How TILES are Made
Summary
TLDRThis video explores the production process of modern floor tiles, showcasing two factories specializing in ceramic and porcelain tiles. Raw materials are mined, crushed, and ground into fine particles, mixed with water and additives. Porcelain tiles involve the addition of andesite and extrusion, while ceramics are pressed into shape. Both undergo drying, printing, and glazing before being fired in a kiln at high temperatures. The process concludes with quality checks and sorting, highlighting the factories' 24/7 operation and the use of advanced automation for efficiency in the South African market.
Takeaways
- π οΈ Modern floor tiles are crafted in various shapes and sizes to customize the personality of a room.
- π Two primary types of tiles are mentioned: ceramic and porcelain, both made from a mixture of different clays and sand.
- βοΈ Raw materials for tiles are sourced from quarries and then processed in factories.
- π¨ The initial stage of tile production involves crushing and milling the raw materials into fine particles.
- π§ Water and other additives are mixed with the ground materials to form a suitable mixture for tile creation.
- π At the Vitro factory, porcelain tiles are made with the addition of andesite, and the clay is processed using a screen feeder and extrusion machine.
- π The Pegasus factory's process for ceramic tiles involves pressing the fine powder mix into tile shapes.
- π₯ Both types of tiles undergo a drying process to strengthen them before further treatment.
- π¨οΈ Tiles are prepared for printing with a primer coating, followed by either screen printing or modern inkjet printing techniques.
- π§ A protective glaze is applied, which becomes transparent after the firing process in a kiln.
- β¨οΈ Tiles are fired in a kiln at high temperatures to bake the clay and other materials, followed by a cooling process to prevent warping or cracking.
- π Quality control checks for strength, size, and precision, with tiles sorted into different quality grades by a computerized system.
- π€ Automation and robotics, such as laser-guided forklifts, are used to maintain high efficiency in the production process.
- π‘ Both ceramic and porcelain tiles are designed for durability and aesthetics in various home settings, responding to modern design demands.
- π The factories cater to both local South African and international markets with their high-quality floor tiles.
Q & A
What are the two main types of modern floor tiles mentioned in the script?
-The two main types of modern floor tiles mentioned in the script are ceramic tiles and porcelain tiles.
What materials are used to make both ceramic and porcelain tiles?
-Both ceramic and porcelain tiles are made from a mixture of different clays and sand, with the addition of cement in the form of andesite for porcelain tiles.
How are the raw materials for tiles initially processed?
-The raw materials are mined in a quarry and then put into a crusher machine to break up the larger pieces. They are then sent to huge milling machines where they are ground to very tiny particles and mixed with water and other additives.
What is the purpose of the screen feeder in the production of porcelain tiles?
-The screen feeder, which is like a cheese grater, presses chunks of the clay through holes at the bottom, preparing the clay for extrusion.
What is the extrusion process in tile production?
-The extrusion process involves a vacuum removing all air from the clay mix and a large screw pressing the clay through a metal die, punching out a sheet of material that will form the tiles.
How do the factories produce tiles of different sizes?
-Tiles are cut to size after the extrusion process, and both porcelain and ceramic tiles can be produced up to 600 millimeters square.
What is the purpose of the drying process in tile production?
-The drying process removes some of the moisture from the material, making the clay more supple and giving the tile more strength.
What are the two methods of printing used on the tiles?
-The two methods of printing used on the tiles are screen printing, where different colors are applied through a screen, and inkjet printing, which can print any design entered into the computer.
What is the role of the glaze in the production of tiles?
-A protective top coating of glaze is sprayed onto each tile, which turns white shortly after coming out of the spray tunnel but becomes transparent during the firing process in the kiln.
What happens during the firing process in the kiln?
-During the firing process, the tiles are first dried at a low temperature to remove water. Then, the temperature is raised to 1185 degrees Celsius to bake the clay and other materials in the body of the tile.
How do the factories ensure the quality and precision of the tiles?
-Each tile passes tests of strength, size, and geometrical precision, and a computer sorts each tile into its own quality grading, with A-grade tiles and V-grade tiles being sorted automatically at high speed.
How do the factories maintain high efficiency without the need for breaks?
-The factories utilize highly automated processes and robotic forklifts guided by a system of lasers reflected around the factory, ensuring efficient movement of boxes of tiles to the next stage of production.
Outlines
π The Manufacturing Process of Floor Tiles
The script delves into the manufacturing process of modern floor tiles, highlighting the production at two distinct factories specializing in ceramic and porcelain tiles. Both types begin with raw materials sourced from quarries, undergoing a series of processes including crushing, milling, mixing with water and additives, and extrusion for porcelain tiles or pressing for ceramics. The tiles are then cut, dried to increase strength, and undergo a detailed decoration process involving screen printing or inkjet printing. A protective glaze is applied before the tiles enter a kiln for firing, where they are subjected to high temperatures to harden. The process concludes with quality checks and sorting, ensuring the tiles meet the required standards before being packaged and shipped. The factories operate around the clock, emphasizing the importance of automation and machinery to maintain efficiency.
π€ Automation and Efficiency in Tile Production
This paragraph focuses on the significance of quality machinery and personnel in maintaining the high production standards of tile factories, which operate 24/7 without breaks. Automation is key to this efficiency, with the introduction of robotic forklifts that use laser guidance systems to move boxes of tiles efficiently through the production stages. The narrative also touches on the modernization of home design techniques and the role of these factories in producing tiles that cater to both the South African and international markets, showcasing the latest production techniques to ensure a tough and attractive finish for residential spaces.
