Manufacturing of ceramic tiles and their features. Production of ceramic tiles: technology, types of equipment, prospects

For the manufacture of tile the following equipment is required in a factory:

Concrete mixer: intended for mixing cement and other ingredients.
Vibrating machine: designed for compacting concrete mix.
Forms: designed to form tiles.
Special camera: designed for spraying patterns and glaze.
Bake: designed for drying formed products.

The listed equipment will be enough for the manufacture of ordinary or standard tiles. But, if the manufacturer decides to produce more unique products, then he will need some other devices. This could be:

Multifunctional camera for spraying, which costs a lot of money.
Professional stencils set, with the help of which the drawings will be applied.

Price for production equipment (manufacturing) ceramic tiles rather big. But the payback is good.

The video below discusses special equipment for the production of tiles:

Calculation of raw materials

For the manufacture of tiles, the following materials will be required, each of which plays a specific role in the raw material:

(responsible for maintaining the size after the drying procedure).
(responsible for the elasticity of the mixture).
Feldspar composition (responsible for viscosity).
Carbonate composition (responsible for viscosity).
Various additives.

Refractory or refractory clay is required for the production of tiles. The last option is most suitable for the amount of impurities.

To bring the clay to the required state, various additives are used. They are of the following types:

Glaze (creates a protective layer and gives the product a beautiful aesthetic appearance).
Lean additives (they reduce clay shrinkage and make plasticity several times less).
Fusions (reduce the melting point of clay).
Plasticizing (make the clay more plastic).
Engob (used for decorative processing of the product).
Steam generating (make the structure of the product more porous).

Manufacturing technology

The production of tiles differs little from the manufacture of ceramic products. It has remained unchanged for many years.

Factory methods

Tile in factories goes through the following stages:

Preparation of the mixture.
Formation of products.
Drying in chambers.
Glaze tiles.
Firing in a kiln.
Sorting of products.

Mix preparation and product formation

At the preparation stage, the components are mixed to obtain the required homogeneity. First of all, the clay is crushed, then various additives are added to it to obtain the desired chemical.

Before the stage of formation, the clay must be moistened. How much the raw material will be wetted, and what additives will be included in it, depends on the indicators of the finished product.

Molding refers to the pressing of articles. For this, the prepared raw material is poured into molds and pressed under a pressure of 400 kg / cm 2. As a result of this process, a fairly strong and very dense product is obtained.

Drying and glazing of tiles

During the drying phase, unnecessary moisture is removed from the products. This stage is of particular importance. The fact is that moisture will evaporate during the firing process. The resulting steam severely destroys the integrity of the tile products.

If the drying stage is neglected, then a lot of rejected products can be obtained at the exit.

Glazing is necessary to give or light shade... The glaze is applied before the firing stage. The high temperature and subsequent cooling transform this coating into a specific glass.

This coating has protective functions. As a result, the tile not only gets an aesthetic appearance, but also protects the product from negative influences.

Firing and sorting of products

Another very serious stage is firing. High oven temperatures lead to the necessary chemical reactions, as a result of which physical changes occur in the tile. In the oven, the products move through the tunnel.

The oven temperature is different. It ranges from 900 to 1300 ºС. It is very important at this stage to gradually reduce the ambient temperature. With a non-smooth transition or with a sharp change, the product may deform.

At the stage of sorting, the products are checked. Here, the thickness, overall dimensions, the presence of cracks and the degree of rejection are evaluated. Only after that the tiles are packed and sent for sale.

The following video shows the production of tiles in the factory:

With your own hands

For self-made tile will need to go through the following steps:

Preparation of raw materials.
Raw material production.
Biscuit firing.
Subsequent decoration.

Preparation of raw material and production of raw material

On the first preparatory stage it is very important to choose the right type of clay. Here it is imperative to take into account its plasticity. Plastic raw materials allow you to form absolutely any shape.

The best option in this case is clay of medium fat content. If there is clay with a high fat content, then the value can be averaged, sand, pumice or chamotte can be added to the material. This method will avoid rupture during firing and will make the raw material less refractory.

After mixing the components, the resulting mass is wrapped in plastic bag. It is very important here to completely shut off the oxygen supply. The raw material must absorb the available moisture. Air locks in the tiles greatly reduce the quality characteristics. This method will significantly improve the quality of the clay.

For molding, use polyurethane molds or any other suitable for characteristics. When shaping, it is very important to distribute the clay well in shape and tamp it carefully. In this case, the thickness of the future product over the entire area of \u200b\u200bthe form should be the same.

The prepared raw is dried. Readiness is judged by the hardening and clarification of the tile.

It is important to remember that the raw material itself is very fragile.

Firing and subsequent decoration

Firing is also carried out under the influence of high temperatures. The result should be a glass-like product. At home, it will not be possible to achieve a temperature of 1300 ºС, 850 ºС will be enough. Biscuit roasting is called because the raw material shrinks. This must be taken into account when calculating the dimensions of the product.

