Company Profile
M. D Message
Vision / Mission
Core Values
Factory Visit
Laying Instruction
Management
Technology
Production Process
 
About Us >> Production Process

 

1.       Vitrified

   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

  granules).

 

  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.

 

 

6.      Drying

  The pressed tile is sent to the Horizontal Dryer, which is heated up to 2500C to remove the moisture of the pressed

   tile.

 

 

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.

 

 

9.  Polishing

 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

      tools.

 

 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

     for polishing.

 

 

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

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.

 

 

© copyright 2010, Cengres Tiles