How Porcelain Tile is Made
The Magic Begins
Water and raw materials mix together until a sand-like consistency is reached. Recipes vary slightly however feldspar, clay, silica sand and other materials are included in the mixture.
Getting the Perfect Consistency
In this next step, a spray dryer removes the excess moisture from the mixture until the perfect consistency is reached before the mixture is moved into a press.
Creating the Tile
Now, the porcelain mixture is pressed to form the tile. Each size and shape of available porcelain tiles use a special punch to create the body of the tile, called Greenware.
Greenware is the term used for tiles that have not been glazed or fired. Prior to that step, the raw materials are placed in a dryer to remove moisture, readying the tiles for the next step.
Printing & Glazing
After the tiles have dried, the next step is to add the pattern and colors using a state-of-the-art inkjet printer. After the pattern is applied, the glaze is applied to protect the tiles.
Into the Kiln
The tiles are then fired in a Tunnel Kiln or Roller-Hearth Kiln at 2300℉ and 2455℉ for longer periods of time to remove all the moisture in the tiles. Most factories have a minimum of 2 Roller-Hearth Kilns operating at the same time 24hrs a day, 7 days a week.