ORDERING OF RAW MATERIALS
Every production starts with ordering raw materials. For Double Charge Vitrified Tiles, Various types of clays like China Clay and many minerals like Potash and Silica and many others are ordered according to their over all usage and reserve stock considering.
QUALITY TESTING OF RAW MATERIAL
Every material we receive has to go through quality testing. For each material we have predefined parameters. if received material does not match with our criteria, we reject material send it back to supplier immediately. This step ensures quality of input. Quality materials always produces great Double Charge Vitrified Tiles if the process parameters are set, maintained and checked time to time on regular basis. And our production department is not only well equipped but also well maintained as well in terms of temperature of kiln, dryer and spray-dryer, cyclical speed of kiln and polishing and many other criteria falls under our Quality-Checking department. And it works proactively.
Each material may have the quality but may not have in proper sizes of their particles. So we Grind most of the materials (Some we do not grind because they are already arrive grinded from supplier). Once average size of particle in material reaches to desired size, they are brought by conveyer or pipe to their respective storage tanks.
ELEMENTARY BODY SLURRY
Body making is fundamental process of any vitrified tiles but for Double Charge Vitrified Tiles it is all there is. Because all the other process are just refinements to Body slurry making. There are 3 different Elementary Bodies: Base Body, Top Body and Super White. They each has several different compositions according to designs to be produced. Once they are prepared in Ball Mills (generally in the batch of 40 Ton) they are kept stored in their respective storages. Each batch with different composition are kept in different storage tanks
SECONDARY COLOR BODY SLURRY
Once Elementary Bodies are ready, there are set of Secondary Colour Bodies to be produced in this stage. There are 15 to 50 different Secondary Colour Bodies in stock and production in our factory at a time. This depends upon a how many designs in various shades are there in production. Each of them will be named according to pigments used in it but every time it is not the case. Actual composition is like Elementary Body + Pigment1 + Pigment2 =
Secondary Colour Body Slurry. Once produced they are stored in their respective storage thanks
QUALITY CHECK OF SLURRY
Before storing slurry of either Elementary Body Slurry or Secondary Colour Body Slurry, we conducts several quality tests on them:
- Particle Size
- Residue Test
If all the test met with the standards then Slurry is bought to it storage tanks, if not adjust is made and repeat the process. For example if particle size is bigger than our standard, we still stir heavily with Ball Mill Machine for more 1 or 2 hours. And after that time we test again and stir heavily with Ball Mill Machine for more 1 or 2 hours. And after that time we test again and if results are still not as per standards, we repeat the process. This is our Quality maintenance by process standardization. This will result into consistent quality over period of time.
Before slurry is stored, it is passed through Iron-Remover. Lesser the Iron better would be body of Double Charge Vitrified Tiles.
POWDERING OF SLURRY
Slurry cannot be used directly to make biscuit of tiles. Slurry is converted to Powder. To make powder out of slurry, slurry is transferred to Spray-Dryer where funder fire moisture is evaporated and slurry becomes powder.
STIRRING & SIEVE
Initially powder may have many lumps which is very bad for making raw biscuit so powder goes through process of Mechanical Stirring which breaks down most of lumps. A Mechanical Sieve is attached to Stirrer machine. Which separates remaining lumps. Lumps will be thrown away.
Design is a part of Body itself unlike other types of Vitrified Tiles. So entire upper body is supplied with 2 or 3 or in some cases around 5 Secondary Colour Body Powder and Elementary Body Powder into Feeder. Feeder then makes design pattern our of it. Then all the arrangement is sent to Press.
Bottom Body is generally made with Elementary Body made out of material we prepared in step 4.
Press mechanism works two times to make single raw biscuit. First for Upper layer of Tile which had design made out of Powder of Secondary Body Slurry. And then mechanism pulls material to feeder where it make another layer of Base Body with Elementary Body. Then Entire material comes back to Press. Where it presses it with very high pressure and Raw Biscuit has taken its shape.
Raw Biscuits are directly sent to Oven by conveyer. So that it harden it little bit which helps Biscuit to stay in one piece during journey up to kiln. The Time it takes under oven is around 2-3 minutes. This depends on length of conveyer from Press to Kiln.
This is very crucial process above all. Biscuit goes in Kiln where temperature reached from 1500 Celsius to 2000 Celsius degrees. Technically this process is called Vitrification and that is why Tiles is “Double Charge Vitrified Tiles“. Once Biscuits come out of Kiln it is now more Raw. It is hardened and now it is called Backed Biscuits.
Now Backed Biscuit is very hot, and cannot be used in machines for further process. Otherwise it will damage machineries. So 10-12 hours they are kept on floor for letting it cool.
Next Process is what it gives beautiful look as you know it: polishing. There are 1 to 3 different machines and can be further classified but for the sake of simplicity we put them under machines and can be further classified but for the sake of simplicity we put them under Polishing. First it starts with calibrating surface, then polishing heavily with Polishing Abrasive Material so that it gates sinning surface.
Backed Biscuit size is little bigger that what is ought to be. And it is by intentional. Now at this stage we make it exact 600X600 MM by Rectifying machine . Some call it Dimond Cutting, some call it Sizing or even some people call it Laser Cutting.
To gear-up quality of Surface, we put Nano polishing where Machine spreads Nano material over surface and machine make it part of surface by creating thin layer over tile. Which fill the all the pin holes and make surface even smooth and shinier.
We check quality to every essential and precautional step in production process but 100% material never be of 1st quality ever. We sort tiles in to 4 Grades. Namely:
All the Double Charge Vitrified Tiles are packed into their respective boxes. If boxes can be different than our brands if customer has asked we have approved it. There are generally 4 pieces of Tiles are put in a box but for further details check of packing details section.
All the necessary labels are applied to box. Which includes manufacturer name, brand name, MRP, instruction to apply tiles and various other information which helps consumer to take informed decision
Finally every thig is done. Now boxes are sent to storage.