At the stage of decoration, you can show your imagination. Various patterns will decorate any product. The most important thing here is to use frosting. It can be applied by brush or simply by spray. The method of pouring is often used. A glossy shine is achieved using varnish or enamel.

At the end of the decoration, the product is fired a second time. It is important here not to exceed the set temperature, otherwise the tiles may crack.

The video below shows the manual process making ceramic tiles:

Ceramic tile production as a business

The tile making business will always take place. By opening your own mini-production, it is quite easy to find buyers due to the fact that the tile will cost a little less than that of competitive manufacturers. Moreover, it will not be of low quality. It is these two factors that always come first among the consumer.

So, the purchase of equipment will require approximately 300,000 rubles. The purchase of the material will require about 350,000 rubles.

You will also have to pay for additional equipment:

Multifunctional spray chamber: approximately 90,000 rubles.
A set of professional stencils: 18,000 rubles for 200 pieces.

In addition, it will be necessary to rent the area where the equipment will be installed and the production process will be carried out. On average, this will require about 35,000 rubles. In the same figure, we will include considerable costs for electricity.

The process is not automated, so you can't do without workers. On wages we will allocate about 90,000 rubles for the maintenance personnel. This will require money for the very process of opening a business. This is about 45,000 rubles.

Let's divide the listed costs into two types:

Disposable, which will amount to 453,000 rubles.
Monthly, which will be approximately 475,000 rubles.

To determine the income, we will assume that the production volume is 5,000 m2 of tiles. Let the price per square be 210 rubles. Then the monthly profit will be equal to 1,050,000 rubles. Net income minus monthly costs will amount to 575,000 rubles. It will take a little more than a year to fully recoup the investment.

The amount of income from the production of tiles is very good, but all of them are so smooth. This business has its pitfalls.

First, the sales of tiles are highly seasonal. So, in winter it is bought very little, mainly people start thinking about construction and repair in spring and summer. It is at this time of the year that you can count on the full sale of the made tiles.
The second factor is fashion trends. You cannot release tiles in in full in the months when it is in little demand. After all time will pass and the tile will become unfashionable and not interesting. Buyers' demand for it will fall.

Getting certain types ceramic slabsok (in accordance with the technical characteristics) primarily depends on the production technology. Figure 1 shows the main stages of various technological cycles and lists the main types of ceramic tiles that they allow to obtain.

Fig. 1
Technological cycles for the production of various types of ceramic tiles

The secret of obtaining high-quality new material is a thoroughly worked out technological process of production, which is constantly being improved. It is based on high temperature firing, which varies depending on the type of material from 900 to 1200 ° C. A wide variety of natural raw materials are used for production. The body of the tile is prepared from a mixture of clay (to give plasticity), quartz sand (to harden the tile body) and feldspar (to soften). For the preparation of the glaze, sand, kaolin clays, pre-prepared glass chips, and oxide-based pigments (for color imparting) are used.

For the manufacture of the tile body, the raw materials are carefully crushed and mixed to obtain a perfectly homogeneous mass for subsequent molding. There are two methods for molding - pressing and extrusion... Pressed tiles are obtained from a powder solution that is compacted and pressed under high pressure... Extruded tiles are produced by passing a wet mixture of raw materials through appropriate holes, giving it the final appearance.

The pressing method allows tighter control of the size, and, in addition, obtain a better surface quality.

After shaping, the tiles are first dried to remove the low moisture content. Then they are fired (unglazed tiles). Chemical and physical characteristics - density, resistance to mechanical and chemical influences - it gets in the process of firing. During firing, the high temperature makes the material resistant to aggressive chemicals and physical environmental influences.

Ceramic tiles are divided into unglazed and glazed. Glaze ( german Glasur, from Glas - glass) - glassy protective and decorative coating on ceramics, fixed by firing (transparent or opaque, colorless or painted).

Unglazed tiles are practically uniform throughout their thickness and usually do not have any decorative patterns.

Glazed tiles can be single-fired and double-fired (enamel is applied to the initially fired product, and it is re-fired).

Different types of ceramic tiles are produced as a result of various combinations of technological processes (for example, single firing or double firing), the use of different raw materials (white and red clay rocks), as well as molding (pressing or extrusion).

Single fired tiles

The product is obtained by pressing a mixture of raw ingredients. The color of the fired mixture ranges from light yellow to dark brown, depending on the iron content of the clay and on the porosity. Most single-fired ceramic tiles are made from a light mixture due to its production advantages and also due to the high market demand.

The compressed mixture is glazed, and then fired once, which ensures good adhesion of the glaze to the mixture.

