Ceramic and Porcelain Tile Manufacturing

How Porcelain Tile is Made

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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.

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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.

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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.

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Curing Begins

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.

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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.

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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.