Proses Produksi Pembuatan Keramik di Pabrik Modern | Bagaimana Cara Pembuatan Keramik

Summary

This video explores the process of manufacturing ceramic tiles at a modern factory. The production begins with raw materials like clay and kaolin, which are mixed, pressed, and dried. After drying, the tiles undergo glazing, decoration using digital ink injectors, and a final firing process in a high-temperature furnace. The factory uses cutting-edge technology for tile decoration, producing over 2.5 million square meters annually. Quality control ensures each tile meets specific standards before being packed and distributed to over 90 countries.

Takeaways

• 🏭 Ceramic and porcelain tiles differ in material and processing, with porcelain being glossier and more fragile.
• 📏 Ceramic tiles are more commonly used in bathrooms and kitchens due to their durability and ease of use.
• 🏢 The factory described in the video specializes in manufacturing ceramic wall tiles using advanced technology.
• 📦 The factory produces over 2.5 million square meters of ceramic tiles annually, focusing on quality and precision.
• 🧱 The main materials used in ceramic tile production are clay, sand, feldspar, carbonate, and kaolin.
• 💧 The ceramic tile manufacturing process involves drying, pressing, and spraying water to form the tiles.
• 🎨 Tiles are decorated using digital ink injection machines, which allow for personalized patterns such as marble or wood effects.
• 🔥 The firing process takes place in a kiln at temperatures between 1100 and 1200 degrees Celsius, using natural gas for heat.
• 📊 After firing, the tiles undergo rigorous quality control checks, including size and pattern accuracy.
• 🌍 The factory distributes its ceramic tiles to over 90 countries worldwide.

Q & A

What are the main differences between ceramic and porcelain tiles?

Ceramic and porcelain tiles differ in both material and processing. Porcelain has a glossier and smoother surface, is more difficult to cut, and is more fragile compared to ceramic tiles. Ceramic tiles, however, are more commonly used in places like bathroom floors and kitchen walls.

What raw materials are used to make ceramic tiles?

The main raw materials for making ceramic tiles include clay, sand, feldspar, carbonate, and kaolin. These materials are sourced through extraction processes from quarries and stored in large quantities for production continuity.

What is the role of the 'biscuit' in ceramic tile production?

The 'biscuit' is a solid dough formed by mixing the ceramic base materials with water, which is then dried to form round and hollow granules. These granules are important for filling the mold completely and ensuring that the tiles are compacted perfectly during the pressing stage.

How is the pattern applied to ceramic tiles during production?

Patterns are applied using a digital ink injector machine, which works like a printer to decorate the tiles without contact. The process is computer-controlled, allowing for personalized designs, including patterns resembling stone, marble, wood, or other effects.

What is the significance of the combustion process in ceramic tile production?

The combustion process is crucial for transforming raw materials into finished ceramic tiles. Tiles are fired in a roller kiln at temperatures between 1100 to 1200 degrees Celsius, optimizing heat recovery to reduce gas consumption and prevent thermal shock, which can break the tiles.

How does the drying process affect the tiles during production?

After pressing, the tiles are dried in a horizontal dryer until they retain only 0.5% moisture. This step is critical for preventing the tiles from becoming brittle. Once fully dried, they are ready for glazing and decoration.

What technologies are used to ensure the quality of ceramic tiles during manufacturing?

The factory uses automated machines for sorting and inspecting the tiles for size, pattern, and surface texture. After machine inspection, a manual visual inspection is performed to ensure the tiles meet specific standards for flatness and consistency.

How does the factory reduce excess gas consumption during tile production?

The factory's furnace is designed to optimize heat recovery. Hot gases generated during the firing process are reused to heat the tiles during the initial combustion stage, significantly reducing gas consumption.

What is the production capacity of the ceramic tile factory?

The factory has a production capacity of over 2.5 million square meters of tiles per year, and it operates in a facility that covers 160,000 square meters.

How does the factory ensure that the tiles are uniform in size and shape?

The factory uses automated systems for checking the dimensions, surface patterns, and texture of the tiles. Any discrepancies are corrected during the sorting process to ensure uniformity in size and shape before packing and distribution.