Ceramic tiles can be made with a glass-dense or porous base. It is extremely important characteristic tiles, because water absorption also depends on porosity, which in turn determines its frost resistance, mechanical strength and, consequently, the field of application. Depending on the water absorption of ceramic tiles, it is necessary to select suitable materials for their installation.

Low porosity ceramic tiles suitable for indoor and outdoor floors and is characterized by high resistance to mechanical agents and frost. Products are subject to increased shrinkage during firing and are therefore sold in batches by size.

Highly porous tiles, single firing It is made from a special mixture designed to prevent shrinkage during firing: therefore, tiles with a narrow seam are possible. The product has increased porosity (greater water absorption) and low mechanical strength, which makes it suitable only for wall cladding.

Another type of single-fired tiles is pressure glazed tiles... It is made using modern technology, according to which a layer of glaze is pressed together with the mixture, and then fired. The finished product has a low porosity and, due to the high thickness of the glaze layer, is especially suitable for floors subject to high loads during heavy traffic.

Double-fired tiles

The product was manufactured by this method before the introduction of the single firing method: according to this traditional technology glaze is applied to the fired mixture, then the product is subjected to a second firing. The disadvantage of this technology over the single-firing method is the higher production cost (two firing instead of one), as well as the impossibility of manufacturing low-porosity products (glazing of the fired low-porosity mixture is impossible).

Currently, double-fired ceramic tiles are used for wall and floor cladding, especially when it is necessary to give a gloss to the tile surface. In this case, double firing has a technological advantage over single firing: with the latest technology, during firing, gas from the decomposition of the mixture penetrates through the glaze, which forms small traces on the shiny surface of the tile in the form of pin ends, cracks; there is no such disadvantage with the double firing technology.

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In this article, we will look at production of ceramic tiles, namely, technology and interesting video, according to which the material used for decoration, both external and inside buildings and structures. For the first time, they began to make tiles in ancient times. This issue was of interest to various ancient peoples: Assyrians, Babylonians, Egyptians and other representatives of various races. If we talk about some of the pyramids that were built in Egypt before our era, then the decor of some of them is made on the basis of colorful tiles, which is quite surprising for ancient times.

Over time, decoration with ceramic plates became widespread in almost all countries, but in the twentieth century, its production reached an industrial level. Due to the fact that equipment for the production of ceramic tiles it was improving and improving all the time, it didn't take long to wait for the moment when the process was fully automated. If a novice entrepreneur decides to start manufacturing ceramic tiles, then he will certainly need a clear and calculated business plan. Next, we will consider the main points that should be paid attention to when implementing the production of ceramic tiles.

How to get raw materials?

The main components of the raw material base are clay materials, the source of which is earth's crust... Some representatives of natural minerals are added to this base. In order to reduce temperature regime, in which firing is carried out, a little feldspar is added, and additives with a certain chemical composition are used to improve the forming processes. Before the mineral component of the raw material is sent to the tile factories, it is specially enriched.

After the plant receives the initial material, it grinds and is classified according to the size characteristics of the particles. If rather large lumps have formed, then they break into different types crushing machines. Depending on what material needs to be obtained, used and different types crushing apparatus.

Production of ceramic tiles begins with the fact that all the necessary ingredients are thoroughly mixed together. After that, the resulting mixture is diluted with water and ground using special devices. For example, it can be a ball mill or wet grinding. With the latter option, you will also need a press filter and spray drying in order to remove excess moisture later.

From the obtained raw materials, it is necessary to form a tile blank, taking into account the desired shape and size of the product. For this, a special apparatus is used containing two steel plates, aimed at compressing the material together. Sometimes steel cones are used, which, by rotation, form the desired shape of the tile.

If it is necessary to reduce the particles of the raw material more, then it can be ground again in a hammer mill or a Müller mill. The principle of the hammer mill is that it contains steel hammers that move at high speed and crush the raw material. If we talk about the Müller mill, then its work is based on the shallow rotation of the ladle, in which special steel plates are placed. Sometimes the technology for the production of ceramic tiles involves the use of cone crushers or shaft apparatus.

To make tiles high Quality, will have to grind the raw materials for the third time. For this, special types of mills are used, called drum mills. In addition to these, various robust crushing techniques are also common. In order to produce quality raw materials, many experts advise using ball mills. They are based on two large-scale cylinders in constant rotation, which are filled with special bodies that grind raw materials.

In order to separate elements of approximately the same diameter from the rest of the raw materials, a screen should be used. It must be at a certain angle of inclination, or mechanical vibration is involved in the process. The electromechanical method can speed up the separation of particles. Screens are classified based on the number of holes located on one linear inch of their surfaces. The higher the value of this indicator, the smaller the diameter of the holes.

The production of ceramic tiles also involves the use of glaze. It belongs to the class of glass materials, which melts on the surfaces of the tiles when fired, and after cooling is firmly fixed. Glaze is used to decorate tiles, as well as to protect the material from moisture. Glass material can be painted in different colors, and in some cases form the basis of a textured coating.

