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Good ceramic tile is made by this way, the whole throwing glaze production process is detailed

The whole cast glaze by 3D inkjet technology the most advanced in the world, through the use of the top and the pigment ink, the natural stone texture and color fidelity reduction glaze texture simulation reaches more than 95%, the natural charm on the tiles, rich layers, color changeable, three-dimensional sense of strong. You can also enjoy the beauty of nature in your home. Now, Xiao Bian explains the production process of all throwing glaze products for you. Let's have a deep understanding of it.
Raw material exploitation and storage
Ceramic raw materials from mines, soil, natural raw materials, can be directly mining in mines: plastic raw materials: black mud, white mud, determines the life of ceramic tile base material; ridge: quartz, determines the performance of ceramic tile; solvent: Feldspar, determines the vitality and toughness of ceramic tile.
Raw material incoming inspection
Ceramic tile production has strict requirements for the chemical composition and mineral composition of raw materials, so a series of strict analysis and inspection should be carried out before large quantities of raw materials enter the yard of the factory.
The first step is to use advanced chemical analysis instrument to analyze the 7 components, plasticity index and whiteness index of raw materials;
The second step is to use a quick grinding mill to measure the fluidity and thixotropy of the slurry;
In the third step, the ball fineness was measured by laser particle size analyzer;
The fourth step is pressing the sample cake with the hydraulic press according to the production process;
The fifth step, put into the furnace burning, detection of the degree of sintering, shrinkage index, etc., to determine the appearance of ceramic tile appearance, black, bubble, cracking, black heart and other oxides.
The qualified raw materials can be put into the factory. However, the raw materials directly mined by nature are unstable due to climate, weather, formation time and hierarchical structure, so they must be homogenized.
Raw material storage (homogenized, stale)
All of that is a procedure of raw materials by mechanical stirring; stale, refers to the mixed mud placed for a period of time, make the reaction between mud, the water is more uniform. Only after homogenization and raw materials can be processed, can the stability of batch production be ensured. Homogenization of mining, homogenization, processing (mud) homogenization, the three steps are indispensable.
More than ten thousand tons of raw materials are fully absorbed by multiple excavators and mining machines, and the raw materials can be transferred into semi closed raw material bins.
Mixed ingredients
Technical personnel mastered a list of ingredients, mature ingredients formula generally through the laboratory repeated several small test, production line in the trial plate, in order to enter the production. The batching agent starts with the list of ingredients issued by the technician, and the raw materials are added to the feeder through a large forklift, and then the ball mill enters the ball mill through the conveyor belt.
Principle of formula determination:
(1) the composition of the blank and glaze should meet the requirements of the physical, chemical and physical properties of the product;
(2) the production process and equipment conditions should be considered when making the formulation;
(3) to understand the influence of various raw materials on the properties of the products;
(4) the formulation should consider the rationality of the economy, the abundance of the resources and the stability of the sources.
Ball milling
The ball mill is iron in crushing and grinding equipment large flint ball liner, a ball mill once can be added: 40 tons, 40 tons of mud stone and 50 tons of water. The ball mill work, by rotating the ball from the mud ground. According to the formula of milling workers list to add various additives in ball mill, ball milling process for laser particle size analyzer for continuously detecting slurry fineness, compliance to the ball, the original "material + water" became the mud water content is around 30%.
The large tonnage ball mill, by milling wear-resistant alumina qualitative ball long time, ensure the raw materials of coarse particles become finer and more uniform.
Slurry size measurement
The size of the slurry after ball milling can pass into the next production process and the performance requirements of the slurry:
(1) liquidity and suspension are better for transportation and storage;
(2) moisture content should be suitable to ensure high powder output and low energy consumption during milling process;
(3) the proper fineness ensures the stability of the product size shrinkage, firing temperature and performance;
(4) sizing paste to see the color of the body.
Bleeding into the pond (except iron)
The qualified slurry is put into the slurry tank, and the iron removing device is installed at the entrance of the pulp pool to remove iron from the slurry.
