The Manufacturing Process Behind High-quality Porcelain Slabs

By Author: Jaydip Dabhi
Total Articles: 9
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The reason porcelain tiles are so reliable and durable for decades is the way it gets manufactured. Porcelain slabs are made out of porcelain, a material that fits every demand and is extremely popular in the tile industry. Porcelain tiles provide so many advantages for a variety of requirements.

In addition to its excellent appearance, this hard stone is durable and versatile. Isn't it amazing how many distinct traits can be found in a single stone? But have you ever wondered how this stone acquires all of these characteristics and what steps are involved in the production of porcelain?

As a highly reputed porcelain tiles manufacturer in India, Neelson Ceramics has been providing variety of porcelain tiles all over the world for various requirements. Let's review the basic steps involved in creating porcelain slabs:

What are Porcelain Slabs
Engineered stone slabs, known as porcelain slabs, are created by firing solid clay at a very high temperature. These slabs have a water absorption rate of less than 0.5% and are rigid and dense due to the high baking temperatures.

With the added functionality ...
... of engineered slabs, these slabs are particularly made to resemble genuine stone tile flooring. This combination produces a beautiful and long-lasting stone slab that suits a variety of project needs.

How are Porcelain Slabs Manufactured
There are a series of steps to be followed for making highly durable and innovative porcelain slabs for various needs.

Raw Materials and Preparing The Mixture
Since it defines the structure of a component, the careful selection of raw materials is the most important step in the production of porcelain tiles. The right amount must be combined to provide the desired color and hardness characteristics.

The first step in creating porcelain slabs is to carefully choose the right quantity of raw ingredients, which often include feldspar, silica, clay, and other minerals. The quality and uniformity of the final product is assured by the careful blending of all these components into a homogenous mixture.

Water is then gradually added to the mixture to produce "slip," a paste-like consistency.

Shaping the Slabs
To achieve the required color for the slab, ceramic pigments—which comprise colorants—are added to the slip in the next step of the production process. The porcelain slabs are then shaped by pouring this slip into molds.

Molds can come in a variety of sizes and styles that allow for personalization; there is no such thing as a diameter consideration. The technique known as "dewatering" is then used to progressively eliminate the surplus water remaining in the slip, allowing the material foundation to solidify within the mold gradually.

Pressing The Slips
The pressing of slip, which utilizes hydraulic presses to assist in forming the slabs, is the next step. To condense the material, the slip is sandwiched between two large molds and subjected to tremendous pressure.

Another name for this shaping technique is dry pressing. The residual slip is then fed into an atomizer, which has nozzles to form slabs, to begin the extrusion process.

Drying
The slabs must completely dry after shaping in order to eliminate any last traces of moisture from the mixture. When creating slabs, drying is essential, and it must be done correctly to ensure that the slab is long-lasting and free of fractures and deformities when fired.

The thickness and size of the porcelain slabs greatly influence how long the drying process takes, which can range from a few hours to several days.

Firing

The primary cause of the porcelain slabs' hard surface is the extraordinarily high temperatures at which they are fired in kilns after drying. Generally speaking, the temperature of the kiln falls between 1200 and 1400 degrees Celsius (2192 and 2552 degrees Fahrenheit).

The raw material subsequently becomes a solid, dense slab of porcelain as a result of this fire process. The porcelain's exceptional strength and durability are also a result of the high temperature.

Glazing
Before the second firing, we apply glazed layer to certain glazed porcelain tiles. Glazing the tile typically adds extra protection and improves the surface's overall visual look of the tiles.

Additionally, this method can help achieve various finishes or textures on the surface. Glaze is a liquid-like substance that coats the porcelain slab's surface like glass when burned at a high temperature.

Second Firing

Only after applying the glaze to the slab's surface does a second firing become necessary. Typically, it is carried out at a temperature that is slightly lower than the initial firing temperature. The glaze fuses on the surface after the subsequent firing.

Depending on the intended result, this procedure is necessary to produce a smooth, glossy, or textured finish.

Quality Control
Quality control is a very important phase, as it ensures that the process's results meet the necessary standards. The porcelain slabs go through stringent quality control inspections during this process.

Here, we investigate whether slabs satisfy the necessary requirements for texture, strength, color, size, and shape. Additionally, we remove any flaws or blemishes at this point.

Cutting and Finishing
Slabs are cut into the suitable sizes by using specialist equipment, such as diamond-tipped saws, once they have passed quality inspections. The edges are then finished using a variety of methods to produce the desired appearance, including straight, rounded, or beveled edges.

Packing and Distribution
After that, we carefully bundle the porcelain slabs to guard against breakage during transit. After that, the slabs are carefully moved and sent to distributors, shops, or project locations, where they will be used to create stunning surfaces for residences and businesses.

Conclusion

Porcelain slab production is a challenging and complex process that combines state-of-the-art technology with traditional craftsmanship. From raw materials to finished products, every step in the creation of these beautiful and long-lasting surfaces, which have captured the hearts of architects, designers, and homeowners alike, is crucial.

Understanding the production process for porcelain slabs helps us appreciate the beauty and imagination that go into creating these stunning works of art, which are both functional and purely aesthetic. At Neelson Ceramic, we have the top-quality porcelain slabs that we manufacture for all our customers in India and worldwide. We have been a trustworthy porcelain tiles exporter for over ten years. Contact us today to learn more about our products.

Porcelain tiles : https://www.neelson.in/porcelain-tiles-600x1200-mm