What is the technology for the production of ceramic tiles?

So, the raw material base is ready, you can proceed to the process of direct production of tiles. For production, you will need to purchase some equipment to help automate the process. Let's consider all stages of the production process sequentially.

1. Dosing stage.

Qualitative characteristics final product largely depend on the type of raw material that was used in the manufacturing process, as well as on its quantity. Also, it depends on the raw material base what color the base of the tiles will be, and the color spectrum ranges from white to red shades. The shade is influenced by raw materials that contain iron. Therefore, it is at the dosing stage that it is very important to correctly select the proportions of all raw material components. For this, a number of calculations should be carried out taking into account the physical and chemical properties of the material. Only after all the proportions have been carefully measured and checked, you can start mixing the raw materials.

2. Stage of mixing and grinding.

In order to mix all the ingredients, you must lower them into the mixer form. Experts advise sometimes adding water to the mixture so that it turns out to be finer and the components are mixed more thoroughly. This mixing procedure is a coarse grind and will require a ball mill. After such manipulations, a material filled with water is obtained at the exit. Certain loads are applied, and at the end the water is removed from the material and it remains to carry out dry grinding. The moisture removal is carried out using a press filter, which, in turn, should remove almost half of the moisture.

3. Stage of spray drying.

At this stage, you will need a special sprayer, which includes discs that rotate around their axis at high speed. Sometimes these discs are replaced with nozzles. Air currents push moisture out of the particles. If the material is formed by grinding, and then granulated, then the result is basically identical, but here you will need special devices for granulating.

4. Stage of formation

At the stage of formation, the production of ceramic tiles most often consists of dry pressing. A mixture of free-flowing powder that contains organic binders or a small level of moisture enters the hopper. From the hopper, the powder is directed to the area of \u200b\u200bthe profile press, where it is compressed using steel plungers. Compressed material comes out to the bottom of the plungers, because operating pressure in the apparatus can reach more than two and a half thousand tons.

Ceramic tiles - manufacturing process (diagram)

In order to obtain very thin tiles, wetting agents are used. Besides, irregular shape products, their increased strength and at the same time cost-effectiveness are achieved by extrusion and stamping. Plastic raw materials are compacted in special cylinders in which there is high pressure, after which they are dispensed in portions, certain parts... Each part is stamped using a hydraulic and pneumatic press.

The production of ceramic tiles can be carried out in another way. The hydraulic press has two rigid mold halves, between which the extruded parts are compressed. Under the influence of vacuum, a portion of raw material is pressed against the upper surface of the press mold, thereby releasing the lower one, after which air is pumped, forcing it to release the upper surface and move to the lower layer. The raw materials that remain can be reused.

One of the most modern processes is glazing using pressure. Thus, the raw material is both shaped and glazed at the same time. The mold is preliminarily spray-dried, and only then glaze is applied to the material in it, filling the matrix. With this method, the amount of waste material is much less, and the defects in the glazing itself are insignificant than when using the conventional method.

After the tile has been formed, it must be dried. In order for a tile business idea to really generate income, you need to carefully monitor the quality of the products. Therefore, you should not rush to dry - in order to avoid shrinkage cracks, it may take more than one day to dry the product. Equipment for the production of ceramic tiles, which will be needed to implement the process, must also include a dryer: tunnel or continuous. The device is heated with gas or petroleum products. Sometimes microwave energy or an infrared lamp is used for heating. Thin tiles are best dried using an infrared lamp, while thicker tiles are best dried using microwave energy. Another option is impulse drying with hot air flows that are directed transversely to the product.

At the next stage, the material goes through the glazing stage. There are several options for applying crushed glazes to the material: centrifugal glazer or disking, waterfall application, spraying and stencil printing. Disking involves the application of glaze using a rotating disc. In waterfall application, the glaze is fed in a direct stream onto a conveyor through which the formed tile bases pass. And in order to apply the glaze using the printing method, you need special equipment, for example, a sieve that has a rubber squeegee. If a dry method of applying glaze will be used, then the need to purchase special glass and powder materials should be included in the business plan. They are applied to the product, and when the tile goes through the firing stage, they are connected to each other and form a durable layer, similar to granite.

The production of ceramic tiles ends at the firing stage. Its main function is to fix the glaze, create porosity and strengthen the product itself. This can be done both in ovens and on their surfaces. there is certain types tile materials that need to be fired in two stages. If we talk about tiles that are made by wet grinding, then the firing is carried out once, and the temperature should be at least two thousand degrees. In more detail, the manufacture of tiles is presented in the video of the technological process, which can be found at the end of the article.

What should be highlighted when drawing up a business plan for the production of ceramic tiles?

