INTRODUCTION

• Ceramic tiles today have become an integral part of home improvement. It is considered as a lifestyle product, which keeps on evolving as per the latest fashion trends.
• No doubt, well planned and designed ceramic tile solutions can make a huge difference to the way your interiors and outdoors look and express.


RAW MATERIAL OF SILP HOUSE

1) QUARTZ
2) CLAYS
3) FELDSPAR
4) TALC POWDER
5) BISCUIT POWDER
6) LIME STONE
7) DOLOMITE POWDER
8) SODIUM SILICATE
9) SMS (SODIUM META SILICATE)
10) STPP (SODIUM TRY POLI PHOSPHATE)

1. BALL CLAY

a. Chemical composition of ball clay is Al₂O₃ 2SiO₂ 2H₂O
b. These are secondary type of clay. They impart high strength and good workability to white ware bodies. The primary mineral phase present in the clay is kaolinite.
c. Ball clay have fine particles high plasticity and drying shrinkage, high green strength and contain large amount of impurity which make body burning, low maturing and less translucent of firing.
d.In normal practice ball clay are used in the range of 10% to 40% in various white ware composition.
e. Ball clay contain less iron impurity but they contain higher proportion of alkalies.

2. QUARTZ

a. This is a crystaline form of silica containing more than 99.75% SiO₂.
b. It is widely used because it is hard chemically stable and relatively in-fusible.
c. It does not fuse below 1725˙c and on repeated heating at high temp. It expands slowly up to about 14%.
d. Quartz mainly used as filler material which during fired at high temp. They convert into viscous liquid.

PROPERTY
i. It is non plastic material.
ii. It melts at high temp. About 1750˙c.
iii. At high temp. It decrease the viscosity.

3. FELDSPAR a. Potash feldspar :- K₂O Al₂O₃ 6sio₂
b. This name is given to a group of minerals containing alumina, si₁₀ and abase usually potash soda or lime.
c. The major materials of commercial interest are potash feldspar, soda feldspar and lime feldspar.
i. POTASH FELDSPAR - K₂O Al₂O₃ 6sio₂
ii. SODA FELDSPAR - Na₂O Al₂O₃ 6sio₂
iii.LIME FELDSPAR - cao Al₂O₃ 6sio₂

d. The feldspar act as fluxing material
e. In industries two type of feldspar is used
I. Potash feldspar (for body)
II. Soda feldspar (for glaze)
→ Potash feldspar is generally preferred in the body because of its long firing range.
→ Soda feldspar is preferred in glaze because of its reduces the melting temp. And viscosity of the melt.

4. TALC (3Mgo 4SiO₂ H₂AO)

a.Talc is naturally occurring magnesium silicate has wide use in ceramic industry. For small addition in art ware, sanitary ware for it's effect on physical properties like lowering the maturing temp. And moisture expansion.

5. LIME STONE

a.It is softer variety of calcium carbonate on heating, it is converted into CaO which is particularly infusible but when mixed with quartz or china clay in stable proportion. It forms into a glassy liquid.
b. Pure lime stone can be made up completely of calcite but if other material is being laid down as well such as sand, then the lime stone will be impure.

6. DOLOMITE

a. Chemical formula of the dolomite is CaMg(Co₃)₂
I. Colour is pink or pinkish and can be colourless, white, yellow, grey or even brown or black when iron is present in crystal.
II.   Luster is pearly to vitreous to dull.
III.   Transparency crystal is transparent to translucent.
IV.   Hardness - 3.5 -4
V.   Sp. Gr -2.86

7.  SODIUM SILICATE (Na₂SiO₄)

a. Ti is used as deflocculant agent in slip. It keeps the non-plastic to suspend in slip.

8. BALL MILL

1. Ball mill is a cylindrical horizontal construction made up of mild steel.
2. These mills consists of an iron shell or hollow cylinder lined inside with alumina bricks lining about 2 inches.
3. The purpose of lining is to keep the material out of contact with iron casing.
4. Charging the all materials into ball mill as per composition by weighting hopper car.
5. Then all raw material grinded about 2:30 hours.
6. After grinding they should be check the property of the slurry.
I. Density = 1680 to 1720 gms.
II. Viscosity = 40 to 60 sec. Form 100ml standard ford cup.
III. Residue (%) = 4.5 to 7.5


9. VIBRATIVE MACHINE

a. The main purpose of these vibrative machines are for particle size distribution as per requirement.
b. In these machine different types of sieves used for particle size distribution.
c. After sieving the magnetic channel for removing iron impurities.

10. SPRAY DRYER

1. This is a device in which slip is converted into granule dust particles.
2. The slip is from the feeding tank enters into the spray dryer through the piston pump.
3. The slip is forcely enter in the chamber through the grms and sprayed through the nozzles. The hot air also enters from upper side of the dryer.
4. The slip absorbs the heat from the hot air reduce some percentage of water is evaporated.
5. According to our requirement the size and no. Of nozzle can be charged then powder is collected form the bottom of the chamber out let collected on the conveyer belt.
6. To remove course particles a vibrating sieve 10# is arranged below the powder enter into bucket elevator and finally into the silos where the powder is stored.
7. This powder contain 5 to 5.6% of moisture form cy. cloner.
8. Fine dust falls on the conveyer belt through the blower and enter into the scrubber tank and some of the dust is exhausted out.

11. DERFECT

a. LAMINATION (WIND BLOWN)

• Lake of moisture irregular pressing and high moisture.
o REMEDIES
• Maintained uniform pressure
• Giving equal load applying on the tiles
• Uniform particle size.
b. BODY DIRT

• Body dirt is after firing the inorganic materials comes out in the surface of the body.

12.PRESS DEPARTMENT

Generally press is used for pressing and shaping of tiles.

PUNCH TYPE

1.TOP PUNCH :-
(a) SIMPLE PUNCH
(b) ISOSTATIC PUNCH
2.BOTTOM PUNCH :-
(a) PLANE PUNCH
(b) RASTIC PUNCH.

SPECIFIC PRESSURE FORMULA (TILES CAVITY AREA (Cm²))/(CULINDER AREA (Cm²))SP.PRESSING=PRESSING BAR PUNCH TYPE TOP PUNCH :-(1) SIMPLE PUNCH (2) ISOSTATIC PUNCH (2) BOTTOM PUNCH :- (1) PLANE PUNCH :- (2) RASTIC PUNCH. SPECIFIC PRESSURE FORMULA (TILES CAVITY AREA (Cm^2))/(CULINDER AREA (Cm^2))×SP.PRESSING = PRESSING BAR