Obtaining certain types of ceramic tiles (according to technical characteristics) primarily depends on production technology. Figure 1 shows the main stages of various technological cycles and lists the main types of ceramic tiles that they can produce.
Fig.1
Technological production cycles of various types ceramic tiles
The secret to obtaining high-quality new material is carefully crafted technological process production, which is constantly being improved. It is based on firing at high temperatures, varying depending on the type of material from 900 to 1,200 °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 impart plasticity), quartz sand (to impart hardness to the body of the tile) and feldspar (to impart fusibility). To prepare the glaze, sand, kaolin clay, pre-prepared glass chips, and oxide-based pigments (to add color) are used.
To make the tile body, the raw materials are thoroughly crushed and mixed to obtain a completely homogeneous mass for subsequent molding. There are two methods used for molding - pressing and extrusion. Pressed tiles are made from a powder mortar that is compacted and pressed under high pressure. Extruded tiles are produced by passing a wet mixture of raw materials through appropriate holes to give them their final appearance.
The pressing method allows for tighter control of size and, in addition, a better quality surface.
After molding, the tiles are first dried to remove any small moisture content. Then they are fired (unglazed tiles). Chemical and physical characteristics- density, resistance to mechanical and chemical influences - it acquires during the firing process. When fired, 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) - a glassy protective and decorative coating on ceramics, fixed by firing (transparent or opaque, colorless or colored).
Unglazed tiles are almost uniform throughout their entire thickness and usually do not have any decorative patterns.
Glazed tiles can be single fired or double fired (enamel is applied to the initially fired product and it is fired again).
As a result various options combinations of technological processes (for example, single firing or double firing), the use of different starting materials (white and red clay rocks), as well as molding (pressing or extrusion), are produced different kinds ceramic tiles.
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 the porosity. Most single-fired ceramic tiles are made from a light-colored mixture: this is due to its production advantages as well as high demand in the market.
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 dense, glass-like or porous base. This is extremely important characteristic tiles, because Water absorption also depends on porosity, which in turn determines its frost resistance, mechanical strength and, consequently, its scope of application. Depending on the water absorption of ceramic tiles, it is necessary to select and suitable materials for their installation.
Low porosity ceramic tiles suitable for indoor and outdoor flooring and is characterized by high resistance to mechanical agents and frost. Products are subject to increased shrinkage during the firing process and are therefore sold divided into lots according to caliber.
Highly porous single fired tiles It is made from a special mixture designed to prevent shrinkage during the firing process: therefore, laying tiles with a narrow seam is 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-firing tiles is pressure glazed tiles. It is made using modern technology, according to which the glaze layer is pressed together with the mixture, and then fired. The finished product has low porosity and, thanks to the high thickness of the glaze layer, is particularly suitable for floors subject to high loads and heavy traffic.
Double fired tiles
The product was produced using this method before the introduction of the single firing method: according to this traditional technology, the 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 cost of production (two firings instead of one), as well as the impossibility of producing low-porosity products (glazing of a fired low-porosity mixture is impossible).
Currently, double-fired ceramic tiles are used for wall and floor cladding, especially when it is necessary to add shine to the surface of the tile. In this case, double firing has a technological advantage over single firing: with the latter technology, during the firing process, gas from the decomposition of the mixture penetrates through the glaze, which forms small marks in the form of pin ends and cracks on the shiny surface of the tile; There is no such disadvantage with double firing technology.
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Decorative tiles are used for interior and exterior decoration. The production of ceramic tiles dates back to ancient times and peoples, including the Egyptians, Babylonians, and Assyrians. For example, the step pyramid for Pharaoh Djoser, built in Ancient Egypt around 2600 BC. , contains colorful tiles.
Later, ceramic tiles were made in virtually every major European country. By the beginning of the twentieth century, tiles began to be produced on an industrial scale. The invention of the tunnel kiln around 1910 led to the automation of production.
Obtaining raw materials for the production of ceramic tiles
The raw material used to form the tiles consists of clay minerals mined from the earth's crust. Natural minerals such as feldspar are added to lower the firing temperature and chemical additives required for the molding process. Minerals are often pre-enriched before being sent to the ceramic plant.
