1. MANUFACTURING PROCESS OF
PROCELAIN TILES
NISHANT SINHA

2. WHAT IS A PROCELAIN TILES?
▪ Ceramic tiles with a water absorption rate of less than 0.5% .
▪ Used to cover floors and walls.

3. OVERALL MANUFACTURING PROCESS
▪ Preparation of raw materials.
▪ Pressing and drying.
▪ Firing process with or without glaze.
▪ Additional refinements.
▪ Packaging process.

4. Raw Material Supply Mixing Extrusion Pre-CureCoating Racking and Derecking
CuringDepalletingPost-cure Coating
& Drying
Inspection
Yard Stacking Loading & Dispatch
Collecting
& Packing

5. RAW MATERIALS
▪ Sand
▪ White clay
▪ Talc
▪ Feldspar
▪ Calcite
▪ Dolomite

6. MIXING
▪ All the Raw Materials are crushed in an uniform size.
▪ Sometimes, water is added and the ingredients are wet milled or
ground in a ball mill.
▪ Excess water is removed using filter pressing followed by spray
drying.

7. EXTRUSION
▪ The dry powder is
mechanically placed into
moulds of the required size.
▪ The body of the tile is
pressed to that size in a
hydraulic press.
▪ The pressure applied ranges
from 3,500 to 7,200 tons

8. DRYING
▪ The moisture content in the
body is reduced to the
required levels by placing the
tiles in dryers.
▪ Here heat is applied by
convection from hot gases
applied to the surface of the
tiles.

9. RACKING AND DERACKING
▪ Temporary storage further
process.
▪ Helps in removing excess
moisture, if present.
▪ Also helps in the products to
get stable.

10. GLAZING
▪ Unglazed, extruded tiles are fired
after the drying stage.
▪ Ceramic tiles have a single or multiple
coats of glaze applied.
▪ The glaze adds protection texture and
enhances chemical resistance.
▪ Silica is the prime component of
glaze.

11. FIRING
▪ Most important part of the
process because it will
determine:
– Mechanical strength
– Dimensional
– Stability
– Chemical resistance
– Ease of maintenance
– Fire resistance.
▪ Fired at temperatures of
around 1220 Celsius in
approximately 40 minute
process.

12. BYPRODUCTS
▪ A variety of pollutants are generated during the various manufacturing steps, such as:
– Fluorine
– Lead compounds.
▪ Lead compounds have been significantly reduced with the recent development of no-lead or
low-lead glazes.
▪ Fluorine emissions can be controlled with scrubbers, devices that basically spray the gases with
water to remove harmful pollutants.
▪ The tile industry is also developing processes to recycle wastewater and sludge produced during
milling, glazing, and spray-drying.

13. QUALITY CONTROL
▪ Most tile manufacturers now use statistical process control (SPC) for each step of the
manufacturing process.
▪ Statistical process control consists of charts that are used to monitor various
processing parameters, such as :
– particle size
– milling time
– drying temperature and time
– compaction pressure
– dimensions after pressing
– Density
– firing temperature and time
▪ These charts identify problems with equipment, out of spec conditions, and help to
improve yields before the final product is finished.
▪ Work closely with their raw material suppliers to ensure that specifications are met
before the material is used.