Tiles may be found in our bathrooms, kitchens, and even our living rooms and bedrooms. They’re so common, but many of us are unaware of the complicated manufacturing process that goes into making them. In this post, you will learn about the subtle variations between porcelain and ceramic tile production, as well as the larger tile manufacturing process that allows us to turn lumps of dirt into statements of beauty.
Wall tiles and floor tiles used for internal and outdoor décor are classified as whitewares. Tile manufacture traces back to ancient eras and peoples, such as the Egyptians, Babylonians, and Assyrians. Colourful glazed tiles, for example, were used in the Step Pyramid of Pharaoh Djoser, which was constructed in ancient Egypt in approximately 2600 B.C. Ceramic tile was later made in almost every major European country and in the United States. By the turn of the twentieth century, the tile was being produced on a large scale. Around 1910, the tunnel kiln was invented, which enhanced the mechanization of tile manufacturing. Tile production is now highly mechanized.
Whatever floor covering option you finally choose, it will be built or manufactured in some way. However, how ceramic is made is a realm unto itself. The method is centuries old, and the benefits are numerous and desirable: beauty, durability, usefulness, and adaptability. Ceramic tile is a work of art that you walk on: a stunning entryway, a rejuvenating bath/spa surface, or a visual feast in a gourmet kitchen. Ceramic tile is a work of art that you admire as the owner and want as a visitor.
But..
How Are Tiles Made in India??
Ceramic tile’s basic components and overall production methods haven’t evolved all that much over the years. All ceramic tiles are made from natural earth materials that are moulded into tiles, and then baked at extremely high temperatures in kilns. Let’s go through the whole journey of how tiles are made-step-by-step-
Step 1 is simple and natural.
The mining of raw materials, which are primarily clay and minerals, is the first step in the process.
Clay minerals extracted from the earth’s crust, natural minerals such as feldspar used to reduce the fire temperature, and chemical additives necessary for the shaping process comprise the raw materials used to make tile. Minerals are frequently processed or beneficiated near the mine before being sent to the ceramic factory.
Step 2 turns mud into fine sand.
The raw materials must be crushed and sorted by particle size. Screens are used to separate particles within a particular size range.
They work in a slanted stance and are mechanically or electromechanically vibrated to facilitate material flow. The mesh number, which is the number of openings per lineal inch of the screen surface, is used to classify screens. The smaller the pore size, the higher the mesh number.
The clay and mineral combination is combined and ground into a semi-fine powder. A moist slurry or mud-like consistency is formed by adding water. The slurry is then fed into a huge drier. And what’s the end result? A fine clay powder that has the texture of warm, fine sand.
Step 3 witnesses the formation.
The clay is then crushed or moulded into a tile shape. At this stage, the pressed tiles are referred to as green tiles.
Extrusion is another approach that may be used to replace the pressing process. Extruded tiles are created by pushing clay material through a mould to get the required shape rather than pressing the tile. Extrusion with punching is used to manufacture irregularly shaped tiles and thinner tiles more quickly and cost-effectively. That entails compacting a plastic mass in a high-pressure cylinder and pushing the material to flow out in short slugs. Using hydraulic or pneumatic punching presses, these slugs are subsequently punched into one or more tiles.
Step 4 dries it all up.
After forming, ceramic tile must typically be dried (at high relative humidity), especially if a wet technique is chosen. Drying removes water at a slow enough pace to prevent shrinkage cracks, which might take several days. Continuous or tunnel driers that are heated with gas or oil, infrared lamps, or microwave radiation methods are used.
Step 5 is the glazing process.
It is the next step in the production process for tiles with a glaze. If the tile is to be left unglazed, this stage is skipped, and the tile is sent directly to the firing kiln.
The glaze liquid is made from frit, a glass derivative, and coloured dyes. The glaze is either sprayed on with a high-pressure sprayer or poured directly onto the tile.
Step 6 is when things heat up.
After glazing, the tile must be intensively heated to reinforce it and achieve the necessary porosity. The ceramic tiles are now baked in the kiln at about 2000 degrees Fahrenheit.
Monocoturra tiles, also known as single-fired tiles, are burned only once after the glaze is applied. The other is known as biocuttura or twice fired tile. After the green tile has cured, the Biocuturra tiles are fired for the first time and then fired again after the glaze is applied.
Step 7 wraps it up.
The tile is ready to be packaged and sent after it has been baked and tested.
The finished product must meet certain physical and chemical requirements. Mechanical strength, abrasion resistance, chemical resistance, water absorption, dimensional stability, frost resistance, and linear coefficient of thermal expansion are all measurable properties. Slip resistance, which may be evaluated by measuring the coefficient of friction, has lately become a problem, and so now it is also measured.
There is so much labour and machinery that goes into making the tile business what it is today that we regard the tile as a symbol of human technological development. You can find many tile manufacturers in India today, but one that stands out the most is AGL Tiles.
AGL leads the way in developing the most diverse range of designs across the whole tile and marble product line, from ceramic tiles to Nanotech, Roto-Drum, and New Digital Technology. Their cutting-edge design technology meets the aesthetic and performance needs of designers, architects, construction firms, and homeowners all across India. Asian Granito India Ltd.’s robust and distinct product range comes with the guarantee of global quality, driven by innovation and a strong determination to achieve. So, make sure to check that out.
On that note, I’ll take your leave, and as always, don’t forget to like this post if you enjoy it.