The starting materials are crushed and classified according to particle size. Primary crushers are used to reduce large lumps of material. There are different types of crushers that make it possible to obtain the output material of the desired classification.
The first step in producing ceramic tiles is mixing the ingredients. Water is then added and the ingredients are wet ground or ball milled. If wet grinding is used, excess water is removed using a filter press followed by spray drying. The resulting powder is then pressed into tiles of the desired shape. Forming is accomplished by compressive movements between steel plates or by rotational movements between steel cones.
Secondary crushing reduces small pieces with particles. Hammer mills and Mueller mills are often used for these purposes. The latter uses steel discs in a shallow rotating "pan", while the hammer mill uses fast-moving steel hammers to crush the material. Shaft or cone type crushers are also used.
The third particle grinding step size is necessary to produce high quality tiles. Drum mills are used in combination with other methods. One of the most common types of such mills is ball mills, which consist of large rotating cylinders partially filled with spherical grinding bodies.
Screens are used to separate particles within a certain size range. They work in an inclined position and mechanical vibration or electromechanical method improve the flow of material. Screens are classified according to the number of holes per linear inch of screen surface. The higher this number, the smaller size holes.
Glaze is a glass material intended to melt on the surface of the tile during the firing process, and is securely fixed to the surface of the tile during cooling. Glazes are used to provide moisture resistance and decoration, as they can be colored or given special textures.
Ceramic tile production: technology
Once the raw material is processed, several steps must be followed to obtain the finished product. These steps include dosing, mixing and grinding, spray drying, molding, drying, glazing and firing. Many of these steps are now carried out using automated equipment.
Dosing
For many ceramic products, including tiles, quality is determined by the quantity and type of raw material. The raw material also determines the color of the body of the tile, which can be red or white, depending on the amount of iron-containing raw materials used. Thus, it is important to mix the correct volumes of ingredients to achieve the desired properties. Calculations are made that take into account the physical and chemical properties of the composition of the raw materials. Once the appropriate weight of each raw material is determined, the components are mixed.
Mixing and Grinding
After the ingredients are weighed, they go into the mixer. Sometimes it is necessary to add water to improve mixing with multiple ingredients in a batch, as well as to achieve a fine grind. This process is called wet grinding and is often performed using a ball mill. The result is a water-filled mixture called a suspension. After intensive loading, water is removed from the suspension using a filter press (which removes 40-50 percent of the moisture) followed by dry grinding.
Spray drying
Involves pumping a suspension into a sprayer consisting of a rapidly rotating disk or nozzle. Air flows remove small particles from moisture. Raw materials can also be obtained by dry grinding followed by granulation. Granulating machines have been created for this purpose.
Formation
Most often, ceramic tiles are formed by dry pressing. In this method, bulk powder containing an organic binder or a low percentage of moisture is transferred from a hopper to a shaped press. The material is compressed into the cavity by steel plungers and then ejected at the bottom of the plunger. Automated presses are used with operating pressures in excess of 2500 tons.
Wetting agents are also used to produce particularly thin tiles. Extrusion plus stamping makes it possible to produce tiles of irregular shape and small thickness, which makes them of higher quality and economical production. The plastic mass is compacted in a special high-pressure cylinder and is squeezed out of the cylinder in small portions. These portions are stamped using hydraulic or pneumatic presses.
The second method is as follows: the extruded portions are compressed between the two halves of a rigid mold mounted on hydraulic press. The formed part is pressed against the top half of the mold using a vacuum to release the bottom half. Then, by forcing air through the top half, the top is released. Excess material is removed for reuse.
Another process, called pressure glazing, has been developed recently. This process combines glazing and shaping at the same time. Applying glaze (in spray-dried powder form) directly into a matrix filled with body tile powder. Benefits include the elimination of glazing errors as well as the reduction of waste of glazing material (called slurry) that is produced conventionally.