Sizing and removing iron
(1) the slurry passes into the sieve system, and the coarse particles separated from the required size are returned to the ball mill until they are qualified;
(2) after removing iron from the slurry, the impurities such as iron and titanium, which are harmful to the quality of the products, are removed.
The magnetic iron rod is used to adsorb iron filings, and the iron content is less than 0.1%, so as to ensure that the blank body after sintering has no black impurity, and the brick body is pure.
Slurry storage (homogenized)
After screening the iron, the slurry enters the slurry tank and is homogenized.
spray granulation
The slurry into the spray drying tower for drying and dehydration, the principle of this process is the use of the piston pump pressure will be injected into the slurry of about 10 meters of space, spray mist in the drying air under the effect of slurry into particles of a 0.5 mm diameter ranging from -2 mm.
Powder testing (particle size, moisture content)
The powder formed by spray drying must be checked and qualified before entering the next process.
Powder testing items:
(1) particle size distribution, particle size distribution, refers to the proportion of particles of various sizes in the powder;
(2) the detection of powder moisture, the general ceramic powder moisture control at 6%-7%, this particle has very good liquidity.
Powder screening
The powder is sieved to avoid particles that do not meet the requirements of particle size into the next process, so as to guarantee the quality of the product.
Storage of powder silo (homogenization)
Spray dried powder has a certain temperature, and moisture is not uniform, so the powder generally needs homogenization, 48 hours later can be used.
(1) the stale time is too short, the moisture is uneven, the product easy to produce the interlayer;
(2) the stale time is too long, the strength is poor, the fluidity is poor, and it is difficult to fill the mould cavity of the press.
Storage bin of powder press
The powder through the conveyor belt into the compressor hopper, ready for pressing bricks.
Pressure tile machine molding
The powder in the press hopper passes through the cloth grid cloth to press and form the brick press, and the pressing process is divided into three steps:
The first step is to reduce the exhaust pressure; the second step is to pressure and exhaust; the third step is to add pressure to the ultimate.
Pressing to the density required body, the whole process must be very fine. First of all, the packing should be uniform; secondly, pressing time and speed must be very accurate, through computer control; and then demoulding is also very accurate, otherwise prone to cracking. Different press tonnage presses different sizes of products, which determines the thickness, size, density, hardness and other parameters of the body.
The tonnage of the press directly determines the density and hardness of the ceramic tile.
Adobe drying
After the brick molding press contains a certain amount of moisture, even tiny water, will affect the strength of brick, the brick was rushed to the drying kiln drying. After drying the bricks, moisture content decreased from 7% to about 0.5%.
The length of the drying kiln determines the moisture content of the ceramic tile. 320 meters long roller kiln, not only can make the moisture content less than 0.5% and fired brick, no deformation.
Adobe cooling (surface cleaning)
After drying the bricks after cooling, and surface cleaning, may enter the procedure.
Green water
Adobe needs water on the upper bottom glaze, its function is:
(1) to reduce the temperature of the billet to the temperature required for glazing, and to open the pores on the billet surface;
(2) strengthen the combination of blank and glaze, reduce the production defects, such as glaze shrinkage, etc..
Bottom glaze
Drench glaze is the glaze into the bell is located in the high tank glazing unit above the glaze by groove and cushion sieve mesh, the glaze by smooth bell, uniform surface such as a waterfall quietly covered in green body. The glaze amount can be adjusted by the glaze supply and the speed of the conveyor belt. After the smooth surface of tile glazing, lay a good foundation for the highly sophisticated printing process the next step.
Surface decoration
(screen printing, cot printing, ink jet printing)
Surface decoration process is usually referred to as the printing process, the whole throw glaze product surface color and pattern, pattern are very rich and realistic. At present, there are three main printing technologies: screen printing, roller printing and inkjet printing. Different printing technologies present different product surface effects.
(1) screen printing:
Screen printing is to transfer the pre printed glaze to the glaze blank through the capillary net of the silk screen, and the pattern of the printing screen determines the pattern of the tile.
(2) top roller printing:
Roller printing the pre designed patterns with laser drilling way carved in the round rollers, large rollers through the precise rotation and speed, the glaze from below through the leaf rolling pattern is transferred to the surface of glaze, due to slightly different in each brick by the rollers below the position, therefore roller printing products out of the pattern is a little different, this product is more natural.
