Full-glazed glaze adopts the world's most advanced 3D inkjet technology. Through the use of pigments and inks, the texture and color of natural stone are vividly restored. The degree of glaze texture simulation reaches more than 95 percent. The natural charm is vividly above the tiles. Rich levels, varied colors, strong three-dimensional sense. You can also enjoy the beauty of nature while you are at home. Now, Xiao Bian explained the production process flow of full-glazed glaze products for everyone, and came to learn more about it.
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Full glazed tile production process
Track 1: Raw material extraction and storage
Ceramic raw materials come from mines and soils and belong to natural raw materials. They can be mined directly in the mines: Plastic raw materials: black mud, white mud, etc., determine the basic life of the tiles; ridge raw materials: quartz, etc., determine the various properties of the tiles; Solvent raw materials: feldspar, etc., determine the tile's vitality and toughness.
Track 2: Raw material inspection
Tile production has strict requirements on chemical composition and mineral composition of raw materials, so a series of rigorous analysis and inspections must be conducted before large batches of raw materials enter the yard of the plant.
One: Use advanced chemical analysis equipment to analyze the seven major ingredients, plasticity index, whiteness index, etc.
The second step is to grind the slurry with a quick grind and test its fluidity and thixotropy;
The third step: using a laser particle size analyzer to measure the fineness of the ball;
Step 4: press the production process with a hydraulic press to make a sample cake;
Step 5: Put it into an electric furnace for firing. Test the degree of sintering, shrinkage index, etc. to determine the number of black spots, blisters, cracks, black hearts and other oxides that affect the appearance of the finished ceramic tile;
Qualified raw materials can be imported into the plant. However, these materials that are directly exploited by nature are unstable because of climate weather, formation time, and hierarchical structure. Therefore, they must be homogenized.
Track 3: Raw Material Reserve (Homogenization, Aging)
Homogenization is a process in which raw materials are evenly mixed by mechanical movement. Aging refers to putting the mixed materials in place for a period of time so that the materials react with each other and make the moisture more uniform. Only after the homogenization and aging of the raw materials can the production process be carried out in order to ensure the stability of the batch production. After homogenization, homogenization, and homogenization after processing (slurry), three steps are indispensable.
Track 4: Ingredients
The technicians have mastered a list of ingredients. The mature ingredient recipes are generally tested repeatedly in the laboratory, and the production line is tested on the plate before they can enter the big production. After the batcher gets the list of ingredients issued by the technician, the batcher starts the batching. Various raw materials are added to the feeder through a large forklift and then enter the ball mill through the conveyor belt.
Track 5: Principles for Formulation
(1) The composition of the blank and glaze should meet the physical and chemical properties of the product and the requirements for use;
(2) The production process and equipment conditions should be considered when formulating the formulation;
(3) Understand the influence of various raw materials on product properties;
(4) Formulation of formula should consider economic rationality and whether resources are abundant and sources are stable.
Track 6: Put the slurry into the pool (iron removal)
The qualified slurry was put into the pool for use. The iron removal device was installed at the inlet of the slurry pool to remove iron from the slurry.
Track 7: Slurry sifting, removing iron
(1) The slurry enters the sieving system, and the coarse particles that do not meet the requirements are separated and then returned to the ball mill until they are qualified;
(2) After the iron is removed from the slurry, iron, titanium, and other impurities that are hazardous to the quality of the raw materials are basically removed.
High magnetic iron rods are used to absorb iron scraps, and the iron content is less than 0.1%. This ensures that the fired green body has no black impurities and the brick body is pure.
Track 8: Slurry stock (homogenized)
Slurry after sifting and removing iron enters the pool reserve and is aged and aged.
Spray granulation: The slurry flows into the spray drying tower for drying and dehydration. The principle of this process is to use the pressure of the plunger pump to spray the slurry into a space of about 10 meters high, spray it into a mist, dry and dehydrate under the action of hot air, The slurry turns into powder particles with diameters ranging from 0.5mm to 2mm.
Track 9: Powder Testing (Particle Size, Moisture)
The powder formed by spray drying needs to pass the inspection before it can enter the next process.