Drying
Ceramic tiles generally need to be dried (high relative humidity) after formation, especially if used wet method. Drying, which can take several days, removes water at a slow enough pace to prevent shrinkage cracks. Continuous or tunnel dryers are used, which are heated by gas or oil, infrared lamps or microwave energy. Infrared drying works better for thin tiles, while microwave drying works better for thick tiles. Another method, pulse drying, uses pulses of hot air flowing transversely to the material.
Glazing
Crushed glazes are applied using one of available methods. In a centrifugal glazer or disc glazer, the glaze is fed through a rotating disc which distributes the glaze onto the tile. With the waterfall method, a stream of glaze falls onto the tile as it passes through a conveyor underneath. Sometimes the icing just sprays on. There is also screen printing. In this process, the glaze is pressed through a sieve fitted with a rubber squeegee or other device.
Dry glazing involves the application of powders, crushed frits (glass materials), and granular glazes to the wet surface of the tile. After firing, the glaze particles merge with each other, forming a durable surface similar to granite.
Burning
After glazing, the tile is fired, strengthening it and giving it the desired porosity. After formation, the workpieces are dried slowly (over several days), at high humidity to prevent cracking and shrinkage. Next, a glaze is applied and then the tiles are fired in a kiln or kiln. Although some tiles require a two-step firing process, wet-ground tiles are fired only once, at temperatures of 2,000 degrees Fahrenheit or more. After firing, the tiles are packaged and sent to the warehouse.
Kilns used for firing tiles.
Tiles produced by dry grinding instead of wet grinding typically require a two-step process. In this case, the tile goes through a low-temperature firing called soup firing before being glazed. This step removes volatiles from the material, most or all of the shrinkage. Then firing and glazing are carried out simultaneously. Both firing processes take place in a tunnel or continuous furnace, which consists of a chamber through which the workpieces move slowly along a conveyor on fire-resistant fiber belts constructed from materials resistant to high temperatures or in special containers. Firing in a tunnel kiln can take two to three days, at about 2,372 degrees Fahrenheit (1,300 degrees Celsius).
For tiles that require only one firing - usually tiles that are wet molded - milling rollers are used. These ovens move workpieces on a roller conveyor and do not require additional equipment. Firing in a roller kiln can last 60 minutes, firing temperatures around 2102 degrees Fahrenheit (1150 degrees Celsius) or more.
After firing and testing, the ceramic tiles are ready, they are packed and shipped.
Environmental friendliness
Huge amounts of pollutants are generated during various stages of production; these emissions must be controlled according to standards. Among the harmful substances produced during tile production are fluorine and lead compounds, which are formed during firing and glazing. Lead compounds have been significantly reduced with the recent development of lead-free or low-lead glazes. Fluoride emissions are collected in scrubbers, devices that basically spray water to remove harmful pollutants. This can also be controlled using dry processes: lime-coated fabric filters. This lime can be recycled as a starting material for future tiles.
Industrial ceramic tile production also produces wastewater from milling, glazing and spray drying processes. Waste from tile production is also returned to the process of preparing raw materials for reuse.
Quality control
Most ceramic tile manufacturers now use statistical process control (SPC) methods for each step production process. Many also work closely with their raw material suppliers to ensure the raw materials they receive meet specifications. Statistical process control consists of charts that are used to monitor various processing parameters such as particle size, milling time, drying temperature and time, pressing pressure, post-press dimensions, density, firing temperature and time, among others. These graphs help identify problems with equipment and improve its efficiency.
The final product must satisfy certain physical and chemical properties. These properties are determined using standard tests. Determined characteristics include mechanical strength, abrasion resistance, chemical resistance, water absorption, dimensional stability, frost resistance and coefficient of linear thermal expansion. More recently, the parameter slip resistance has been added, which can be determined by measuring the coefficient of friction.
Prospects
In order to maintain market growth, ceramic tile manufacturers will focus on developing and promoting new models with different strength and performance characteristics. Special attention Now we are focusing on large-sized, durable, granite, polished models. High strength is achieved thanks to special composition raw materials, new glazing technologies, production using improved equipment. Automation of ceramic tile production will play a leading role in efforts to increase production volumes, reduce costs and improve quality. In addition, changes in ceramic tile technology driven by environmental and energy concerns will continue.