Any business idea, before it is implemented, must be comprehensively considered from all sides. An important step in this process is the cost analysis of the equipment needed in the manufacturing process. When organizing the production of ceramic tiles, it is necessary to take into account that you need to purchase a special kiln on which the firing will be carried out.

If the product will be produced by dry grinding, then it will have to be fired more than once. To do this, you need a furnace equipped with the possibility of low-temperature firing, during which shrinkage and volatile substances will be removed from the tile itself. Then both firing and glazing are performed at the same time, in the tunnel section or chamber of continuous furnaces. It is through these chambers that the bases of the tiles move at a low speed along the conveyors, the movement of which is based on a refractory fiber belt. This tape is made of a special material that is not sensitive to high temperatures. The firing process in tunnel kilns lasts two and sometimes three days. At the same time, the temperature remains up to one and a half thousand degrees.

If the business idea concerns the production of tiles by the wet method, then the firing will need to be carried out one-time. Here you will need special milling-type rollers, since this type of furnace moves the workpiece material precisely on roller conveyors. The duration of the process will be about an hour, and the temperature should be no less than one thousand two hundred degrees.

How to minimize environmental damage from production?

Unfortunately, almost all production processes are harmful to the environment, to a greater or lesser extent. The production of ceramic tiles is no exception. There is a large amount of waste at each stage of manufacture, but care must be taken to ensure that the emission meets the established requirements. If we talk about specific, most abundantly emitted substances, then these include fluorine, lead and its various compounds. Thanks to modern technologies the number of lead compounds has decreased - the new generation glaze is produced without lead admixtures, and lead itself is contained in it in small doses.

To control fluoride emissions, you can use special devices that spray water, or fabric filters covered with lime. Moreover, the same lime can then be added to the raw materials for the manufacture of the material, like some other industrial waste.

How to control product quality?

When the business plan for the production of ceramic tiles was drawn up, the level of competition in the market was probably assessed. There are a lot of manufacturers, therefore, in order to take a place in the market, it is necessary to produce quality products. Modern manufacturers control each stage of the production process using statistical control methods. In addition, it is important to find suppliers of a raw material base whose products will meet all standards. It is convenient to control production based on graphical reflection: diagrams or diagrams. For each indicator, its own graph is built, which shows its state. Time parameters, pressure values, particle size grid, temperature conditions at which firing takes place and much more are important. It is on the basis of such control that it will be possible to draw conclusions regarding the efficiency of production as a whole.

When drawing up a business plan, it should also be borne in mind that in addition to overall indicators quality, products must comply with the standards established at the state level. In order to verify compliance, simple product testing can be performed. Calculate values \u200b\u200bfor mechanical strength, chemical resistance, water absorption, abrasion resistance, frost resistance, dimensional compliance, and linear thermal expansion. According to the latest updates, a new indicator has also been introduced that characterizes the sliding resistance of tiles.

If we talk about the prospects for this direction in business, they are quite extensive. The main thing that should be emphasized is new technologies that will make it possible to make a more durable, innovative material. The strength is influenced by the raw material base, its quality, as well as the ways of organizing production processes. That is why it is not desirable to save on equipment, because an automated line will help not only to facilitate work and increase turnover, but also to reduce costs. Also relevant is the question of how to make the production of ceramic tiles less harmful to the environment.

Man has always sought to decorate his home and make it practical. For these purposes, he uses various materials, many of which have remained relevant for millennia. So, the first prototypes were found at the excavations of the Euphrates and Mesopotamia of the Tigris. In ancient times, this material was used to decorate the walls of temples and houses of the nobility. Over time, its popularity grew, and the manufacturing methods improved. Let's take a closer look at modern ceramic tiles and find out how they have earned such an impeccable reputation.

Composition

First of all, let's figure out what ceramic tiles are made of. The main raw materials used in the production of ceramics are represented by the following materials:

Clay materials. They impart to the wet mass the plasticity necessary for forming the workpieces.
Quartz materials (mainly sand). They perform a structural function, that is, they create a "skeleton" of the product. They allow limiting and controlling the change in the size of the product, which inevitably accompanies the firing process.
Materials containing feldspars (aluminosilicates or carbonates of potassium, sodium, calcium, and so on). With their help, when firing the product, its structure remains dense and glassy.

The process of making ceramic tiles consists of the following stages:

Mixing of materials.
Forming.
Drying.
Applying glaze.
Burning.
Sorting.

Let us dwell on each of the stages separately.

Mixing materials

It all starts with the extraction of materials, but we will not consider it, since we are interested in the process of making ceramic tiles. First of all, the clay is mixed with the rest of the components in strictly calculated proportions. The finished mixture goes to preliminary grinding, where it is subjected to grinding and moistening.