Mindmap
Keywords
π‘Floor Tiles
π‘Ceramic Tiles
π‘Porcelain Tiles
π‘Raw Materials
π‘Milling Machines
π‘Extrusion
π‘Drying Process
π‘Screen Printing
π‘Inkjet Printing
π‘Glaze
π‘Firing
π‘Quality Grading
π‘Automation
Highlights
Modern floor tiles come in various shapes and sizes to personalize a room's feel.
Two types of tiles are discussed: ceramic and porcelain tiles, both made from clay and sand.
Raw materials for tiles are sourced from quarries and processed in factories.
Clay and sand are ground into fine particles and mixed with water and additives for tile production.
Porcelain tiles include andesite cement in their mixture and use a screen feeder for extrusion.
The extrusion process involves pressing clay through a metal die to form tile sheets.
Ceramic tiles are produced by pressing a fine powder mix into tile shapes.
Factories use 800 to 900 tons of raw materials daily and produce tiles up to 600 millimeters square.
Drying process strengthens the tiles by removing moisture.
Tiles are prepared for printing with a primer coating in a spray tank.
Printing methods include screen printing and modern inkjet printing for customized designs.
A protective glaze coating is applied and becomes transparent after the firing process.
Tiles are fired in a kiln at temperatures up to 1185 degrees Celsius to bake the materials.
A cooling section in the kiln prevents warping or cracking due to thermal shock.
Tiles undergo quality checks for strength, size, and precision before grading.
High-speed sorting machines automatically categorize tiles into different quality grades.
Factories operate 24/7 with automated processes to maintain high efficiency.
Laser-guided robotic forklifts efficiently move tiles to the next production stage.
Ceramic and porcelain tiles provide a durable and attractive finish for various home spaces.
Factories utilize the latest production techniques for the South African and international markets.
Transcripts
modern floor tiles are available in many
different shapes and sizes to give a
very distinctive personality to the feel
of the room today we're going into two
factories to have a look at the way that
floor tiles are made there are two types
of tiles ceramic tiles and porcelain
tiles both are made from a mixture of
different clays and sand the raw
materials are mined in a quarry and come
into the factory in a very rough form
they're put into a crusher machine which
breaks up the larger pieces the raw
materials are sent by conveyor to huge
milling machines the clay and sand are
ground to very tiny particles and mixed
with water and other additives to create
a mixture that is suitable for making
floor tiles in the vitro factory they
produce porcelain tiles to make
porcelain tiles cement in the form of
andesite is added to the mixture which
is fit to a screen feeder this machine
is very much like a cheese grater a
rotating screw inside the machine
presses chunks of the clay through holes
at the bottom of the feeder the clay is
fed to the extrusion machine inside the
machine a vacuum removes all air from
the clay mix and a large screw presses
the clay through a metal die and a sheet
of material that will form the tiles is
punched out of the machine this process
is known as extrusion
the tiles are cut to size and moved on
the line to the next stage of production
next door to the vitro factory is the
Pegasus factory which produces ceramic
tiles ceramic tiles are produced
slightly differently the raw materials
are milled to very fine powder mixed
with water and the mix is pressed into
the shape of a tile each factory uses
800 to 900 tons of raw materials per day
and produces tiles up to 600 millimeters
square both porcelain and ceramic tiles
are passed through a drying process to
remove some of the moisture from the
material the clay is quite supple as it
goes into the dryer the drying process
gives the tile more strength the patent
mana tile is printed onto the surface to
prepare them for printing both porcelain
and ceramic tiles passed through a spray
tank which sprays a primer coating onto
each tile printing is done in two ways a
screen printing method is used on some
of the lines here we can clearly see the
different colors being applied to the
tiles as they pass through the screen
printing section of the production line
a second method utilizes a very modern
inkjet printing machine to apply the
pattern to the tile this machine will
print any design that is entered into
the computer onto the tiles a protective
top coating of glaze is sprayed onto
each tile this turns white shortly after
it comes out of the spray tunnel but
will become transparent as the time
passes through the firing process in a
kiln the kiln is a long tunnel heated by
gas heaters through which each tile
passes in a process known as firing in
the first section of the kiln the tile
is dried at low temperature to remove
water from the clay if the tiles were
subjected to very high temperatures in
this first phase the water in the tiles
turned to steam and many of the tiles
would explode once the tile has been
dried sufficiently the temperature in
the kiln is raised to one thousand one
hundred and eighty five degrees
centigrade this is where the tile is
fired to bake the Clay's and other
materials that are in the body of the
tile a cooling section at the end of the
tunnel cools the tiles at a uniform rate
before they come out of the kiln this is
done to prevent warping or cracking of
the tile if there was suddenly exposed
to the cool air temperature outside the
kiln while they were very hot the tiles
may walk or crack which is caused by
thermal shock each tower passes tests of
strength size and geometrical precision
and the towers moving to the stacking
machine here the computer sorts each
tile into its own quality grading a
grade tiles will be put together and V
grade tiles will be automatically sorted
into a different stack at very high
speed these factories can each produce
up to half a million tiles every day and
are open for 24 hours a day seven days a
week so quality machinery and personnel
are important to prevent breakdowns
processes are becoming highly automated
in South African factories to maintain
efficiency at a high level without the
need to stop for breaks
this robotic forklift uses a system of
lasers that are reflected around the
factory by special panels these laser
guided vehicles move the boxes of tiles
to the next stage of production very
efficiently in this large factory both
ceramic and porcelain floor tiles
provide a tough and attractive finish to
bathrooms kitchens and the rest of the
home
modern home design techniques have
called for modern tile design these
factories utilize the latest production
techniques to produce quality floor
tiles for the South African and
international markets
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