Track 10: Powder Inspection Project:
(1) Powder particle size distribution detection, particle size distribution, ie particle size distribution, refers to the proportion of particles with various particle sizes in the powder;
(2) The moisture content of the powder is generally 6-7 percent of the moisture content of the ceramic tile powder. The particles have very good fluidity.
Road 11: Powder sifting
The powder is sifted to avoid particles that do not meet the particle size requirements from entering the next process to ensure product quality.
Track 12: Reserves for powder material storage bins (homogenize stale)
The powder after spray drying has a certain temperature, and the moisture is also not uniform, so the powder generally needs to be aged for 48 hours before being used.
(1) The stale time is too short, and the uneven water product is easy to produce interlayer;
(2) Aging time is too long, the strength is poor, and the fluidity is poor, so it is difficult to fill the cavity of the press.
Road No. 13: Powder into the press storage bin
The powder is conveyed by the conveyor belt into the press hopper, ready for pressing bricks.
Track 14: Brick machine press molding
The powder in the hopper of the press passes through the fabric grille and is pressed by the press. The pressing process is divided into three steps:
One: light pressure exhaust; the second step: pressure and then exhaust; the third step: the pressure to the end.
To suppress the blanks that meet the density requirements, the entire process must be very fine. First of all, the filler should be uniform; Secondly, the pressing time and speed should be very accurate and controlled by the computer; then the demoulding should be very accurate, otherwise it will be prone to cracking. Different press tonnages suppress different sizes of products, which determine the thickness, size, density, hardness, and other parameters of the blank.
The tonnage of the press directly determines the density and hardness of the tiles.
Track 15: Brick Drying
After the machine presses the molded brick, it contains a certain amount of moisture. Even a very small amount of moisture affects the strength of the brick. Therefore, the brick is sent to the drying kiln for drying. After drying the bricks, the moisture content dropped from 7 percent to around 0.5 percent.
The length of the drying kiln determines the degree of moisture drying of the tiles. The long 320-meter roller drying kiln can not only make the moisture content of the brick less than 0.5%, but also won't be deformed by firing.
Road 16: brick cooling (surface cleaning)
After drying, the bricks are cooled and the surface cleaned before they can enter the next process.
Route 17: Brick Water Spray
The brick needs to be sprayed before the glaze is applied, and its role is:
(1) Reduce the billet temperature to the required temperature for glazing and open the capillary holes on the billet;
(2) Strengthen the bonding of the billet and glaze, and reduce production defects such as shrinkage glaze.
Route 18: Underglaze
The glaze is used to drive the glaze into a high level tank above the glaze of the bell jar. Through the buffering action of the glaze trough and the screen mesh, the glaze is covered by a smooth bell cover and evenly covered by a quiet waterfall. The surface of the blank. The amount of glazing can be adjusted by the amount of glaze and the speed of the conveyor belt. After the glaze is poured, the surface of the brick is smooth, which lays a good foundation for the next highly sophisticated printing process.
Track 19: Surface decoration
The surface decoration process is usually called the printing process. The surface color, pattern and pattern of the product are all very rich and vivid. At present, there are mainly three types of printing technologies: screen printing, rubber roller printing, and ink jet printing. Different printing technologies exhibit different surface effects.
(1) Screen Printing:
Screen printing is to transfer pre-made printing glaze onto the glazed blank through the capillary mesh of the wire mesh. The pattern on the printing screen determines the pattern of the ceramic tile.
(2) Cots printing:
The rubber roller printing is to engrave the pre-designed pattern on the circular rubber roller with the method of laser drilling. The large rubber roller rolls the sheet of the glazed blank from below through the accurate rotation and the rotation speed. It is transferred to the surface of the glazed blank, because each time the brick passes under the rubber roller, the position is slightly different, so the product pattern printed by the rubber roller is slightly different, so that the produced product is more natural The effect is.
(3) Inkjet printing:
Inkjet printing technology is the use of high-performance inkjet printers, the computer preset pattern directly printed on the surface of the glaze. Since inkjet technology is jet printing, its pattern can be three-dimensional concave and convex, so that the tiles feel real, patterns come alive.