(3) ink jet printing:
Inkjet printing technology is the use of high performance inkjet printer, the computer preset pattern directly sprayed on the surface of the glaze blank. Ink jet technology is a jet printing, so its pattern can be three-dimensional concave and convex, so that the touch of tile true, vivid patterns.
Italy West Stemm inkjet printers, the world's most advanced production, out of the whole cast glazed products, rich colors and magnificent natural color patterns.
Applied glaze
The whole cast glaze product surface with a layer of transparent glaze, the glaze polishing products showing a bright dazzling crystal.
With the tile surface glaze by the conveyor belt to the roller kiln firing, the main fuel roller kiln can use diesel oil, natural gas or coal gas, the sintering temperature can reach more than 1200 DEG C. The kiln can be divided into three zones: the preheating zone, the firing zone and the cooling zone. The firing time and temperature of each belt are strictly controlled by the computer. After high temperature sintering brick changed when it became the true meaning of the tiles.
Brand manufacturers using long wide energy-saving roller kiln, ceramic tile burning time is longer than the usual brick factory, to ensure complete porcelain, as dense as the porcelain, high hardness, wear resistance!
Adobe cooling
After firing, the tile temperature from the roller kiln is very high, and it needs to be cooled so that it can enter the next process.
Edging and sizing
After cooling the ceramic tiles into the edging process, the dimensions of each side are standardized. The grinding process is completed by two sets of machines. After each parallel edge is finished, the ceramic tile is turned at 90 degrees, and the other side of the tile is operated.
Elastic polishing
Complete the edge length, tile in the transmission line into the coarse grinding and polishing machine, brick surface smooth, then throw, throw to throw from the rough, can throw brick thickness 0.1-0.2 mm, polishing machine out of the brick, a bit like the smooth degree of matte brick. Fine polishing machine function rather like Adobe After fine polishing machine polishing machine, surface gloss, smooth as a mirror, can reach about 60 degrees. The working principle of polishing by different mesh grinding head rotation, grinding and polishing to tile, generally head from 24 mesh to 1500 mesh or even higher.
Nano antifouling
In order to improve the antifouling ability, in the ceramic tile surface evenly coated with a layer of nano antifouling agent, also known as the pure bright. The antifouling agent can prevent the cement slurry from penetrating into the surface of the ceramic tile during the construction process, and also prevent the pollution caused by the ink, tea and so on in daily life. You can also enhance the pure bright gloss antifouling tile (over 90 degrees).
Pure bright polishing, antifouling process, to use a lot of water erosion on the tiles, so the process is completed, the brick body attached with a lot of water, need to be dry can process tile next.
Inspection classification
Inspection and classification of the dried tiles. Quality inspection personnel first of the product deformation, edge straightness detection, and then according to different color number of tiles classification, according to the surface quality of the classification.
Brand manufacturers to adopt many strict standards than the national standards of the enterprise, have received professional training in quality inspection personnel, product classification process is very strict and cautious, are demanding quality inspection for each piece of brick, ensure the products comply with the national standard of internal control index in flatness, size deviation and color index, ensuring high-quality products.
Waxing, film
Before waxing tiles all dirt thoroughly cleaned, and then waxing machine liquid wax evenly on the tile surface, the tile surface after drying, and then on the surface of tiles affixed a layer of film. The ceramic tile waxing can clean and polish, increase the beauty, and can prevent insects, moisture-proof, crack prevention, reduce the outside of the ceramic tile corrosion and wear, prolong the service life of ceramic tile. The ceramic tile surface can protect the ceramic tile from being scratched.
Packaging and warehousing
After grading products to enter the automatic packaging process, according to different products and sizes, set up different number of packaged tablets, the number of ceramic tiles large and heavy, small and exquisite ceramic tiles a few more, mainly to inventory, transportation, FCL purchase convenience number. After packing, the ceramic tile can be stored in the warehouse and stored in strict accordance with the product category, model, grade and color number. Quality inspection personnel to warehouse products will be regularly sampling, the good product before leaving the factory quality control.