Vitrified is a product with very high technical characteristics i.e. with high breaking strength, very low water
absorption, very high abrasion, & frost resistance. Its universal classification is under group B 1 a.
2. Storage of Raw Materials
The bulk quantities of body raw materials (Silica, Clay, Kaolin & Feldspar) are kept in bins and stockyard built
with concrete walls to prevent contamination.
3. Batching of Raw Materials
High quality raw materials, such as Clay, Kaolin, Feldspars, and Silica are fed into the weighing Hoppers. These
batched raw materials are loaded into the large ball-mill with alumine pebbles and comes out from the ball-mill in
powder form , as per the set parameters for our production.
The slip from the Ball-mill is sieve through vibrating sieve and then through magnetic separators to remove all the
iron particles and then slip is collected in the Blunger. From the Blunger, the slip is pumped into the service tank,
for spraying and to make the powder in the form of granules and collected into the storage silos (Basic Body
The spray-dried powder must have the moisture content as per the parameters set by our production department and
these granules are checked using granulometric apparatus.
4. Dry Color Preparation
Dry color is added to the basic body according to the composition and directly fed into the press hopper to produce
multi colored tiles and uncolored tiles. Dry color is the latest technology of mixing the color to the basic body to
avoid shade variation and give better / perfect shade.
5. Press Operation
SACMI PH 5000L is used for pressing the tiles of size 60 X 60 CM & 100 X 100 CM. Moulds like metallic,
structured or rubber are used for production and depend upon the type of Models, the Moulds are used.
The pressed tile is sent to the Horizontal Dryer, which is heated up to 2500C to remove the moisture of the pressed
7. Glaze Line Operation
Dry tile will pass through the glazing line with different types of application i.e.
1. Glazing, 2. Soluble Salt etc.
Tiles after glazing are loaded into conveyor belt and tiles are transported to kiln.
8. Clean Operation
Tiles loading into the clean and firing at the temp of 1200 to 1230 0C. Fired Tiles coming out from the kiln are
segregated and sent for polishing or to packing section if sold as unpolished tile.
We pass the tiles thru’ soaking zone for 10-12 min, with constant peak temperature to get better quality.
A. Surface Gauging: In this phase the diamond rollers eliminate all the roughness (micro grooves and
ridges along the sides) to give a flat surface and a finish suitable for subsequent semi polishing phase.
B. Semi Polishing: It is the first stage of polish. In this phase the surface roughness is progressively
reduced by a series of abrasive tools with graded grit size.
C. Polishing: In second phase the tiles will be smooth and more glossy by the help of fine graded abrasive
D. Squaring and Chamfering: Squaring and Chamfering is carried out with the advancing tiles held tightly
between the two belts or pair of belts that run perfect flat beds. While the tiles are fed, the tiles are first
gauged on two sides by special diamond wheels with a high sizing / removal capacity.
E. The Chamfering phase is carried out by the same machine unit by spindles tilted to 450C which cut
directly with diamond tools.
F. Drying: The tiles are dried by passing through a drier to remove the wetness on tiles as water was used
10. Sorting and Packing
From the Kiln or from the polishing lines, the tiles go to sorting & packing line for inspection and classification
according to grades. The passing tiles are inspected by team of well trained sorters to check surface defects. The
tiles are the packed according to grades and caliber according to International Standards. Operators doing the
visual inspection are changed every hour for better quality check and sorting.
11. Ware Housing
After packing the finished products are arranged on palletized. The palletized boxes are then transported to the
ware house area awaiting for delivery.
LATEST MANUFACTURING TECHNOLOGY FOR MAKING CENGRES / CENGOLD VITRIFIED
TILES AND LABS
Vitrified Tiles are generally made by the dust-pressed method of a composition resulting in a title that is dense, impervious, hard, strong, and frost resistant. They are fully vitrified tiles, having water absorption less than or equal to 0.05% and are classified under group B-1a of the International Standard for Ceramic Tiles ISO13006/EN 176
CENgres / CENgold VITRIFIED TILES
CENgres / CENgold vitrified tiles are fired at 1200- 1230 0C and exhibit remarkable technical characteristics such as very low water absorption, high breaking, strength, high resistance to deep abrasion, thermal shock resistant, frost resistant and resistant to chemical agents. These notable features make the CENgres / CENgold, vitrified tiles, the perfect choice for any internal and external applications.
1. THE SALT & PEPPER DESIGN (Vitrified)
These design are full body tiles produced with utilization of a dosing system. Various types of color
pigments in liquid form are mixed with the slip body in certain proportions by dosing systems while
simultaneously being fed into the spray drier. The dried clay granules (moisture of color pigments and clay
body) is fed to the Hydraulic Press and pressed according to the required size. The clay tiles are then dried
in the Horizontal Drier and subsequently fired in the Roller kiln. The mixture of color pigments creates the
salt and pepper effects on the body of the tiles. These design are made available as per minimum single
order quantity 8000 m2- (made to order) in both Unpolished and Polished finishes
2. THE SOLUBLE SALT DESIGN (Vitrified)
Soluble Salt Printing Technology is employed to produce these design. Silk screens are used as the source of
the designs to be printed on the surface of the clay tiles. Using the printing paste made of alkali or coloring
salts, the designs are printed on the proper surface. Soluble salt solution is applied over the printed surface to
aid the penetration of the print into the tile body by 2.8mm to 3.2mm deep. After the drying stage, the tiles
are fired and subsequently polished to obtain the natural marble effect. These products are available in
polished finish only.
3. THE FULL MASS PRODUCTS (MDR – Vitrified)
These design are characterized by the natural design of marble veins and shades. To achieve this aesthetic
design, a sophisticated technology called MDR (Rotary Diaphragm Mixer) was adapted. The tiles are
manufactured with the use of various multi-colored powders differing in their morphology. The basic
powder and colored ones flow through the various pipes while coming from the hoppers on the service
platform over the press. The rotary diaphragm mixer (MDR) simultaneously mixed the different powders
and feeds the feeding hoppers with a series of colored spots inside the basic powder. After pressing, the tiles
are fired and after subsequent polishing, the finished products resemble natural stones and marbles, having
naturally cleared veins or shaded effects. These models are available in both Unpolished and Polished
finishes.-(currently out of production).
4. THE DOUBLE – CHARGED DESIGN (Vitrified)
These tiles are produced by a sophisticated technology known as “Double Charged”. Multi-colored powders
are used to obtain the typical appearance of a natural marble or granite. The double charging process is
rendered by super imposing a layer of micronized powders, which after pressing, firing and eventual
polishing, an aesthetic effect of a natural marble or granite is evolved to a layer of the basic tile body. These
models are available in both unpolished and polished finishes.
5. THE RUSTIC VITRIFIED TILES
Rustic models are usually made from the basic body granules, pressed with structured punches, and enriched
with a suitable quantity of glaze and other application materials. To get the natural and elegant look of
genuine stone, various types of printing and surface applications are employed, then intermittently sprayed
and brushed on the surface thus enriching the natural effect. International shade or color variation, which is
in integral element of the design, is likely to be observed. Beside the familiar glazed surface and unpolished
finish, these products are also available in Lapatto and Marbo finish.
6. THE EASY OXIDE MIXING or DRY OXIDE MIXING (Vitrified)
This is the latest technology for the production of Vitrified tiles with high aesthetic levels and obtains
multiple color combination. This process involves the production of colored powders by means of mixing
dry coloring oxides to the base body granules to get uniform colored granules.