Welcome To The: "Manufacturing Process of Standard Ceramic Tiles"

Welcome To The
Presentation on
Manufacturing Process
of
Standard Ceramic Tiles
Presented to
Presented by Mrinmoy Mitra

Lecturer
Shamima Hossain Department of Business Administration
Roll- 1983 World University of Bangladesh
Md. Rasel Mia
Roll- 1984
World University of Bangladesh

Location facilities of Standard Ceramic
The factory locating in Gazipur,

only 30 KM distance from
capital city of Dhaka.
Therefore they get following
facilities-
1. Available of labors
2. Easy for transportation and
communication
3. Low cost delivery
Manufacturing System of Standard
Ceramic
Standard ceramic follow the
lean manufacturing
system. Which means
their main aim is to-
Reducing Waste
Reducing cost
Continuous Improvement
of product quality.
Production Process of Standard Ceramic
Tiles
Ball Milling
Raw Weighing
material
Dry Pressing Spray Dryer Vibrating Screen

and Homo Tank
Glazing
Coloring & Firing process
Designing
Finishing
Shorting and Packaging
Raw Materials for Ceramic Tiles
The traditional ceramics industry is largely based on
various combinations of clay minerals, feldspar and
silica.
Silica
The mineral raw materials used in the ceramic industry
are mainly inorganic, nonmetallic, crystalline solids
formed by complex geologic processes.
Clay
Clays have the ability to form clay-water composition
and to maintain their shape and strength during drying
and firing
Talc
Preparation of Powder
Raw Materials
Continuous Ball Mill
Service Tanks
Slip Tank
Spray Drier
Preparation of Powder (Continuous ball mills)
The mixing of raw materials takes place with the

help of alumina pebbles.
This ball mill continuously rotates.
This rotation helps the pebbles to grind the raw

materials.
The grinded raw materials are mixed with water to

obtain slurry
Preparation of Powder (Service Tanks & Slip tanks)
Service Tanks
The service tank rotates continuously so
that it wont allow highly viscous slurry to set.
In the vibration chamber filtration of sand

and stone takes place with the help of huge
vibrators.
The slurry free from sand and stone enters

into slip tank.
SLIP TANK
The Slurry in the slip tank is continuously
rotated in order to prevent setting of slurry as
it is highly viscous.
Preparation of Powder (Spray Dryer)
The slip flows from tanks to spray

nozzles and the slip is sprayed in the
upward direction from the nozzles.
Slip sprays in the downward

direction and hot air will pass upwards.
The temperature in the spray drier is

maintained at 720 degree C.
The moisture content is around (4.5-

5.5%)
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Shaping Process (Dry Pressing)
Dry Pressing
Glazing Process
Glazing
Glazing is a layer or
coating of
a vitreous substance
which has been fired to
fuse to a ceramic object to
Color
Decorate
strengthen or waterproof
it.
Colouring & Designing
Coloring & Designing
To form required size of tiles,

the floor tiles are colored and
designed using silk screening
(located in the printing
machine), and then stored in
transfer cars for a while before
firing.
World University of Bangladesh

Firing Process
The firing process is to harden the tiles.
These tiles are heated in a roller kiln for
about 40-45 minutes, depending on the
size and type of the tiles. As a general
rule, the more color and design involved,
the longer the tiles are heated.
Typical firing temperatures for alumina,

mullite, and zirconia reach 2850 F - 3100
F.
Typical firing cycles can range from 12 -

120 hours depending upon the kiln type
and product.
Ceramics shrink approximately 20%

during the sintering process.
Finishing
Parts made of ceramics

sometimes require finishing.
In general, these operations
have of the following
purposes, to-
(1) Increase dimensional accuracy
(2) Improve surface finish

Shorting
The tiles are sorted by
sorting machines to
separate the good tiles
from the defective ones.
The company also uses
computerized machine
to ensure the exact size
of tiles.
Packaging
The final process is
where tiles are packed
according to the
specific size and
quality, stored in a
warehouse as finished
goods ready for sale
US

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Welcome To The

Presented by Mrinmoy Mitra

World University of Bangladesh

The factory locating in Gazipur,

Dry Pressing Spray Dryer Vibrating Screen

Continuous Ball Mill

The mixing of raw materials takes place with the

This ball mill continuously rotates.

This rotation helps the pebbles to grind the raw

The grinded raw materials are mixed with water to

In the vibration chamber filtration of sand

The slurry free from sand and stone enters

The slip flows from tanks to spray

Slip sprays in the downward

The temperature in the spray drier is

The moisture content is around (4.5-

Coloring & Designing

To form required size of tiles,

World University of Bangladesh

Typical firing temperatures for alumina,

Typical firing cycles can range from 12 -

Ceramics shrink approximately 20%

Parts made of ceramics

(1) Increase dimensional accuracy

(2) Improve surface finish

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