΈ The production process of floor tiles is similar to that of wall tiles but involves a different composition of ingredients.
- π°οΈ 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.
- π The mixture is transported via a conveyor belt to a grinder, ensuring a uniform fine texture for tile formation.
- π€ The factory utilizes fully automated machinery to produce standard 10.8 cm square tiles, showcasing the efficiency of modern manufacturing techniques.
- π© A press applies heat and pressure to compact the mixture into molds, creating the tile shape while maintaining the integrity of the material.
- π§Ή Tiles are cleaned with a revolving brush to ensure a dust-free surface, crucial for proper paint adhesion.
- π¨ The factory uses a water-based paint specifically designed for ceramics, which is continuously circulated to maintain a consistent color blend.
- πΏ The painting process is automated, with tiles passing through spray zones and drying under heating elements in seconds.
- π₯ 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.
- β±οΈ 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
π 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.
Mindmap
Keywords
π‘Ceramic Tiles
π‘Humidity
π‘Fireproof
π‘Stain-resistant
π‘Wall Tiles
π‘Molding Process
π‘Automated Machinery
π‘Water-based Paint
π‘Kiln
π‘Vitrification
π‘Border 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
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