The method for preparing the ceramic mass depends on the properties of the feedstock and the desired product. There are such ways:

Semi-dry. The components are first crushed, then dried a little, crushed, mixed and sent for molding. This method is called semi-dry because the components themselves have a certain degree of moisture.
Plastic. The clay is crushed and sent to a mixer, where it is mixed with additives and takes the form of a homogeneous plastic mass.
Wet. The materials are crushed and mixed with the addition of water (up to 60%). A homogeneous liquid mixture is fed into special tanks.

Regardless of which ceramic tile production line is used, in order to obtain a good product it is necessary that all materials are thoroughly ground and mixed.

Molding

Forming is done in two ways: pressing and extrusion. In the first case, special presses squeeze the powdery mass in two directions. Under high pressure, the granules are compacted and partially deformed. Due to this, the tile acquires the appropriate density and strength.

When using the extrusion method, tiles are made from a doughy mass, which is formed by forcing through the holes of an extruder. This method differs from dry pressing by the presence of a liquid phase in the production process. It is due to the fact that the viscous mass is squeezed out of the apparatus and cut off, it is possible to produce products of different shapes. made by the extrusion method, it can be convex or concave. When pressing, only the size of the products can be varied.

Drying

Drying is an obligatory stage in the production technology of ceramic tiles. At this stage, moisture is removed from the finished forms, which was necessary for comfortable molding. Drying conditions play a critical role in ensuring the integrity and strength of the future product, therefore they are strictly controlled. On modern enterprises for the production of tiles, drying installations are used that pour hot air over the raw (molded wet product). Heating leads to the formation of moisture on the surface of the semi-finished product, which quickly evaporates and is removed by the ventilation system.

Good heat exchange, efficient ventilation and high air temperature ensure a fast response of the unit. If you subject the raw to firing, bypassing the drying stage, then it will crack. At the final stages of drying and during the firing process, shrinkage of the tile occurs, that is, a proportional decrease in its linear dimensions. This explains the need for calibration finished products... The higher the level of the enterprise, the more likely it is that its products will be of the same size. Therefore, it is better to choose options in the middle price range (for example, from the firms "Shakhtinskaya ceramic tile", "Euroceramics", "Sokol", etc.) than to get an uneven wall.

Applying glaze

Glaze (enamel) is a glassy coating that is applied to the front side of the tile and fixed during the firing process. Glaze is performed to decorate and strengthen the product. The glaze composition can include various materials and compounds (sand, oxides, frits, coloring pigments, etc.). It can be glossy and matte, colored and monochrome, and sometimes even transparent. Coloring is achieved by adding oxides and metal salts (iron-red, chromium - green, cobalt - blue, etc.) to the composition. The enamel has a vitreous structure and differs from the ceramic base not only in appearance, but also in characteristics, the most important of which is water resistance.

Today, a ceramic tile factory can use several dozen methods of applying glazes to its products. The enamel can be applied in the form of a spray suspension, paste or granules. IN basic version, it is applied to the formed workpieces using a large round drum, which, making one circle, processes several tiles at once. Application can be done before or after firing, and in some cases even during firing.

In order for the product to have a more aesthetic appearance, the enameling process can be accompanied by the application of an image. Patterned ceramic tiles are much more popular than plain tiles. To ensure that each tile has a unique image, but retains the style of the series, the drum is simply shifted along the axis of rotation. Of course, this applies to models with abstract pictures.

Burning

Ceramic tiles are fired in order to make them sufficiently hard and durable. This is due to chemical and physical changes in the composition of the material and glaze, which occur under the influence of high temperatures. Typically, ceramic tile manufacturers use continuous ovens for this purpose. In fact, such a furnace is a tunnel, moving through which with the help of a special conveyor, the tile is first pre-heated (allows you to get rid of the remaining moisture), and then fired.

A characteristic property of clay is its ability to turn into a strong stone-like mass during firing. Depending on the type of product, the firing temperature ranges from 900 to 1300 ° C. After spending a certain time in the oven, the tile is consistently cooled to such a temperature at which, without compromising quality, it can be unloaded from the oven.

Sorting

Before entering the packing line and warehouse, finished tiles carefully sorted. This procedure solves three problems:

Reject products with defects.
Separate the first grade tiles from the lower grade tiles.
Group trading lots by grade and color.

Usually, ceramic tile manufacturers perform sorting in the following way - after leaving the oven, it goes through three sections: flaw detection, calibration, visual inspection. To identify defects, each product is fed onto rails and rolled with a roller. Due to the fact that the rails are located along the edges of the tile, and the roller presses into the center, the defective samples break, not withstanding the load. Painting defects are checked visually, together with the determination of the tonality. All that remains is to sort the products by lot and send them to the warehouse.

As you can see, the technology for the production of ceramic tiles is quite simple. However, in order to obtain a high-quality product, it is necessary to approach each stage with full responsibility and observance of all technological rules... That is why many aspiring entrepreneurs who have opened a ceramic tile factory cannot achieve the proper quality of their products. Now we will briefly find out what properties ceramic tiles should have.