The world-famous Italian Sistem ink-jet printer produces beautiful and colorful patterns in full-glazed products.
Track 20: Glazing
Full-glazed glaze has a transparent surface glaze on the surface to give the full glazed product a crystal-like brilliance.
Road 21: firing
The surface-glazed brick blanks are sent to the roller kiln for firing. The main fuel for the roller kiln can be diesel, natural gas or furnace gas. The firing temperature can reach 1200°C or more. The kiln can be divided into three zones from the entire temperature change: pre-tropical, burned zone, cooling zone. The firing time and temperature of each zone are strictly controlled by the computer. The bricks that have undergone high temperature firing have undergone a qualitative change, and at this time they have become truly ceramic tiles.
Brand manufacturers use ultra-long, wide-body energy-saving roller kiln, tile firing time is longer than the average manufacturer, to ensure that the brick body is completely porcelain, as dense as a porcelain bowl, high hardness, wear-resistant!
Track 22: brick cooling
After the firing is completed, the tiles coming out of the roller kiln are very hot and need to be cooled before they can enter the next process.
Track 23: Edge Length
The cooled tile enters the edging process and normalizes the dimensions of each side. The edging process was performed by two sets of machines. After each parallel edge edging was completed, the tiles were turned 90° to perform another parallel side job.
Track 24: Elastic Polishing
After finishing the edging and cutting, the tiles enter the rough polisher on the conveyor line, grinding the brick surface smooth, and then throwing in the middle, throwing from the rough to the middle, you can throw away the thickness of the brick 0.1-0.2mm, from the machine The bricks are a bit like a matt brick. The function of the polishing machine is more like a polishing machine. The bricks go through a polishing machine and the surface is smooth like a mirror. The gloss can reach about 60°. The working principle of polishing is to grind and polish the ceramic tile by rotating the head with different numbers of meshes. Generally, the mesh number of the grinding head starts from 24 mesh to 1500 mesh or even higher.
Road 25: Super clean and bright antifouling
In order to improve the anti-fouling ability, a layer of nano-antifouling agent should be evenly coated on the surface of the tile, which is commonly referred to as ultra-clean and bright. The antifouling agent can prevent the cement slurry from infiltrating the tile surface during the construction process, and it can also prevent the pollution caused by ink, tea and the like in daily life. Ultra-clean and antifouling can also increase the gloss of tiles (up to 90°).
Road 26: Dry
In the polishing, ultra-clean, and anti-fouling process, a large amount of water is used to flush the tiles, so after the completion of the process, the brick body has a lot of moisture attached, and the tiles need to be dried before the next treatment process can be performed.
Track 27: Inspection Grading
The dried tiles were graded by inspection. Quality inspectors first test the product's degree of deformation and edge straightness, classify the tiles by different color numbers, and classify them according to the surface quality.
Brand manufacturers adopt a much stricter corporate standard than national standards. Quality inspectors are trained. The product classification process is very strict and cautious. Each brick is subject to stringent quality inspections to ensure product flatness, dimensional deviation, and color difference. The indicators meet the internal control indicators of the national standard to ensure the high quality of the products.
Road 28: waxing, filming
Before waxing, clean all the stains on the tiles thoroughly. Then use a waxing machine to evenly spread the liquid wax on the tile surface. After the tile surface has dried, apply a layer of film on the tile surface. Waxing the tiles can decontaminate the glazing, increase the appearance, prevent insects, moisture, and cracks, reduce the external corrosion and wear on the tiles, and prolong the service life of the tiles. Apply a film to the tile surface to protect the tiles from being scratched.
Track 29: Packaging, storage
After grading, the product can enter the automatic packaging process. According to different products and sizes, there are different number of packaged products. The number of large and heavy ceramic tile pieces is small, and the number of small and fine ceramic tile pieces is more, mainly for inventory, It is convenient to transport and purchase the whole box. The packaged tiles can be placed in stock and stored in strict accordance with the product category, model, grade, and color number. Quality inspectors also need to conduct regular random inspections on the products to be put in storage, so as to ensure a good quality of the products before they leave the factory.
