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The production process commences with raw materials feldspar
and dolomite being ground with silica sand and ball clay to
create a liquid known as body slip. This liquid is spray dried
and converted to form the base body powder. To develop colored
body powder, dolomite and feldspar are ground with different
colored stains. This powder is stored separately in silos.
The powder is then retrieved in required quantities and in
required compositions and pressed at a pressure of 400 kg/cm2,
to create green tiles or pre-fired tiles. The green tiles
are then dried in driers for half an hour before being processed
further. The tiles are then sent to the glazing line where
the printing process is undertaken. The tiles undergo up to
fifteen applications including 4-colour printing on each line.
The tiles are then sent to the kiln for firing and are passed
through a roller kiln at a temperature of approximately 1210
degrees Centigrade. In the kilns the tiles are transformed
into finished products conforming to the CEN 177 BIIa International
Standard for Ceramic products and CEN 176 B I International
Standards for Porcelain products.
Each tile is then inspected for surface quality, flatness
and rectangularity using advanced optical sensors and devices.
The tiles are next packed and palletized using automated packing
and robotic palletizing machines and are dispatched to showrooms
or are exported to international clients.
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