Wear resistance

This is definitely one of essential qualities floor tilesas it characterizes its abrasion resistance and ability to maintain an attractive appearance after long-term use. Despite the fact that the material as a whole is quite durable, its type should be selected depending on the operating conditions. So, designed for a simple bathroom, patterned ceramic floor tiles laid in a public toilet will quickly wipe out and lose their appearance.

Water absorption

Water absorption is the ratio of the mass of water absorbed by the tile when it is completely immersed in water, to the mass of the dry product, expressed as a percentage. For the floor, it should not be higher than 3%. For wall marks, this figure rises to 10%. In this regard, for lining swimming pools, for example, not any tile is suitable. Large manufacturers, for example, the Shakhty Ceramic Tile enterprise, can produce various types of specialized products at their facilities, from tiles for baths to ceramics for swimming pools.

Frost resistance

As well as water absorption, this property depends on the porosity of the product. Regardless of the production technology, pores remain in ceramic tiles, into which moisture can penetrate. As you know, when it freezes, water increases in volume. The ability of a tile saturated with moisture to withstand frequent alternating freezing is called frost resistance. This indicator is important when choosing an outdoor finishing material... The fewer pores in the ceramics, the lower the rate of its water absorption, and the higher the rate of frost resistance.

Slip resistance

As you might guess, this property determines the ability of the tile enamel to prevent objects from sliding on it. This requirement is important when finishing the floor of residential and industrial premises, especially those in which it is always humid. In pools and saunas, ribbed tiles are most often used, which have increased slip resistance.

Chemical resistance

This is the name of the characteristic of tile enamel, reflecting its ability to withstand contact with chemicals (acids, bases, household chemicals, additives for disinfection of water in pools, etc.). The tile should not undergo external changes under the aggressive influence of these substances. By the way, considering the resistance of ceramics to certain influences, do not forget that the seams between the tiles can also be subject to destructive effects. To avoid this, they are covered with protective compounds.

Tensile strength

This indicator expresses the level of permissible load that ceramic tiles can withstand. Usually it is directly proportional to the thickness of the product. Load bearing capacity is important mainly for floor tiles.

Surface hardness

This characteristic illustrates the resistance of the surface to damage and scratches. It is especially important for floor tiles. The surface hardness is determined by the quality and composition of the glaze. It is noteworthy that mechanical damage on a shiny surface is much more noticeable than on a matte one.

Despite any crises, ceramic tiles are always in demand. Even if in difficult times people do not build houses and do not make major repairs to apartments, redecorating rarely does without laying tiles. Therefore, this facing material will always find its buyer.

Small business benefits

Experts believe that it is more profitable to open such a business in a small format. In small-scale production, you can afford to have a variety of products, and ready-made ones. In addition, the increased price of imported goods made buyers appreciate the domestic one better. At the same time, its quality is not much inferior to imported samples.

Market analysis

The production market is wide, so you should decide on your niche. The segment of inexpensive and high-quality products remains fairly free. Therefore, it is recommended to study who is already working in this niche in your region, what assortment they offer, at what prices, what composition. Your advantage may be in the original design solutionsfor which you will have to invite experts to develop samples. In addition, it is important to adhere to all established GOSTs. This is the only way to bring the business to a competitive level.

Registration of the enterprise

A production business plan should begin with defining a business registration form. For a small business, where few hired employees will work, it is enough to register an individual entrepreneur. But if you plan to release large volumes, it is better to register a legal entity.

When registering, you must indicate the OKVED code 26.3 - Production of ceramic tiles and slabs. We also recommend that you immediately switch to the simplified taxation system. This will make it easier to do business at the start.

Assortment development

Another important question, which must decide the business plan - what will be your product range. First, you need to decide what kind of tile your company will specialize in. Tiles are distinguished by:

the type of raw material: cotto, ceramic granite, clinker, terralia, metlakh tiles;
production technologies: with double or single firing, glazed, unglazed;
molding method: hand molding, casting, pressing, extrusion, etc.
using decorative elements: mosaic, decorative inserts and more;
texture: porous, antique, mosaic, stone, etc.
purpose: for the pool, fireplace, floor, kitchen, bathroom.

Another task is to determine in what style the ceramic tiles will be made. To resolve this issue, you can invite an artist-designer to the staff, who will develop exclusive options... But in this case, the spending plan will increase significantly. Alternatively, you can purchase templates and molds from leading Spanish or Italian developers.

You also need to decide what format of tiles you will produce. At the start of the enterprise, it is better to focus on standard sizes: 400х400, 330х330, 310х500, 200х300, 250х400, 200х400, 250х330, 200х300, 200х200 mm.

