Fully glazed ceramic tiles, the product texture is delicate, crystal clear, colorful, rich in layers, realistic and natural texture, reproducing the elegant texture of natural precious marble;

Taking into account the performance of ultra-low water absorption, super wear resistance, anti-pollution and easy cleaning, long-term innovation, convenient maintenance, environmental protection and health, etc., it gives the space atmosphere and noble feeling, which is favored by the majority of consumers.

Ceramic machinery manufacturers popularize the production process of fully glazed ceramic tile products for everyone, let's have an in-depth understanding.

1. Raw material mining and storage:

Ceramic raw materials come from mines, soil, are natural raw materials, can be directly excavated in mines: plastic raw materials: black mud, white mud, etc., determine the basic life of tiles;

Ridge raw materials: quartz, etc., determine the various properties of tiles; Solvent raw materials: feldspar, etc., determine the vitality and toughness of ceramic tiles.

Second, raw materials entering the factory testing:

Ceramic tile production has strict requirements for the chemical composition and mineral composition of raw materials, so a series of strict analysis and inspection must be carried out before a large number of raw materials enter the yard of the factory.

Step 1: Use professional chemical analysis instruments to analyze the 7 major components, plasticity indexes, whiteness indicators, etc. of raw materials;

Step 2: Use professional rapid grinding to beat the slurry and test its fluidity and thixotropy;

Step 3: Detect the fineness of the ball grinding with a laser particle size analyzer;

Step 4: According to the production process, press the sample cake with a hydraulic press;

Step 5, put into the electric furnace to fire, test its sintering degree, shrinkage index, etc., to judge the amount of black spots, blisters, cracking, black core and other oxides that affect the appearance of the finished tile.

Raw materials that pass the test can enter the factory, but these raw materials directly extracted by nature are unstable due to factors such as climate, weather, formation time, hierarchy, etc., so they must be homogenized.

3. Raw material reserves (homogenization, staleness):

Homogenization is a process in which raw materials in different periods of the same mine are evenly stirred by mechanical movement;

Staleness refers to the mixing of mud left for a period of time to fully react between the mud and make the moisture more uniform.

Only raw materials that have been homogenized and aged can be produced and processed, and the stability of mass production can be guaranteed.

Mining homogenization, homogenization into the plant, and homogenization after processing (mud) are indispensable in three steps.

Multiple excavators and mining machines fully homogenize thousands of tons of raw materials, and the homogenized raw materials can enter the semi-closed raw material silo.

IV. Ingredients:

The technician has a list of ingredients, and the mature ingredient formula list generally has to be tested repeatedly in the laboratory, and the production line is tested on the board before entering large-scale production.

After the batcher gets the list of ingredients issued by the technician, the batching begins, and the various raw materials are added to the feeder through a large forklift and then enter the ball mill through the conveyor belt.

V. Principles of formula determination:

(1) The composition of the blank and glaze should meet the physical, chemical properties and use requirements of the product;

(2) The production process and equipment conditions should be considered when formulating;

(3) Understand the influence of various raw materials on the properties of products;

(4) When formulating the formula, economic rationality and whether the resources are abundant and the source are stable should be considered.

6. Ball mill:

Ball mill is a large crushing and grinding equipment with flint ball lining in the outer iron, generally a ball mill can be added at a time: 40 tons of mud, 40 tons of ball stone and 50 tons of water.

When the ball mill is working, the mud is ground by turning the ball stone. Ball mill workers also add various additives to the ball mill according to the formula list.

The ball milling process requires a laser particle size analyzer to continuously detect the fineness of the slurry, and only after reaching the standard can the ball come out, and the original "raw material + water" becomes a slurry containing about 30% water.

7. Slurry detection:

The slurry after ball milling can enter the next production process after passing the test, and the slurry performance requirements are:

(1) Good fluidity and suspension for transportation and storage;

(2) The moisture content should be appropriate to ensure high powder yield and low energy consumption in the milling process;

(3) Suitable fineness to ensure the stability of product size shrinkage, firing temperature and performance;

(4) Slurry dripping slurry, look at the color of the green body.

8. Put the pulp into the pool (remove iron):

The slurry that passes the test enters the slurry pool for backup, and an iron removal device is set at the entrance of the pulp pool to remove iron from the slurry.

9. Slurry sieving and iron removal:

(1) The slurry enters the screening system, separates the coarse particles that do not meet the requirements and returns to the ball mill until it is qualified;

(2) After the slurry is removed from iron, the impurities such as iron and titanium that endanger the quality of the product in the raw material are basically removed.

10. Slurry reserves (homogenization and staleness):

After sifting the iron removed, the slurry enters the slurry pool for storage and homogenizes the stale age.

11. Spray granulation:

The slurry flows into the spray drying tower for drying and dewatering, and the principle of this process is to use the pressure of the plunger pump to spray the slurry into a space about 10 meters high.

Sprayed into a mist, dried and dehydrated under the action of hot air, the slurry becomes powder particles with a diameter of 0.5mm-2mm.

12. Powder detection (particle size, moisture):

The powder formed by spray drying needs to be tested and qualified before entering the next process.

XIII. Powder testing items:

(1) Powder particle gradation detection, particle grading is the particle size distribution, which refers to the proportion of particles of various particle sizes in the powder;

(2) Powder moisture detection, generally tile powder moisture control at 6%-7%, this particle has very good fluidity.

14. Iron removal by sieving powder:

The powder is screened to remove iron to prevent particles that do not meet the particle size requirements from entering the next process, and iron impurities in the powder are further removed to ensure the quality of the product.

15. Powder feeding storage and preparation (homogenization and aging):

The spray-dried powder has a certain temperature and the moisture is not uniform, so the powder generally needs to be homogenized and aged for 48 hours before use.

(1) The stale time is too short, and the product with uneven moisture content is easy to produce interlayer;

(2) The stale time is too long, the strength is poor, the fluidity is poor, and it is not easy to fill the mold cavity of the press.

16. Computer ingredients:

Qualified powders will be sent to the "batching system", and computerized automatic batching is carried out according to the actual product category according to the formula.

Ceramic machinery manufacturers

17. Powder into the press storage silo:

The powder is transported by the conveyor belt into the press hopper to prepare for pressing the bricks.

18. Brick machine press forming:

The powder in the press hopper is clothed through the cloth grid, and the pressing brick machine is pressed and formed, and the pressing process is divided into three steps:

Step 1: Gently pressure exhaust; Step 2: Pressurize and exhaust; Step three, add stress to the extreme. Pressing to the green body that meets the density requirements, the whole process is very fine.

The filler should be uniform; Secondly, the pressing time and speed should be very accurate and controlled by computer; Then the demolding should also be very accurate, otherwise it is easy to crack.

Different press tonnage presses products of different sizes, which determines the thickness, size, density, hardness and other different parameters of the green body. The tonnage of the press directly determines the density and hardness of the tiles.

19. Brick drying:

The machine-formed brick contains a certain amount of moisture, even the smallest moisture will affect the strength of the brick, so the brick is then sent to the drying kiln for drying.

After drying the bricks, the moisture content was reduced from 7% to about 0.5%.

20. Brick cooling (surface cleaning):

The dried bricks are cooled and the surface is cleaned before proceeding to the next process.