Introduction of ceramic tile production process

When purchasing Ceramic Tiles, many consumers must be curious about the production process of ceramic tiles: how is it produced? China has a long history and many brilliant achievements in ceramic production, so the technologies of various enterprises are different. Next, We will introduce the ceramic tile production process in detail.

1. Raw material selection

Raw materials entering the warehouse shall be inspected, mainly including sampling, cake beating and trial firing, physical property testing, chemical analysis and other steps. The raw material inspector shall detect the moisture of the samples; then, the tester will pulverize, beat cake and test burn the sample according to the procedure, and test the whiteness, strength, water absorption and other physical properties of the sample cake after the test burn. At the same time, the tester will extract some powder from the pulverizing link for chemical analysis to test whether the content of various chemical components in the raw materials meet the process and technical requirements of the factory

2. Powder preparation

The process of powder preparation includes batching, ball milling, sifting, iron removal, mud homogenization, spray drying, powder making and bunker stale.

Firstly, weigh the corresponding raw materials according to the process formula (including water addition) (according to a certain proportion);

Then, the prepared raw materials are added into the ball mill for grinding into slurry. The grinding medium pebble is prepared in the ball mill according to the process requirements, so as to fully and evenly mixes all kinds of block and coarse and fine raw materials after grinding and crushing. On the one hand, it can promote the physicochemical reaction of the blank in the firing process and reduce the firing temperature. On the other hand, it is also conducive to the separation of impurities in the raw materials;

The slurry after ball milling meets the process quality requirements and is put into the slurry tank. It shall be screened and iron removed on the way. Screening is to remove coarse particles and some impurities that are not ground during ball milling; Iron removal is because iron affects the whiteness of ceramic tiles, and will form black spots, melting holes, impurities and other defects on the surface of ceramic tiles, so it must go through multiple strict iron removal;

After screening and iron removal, the mud shall be continuously stirred and homogenized to make the mud composition more uniform, improve the mud flow performance, increase the plasticity of the mud made in the later stage, improve the green body strength, and reduce the cracking during forming and firing.

After homogenization, the slurry is tested to meet the quality requirements. It is transported to the spray tower by high-pressure atomization, and powder particles are made by hot air drying provided by hot blast stove. In the process of spray granulation, the control of moisture content of powder is very important. The moisture content of powder and the uniformity of moisture distribution in powder will directly affect the pressing operation and the quality of brick.

The powder discharged from the spray tower, due to the difference in moisture content inside and outside the granules, and the uneven moisture content of each part of the powder, need to be conveyed to the silo to be worn out, so as to make the moisture content of the powder more uniform. After the powder is stale in the silo for 24 hours, it can be said that the blank preparation process of ceramic tiles production is completed, and the prepared powder will be sent to the next process through the conveyor belt.

3. Press and Molding

The prepared powder will be sent to the press process. After being distributed through the mold, a certain pressure will be applied to the powder, so that the powder will be pressed into brick. It should be noted that in the process of pressing into brick, the quality requirements of powder and the correct operation process of the press must be guaranteed, otherwise the quality of brick will be directly affected.

4. Drying and printing

After pressing, the strength of the brick blank is very poor. Due to the large moisture content of the brick blank, drying is to evaporate the free water in the brick blank. On the one hand, it can improve the strength of the brick body, reduce the damage of the brick body, and avoid the waste entering the printing and firing process, resulting in unnecessary losses; On the other hand, it can also avoid the billet cracking caused by the violent evaporation of water when the brick with high moisture content is fired in the kiln( Printing is a process for infiltrating polished bricks)

5. Firing

The bricks are dried and then fired in a kiln. Before entering the kiln, the brick blank shall be grouted first, mainly to prevent the brick blank from sticking to the roller when it is softened in the high-temperature section of the kiln. When entering the kiln for high-temperature calcinations, the maximum calcinations temperature generally does not exceed 1250 ℃.

6. Edging and polishing

The semi-finished ceramic tiles after firing should go through the steps of grinding, scraping, polishing, post grinding and air drying, so as to become the bright and flat exquisite ceramic tiles we see in the exhibition hall.

In the edge grinding process, it is strictly stipulated that the size and diagonal of ceramic tiles must comply with the company's internal control standards, with very high precision and high technical requirements for operators.

Enter the polishing process. Polishing is divided into three steps: rough polishing, medium polishing and fine polishing, that is, the grinding blocks used for polishing are arranged from coarse to fine, and the milled ceramic tile surface is gradually ground to have gloss and show the original texture of the brick.

7. Waxing and Package

It has very strict control over product quality, and each branch has a quality supervision team to control the product quality before leaving the factory.

Finally, the moisture on the surface and bottom of the ceramic tile shall be air dried to facilitate the waxing of the finished product, graded inspection and selection of the finished product, packaging and warehousing.