Raw materials

The technology for the production of ceramic tiles requires the use of several groups of components. These include:

The main ones are clay components, thanks to which the mass acquires plasticity and the ability to form (kaolin, clay);
Components for reducing shrinkage - quartz raw materials, due to which the tile skeleton is formed (quartz sands);
Carbonate components, due to which the sintering temperature is reduced, and after firing the goods acquire a glassy structure (feldspars, slags, nephelines);
Additives - thinners, surfactants, mechanoactivating components.

Naturally, the quality of the tiles depends on the quality of these components, so it is better to use raw materials of the highest brands. If every month we produce 5 thousand square meters of tiles. m, the business plan must include at least $ 12 thousand for the purchase of raw materials.

Equipment

Equipment for the production of ceramic tiles includes the purchase of:

semi-industrial furnace (200 degrees);
chambers for spraying glaze, drawings;
forms for tiles;
vibrating table;
concrete mixers.

In total, the purchase of equipment in the business plan must include at least 10 thousand dollars. All components can be bought separately, or you can order a ready-made production line and save a little on delivery. Include in your business plan and purchase a set of stencils for drawing - approximately $ 600 for 200 pieces. If you take a spray chamber with an expanded set of functions, it will cost $ 3 thousand.

But this standard set, which will allow the production of standard tiles. If you plan to prepare exclusive copies, you will have to buy special equipment.

Production technology

Regardless of which tile you specialize in, the production technology will be about the same. She goes through the following stages:

Mixing is a process that goes through the stages of grinding, mixing, homogenization, and moistening.
Molding - the most commonly used method is pressing, when the mass is squeezed from both sides.
Drying - removing excess moisture from the tile. It is important to ensure that the products do not crack.
Glazing - applying a glaze composition to the surface. This step is only used in the manufacture of glazed tiles.
Firing is carried out in special tunnel kilns, where, gradually heating up, the tiles are kept at temperatures above 1250 ° C.

Some factories produce double-fired glazed tiles. In this case, the tiles are first fired, then the glaze is applied and only after that they are fired again.

Staff

To organize a small tile production with a capacity of about 5 thousand. square meters a month, four workers are enough. Two of them will serve the concrete mixer, one - the vibrating table and one more will dry and pack the finished product. You will also need a master who will be familiar with the technological process and will monitor its rigorous implementation.

Premises

There are no special requirements for the premises. The main thing is that it is closed and has an area of \u200b\u200bat least 100 sq. m. Therefore, you can open production in the garage and in the hangar. The room must be divided into the following zones:

warehouse finished products;
manufacturing facility;
warehouse of raw materials.

The only thing that is desirable to provide is that the production is located near the place where raw materials are purchased. Then you can significantly save on transportation and reduce the cost of finished products.

Sales markets

The sales plan for finished products can include the development of such channels:

individuals;
repair companies;
construction markets;
construction stores.

Alternatively, you can open own point on the implementation of tiles. It is advisable to open it in residential areas near new buildings. Then residents who are renovating new apartments will be able to buy tiles from you, and not go to the other end of the city for it.

But if you produce luxury tiles, the store is better located in the city center. Please note that before starting trading, you must obtain a certificate from the State Sanitary and Epidemiological Supervision.

The best option would be to sell products via the Internet. You can sell it using free classified ads. But a great return will be given by your own online store, where buyers can get acquainted with complete list goods and conditions of its purchase.

Return on production

Before opening production, you need to calculate a plan for costs, income and payback.

The expense item will look like this:

equipment - $ 10 thousand;
raw materials - 12 thousand dollars;
salary to employees - 3 thousand dollars;
rent and utilities - $ 1,000;
other start-up investments - $ 1.5 thousand

In total, the launch of production will require at least $ 30,000 in initial capital, and then another $ 18,000 in investments each month.

A square meter of tiles costs on average $ 7. If a month to produce and sell about 5 thousand square meters. meters, the monthly income will be about 35 thousand dollars. However, it must be borne in mind that not every month it will be possible to sell the entire volume of production.

Seasonality of production

Ceramic tiles are a seasonal product. The maximum demand for it is observed in the summer during the most active period of repair work. In spring and autumn, demand is slightly less, and in winter there is practically no demand. However, it makes no sense to build up production volumes for the future in winter. In addition to seasonality, the tile has one more characteristic feature - the assortment is becoming obsolete. What was fashionable last summer is no longer relevant to next year... Therefore, despite the high popularity of the product in the summer, the payback period of the investment can stretch for a year. To reduce it, it is advisable to enter the market with the product by the beginning of the construction season - in March-April.

The production of ceramic tiles is a business that will have to be organized in a highly competitive environment. To slightly reduce her pressure, we recommend using these tips:

all of your employees must have up-to-date knowledge of ceramic tile manufacturing;
seek and listen to the advice of professionals in this field;
always focus on the needs of customers;
make sure that each client has an individual approach;
if you hire a consultant, manager, make sure that they have a good command of the topic and have high professional skills;
strive for the fastest possible order fulfillment without compromising quality.