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Three friends invested 700,000 rubles in the production of ceramic tiles.
Anna Samokhvalova
talked to business founders
They planned to start in two months, but it turned out to be five times longer. But two years later, their average monthly profit is 150,000 rubles, and they work with partners in nine cities.
I asked Ksyusha, Olya and Lena about how they launched their production.
Idea
Ksyusha was renovating the kitchen and complained to her friends Olya and Lena about how difficult it was to find decent tiles for the backsplash.
The artist Olya was working at that time plaster stucco. She drew attention to the fact that the technological processes for producing stucco molding and tiles are the same. Making handmade tiles is not very difficult: you need clay, glaze and a kiln. The tiles are shaped, dried, fired in a kiln, coated with color (called glazing) and fired again.
There is a demand for original handmade tiles, because there are few such offers in Russia. In addition, the cost of tiles is small, and prices on the market are astronomical.
Olya invited her friends to start their own tile production. The moment was right: marketer Ksyusha returned from maternity leave, Lena resigned from her position as executive director, and Olya was looking for something to do for her soul. The friends agreed.
10 months
spent on starting a business
The girls wanted to enter the market with premium tiles: non-standard shapes and colors, manual production and low price - higher than the mass market, but lower than popular ceramics from Spain.
The friends thought that the only difficulty was finding a recipe for the tiles so that they would fire without defects. They planned to pick it up in a couple of months, and at the same time rent a room, buy a stove and start production.
In fact, the preparation took 10 months.
Registration of a legal entity
In June 2016, the girls opened an individual entrepreneur using a simplified taxation system. Costs - 5000 rubles.
We didn’t buy a cash register: the company works only with legal entities and individual entrepreneurs and receives money only into a current account, so a cash register is not needed. A bank account was opened for free, maintenance cost 1,500 rubles monthly. In the future, the girls are going to install an online cash register to serve individuals.
Room
The search for premises took 2 months.
Since production is not automated, the master does most of the work himself. Therefore, we were looking for a room with enough daylight and running water. Another requirement is a voltage of at least 380 volts, this is what the kiln requires. The ideal area of the premises is from 70 to 100 square meters, in order to divide it into office, warehouse and production parts, but without paying large utility bills.
On the city portal, the girls found an 80-meter room in the building of the Yekaterinburg Art Foundation. The rent cost 20,000 rubles per month, utilities were paid separately.
RUB 20,000
paid for the rent of a premises of 80 square meters. m. in Yekaterinburg
The room turned out to be large windows, running water and 380 volt sockets. The girls planned to install a stove in the center and use the rest of the space to work at the computer, mix materials, and store tiles and samples.
There was no need to renovate the premises - they just did some general cleaning. Then the friends bought shelves for products in Ikea, 3 work tables and 4 chairs, a chalkboard for notes and a kettle. The girls spent 27,000 rubles on furniture.
Materials
The friends were unable to find a clay recipe on their own and hired a technologist for a temporary job. The technologist experimented with clay for 8-12 hours a week; a month of her work cost 8,000 rubles. Salaries were paid from personal savings. The technologist spent four months selecting clay, glaze and firing modes. Having found the treasured recipe, the girls said goodbye to the technologist and continued working on their own.
The friends buy clay and glaze in St. Petersburg from the companies Brizcolor and Ceramics Gzhel - they have reasonable prices and a wide selection of glaze colors.
2460 R
the cost per square meter of the most expensive tiles at Mira Ceramics
For 1 square meter of tile it takes 1 kg of glaze and 20-30 kg of clay. The thicker the tile, the greater the material consumption. Together with delivery, 1 kg of clay costs 42 rubles, which means that for 1 square meter you need to purchase clay for 840-1260 rubles. The cost of glaze depends on the color and varies from 200 to 1200 rubles per kg.
As a result, a square meter of the most budget tile from Mira Ceramics costs 1,040 rubles, and the most expensive tile costs 2,460 rubles.
Firing and purchasing your own kiln
While the girls spent two months looking for premises, the tiles had to be fired in other industries. Friends brought the base for the clay tiles and paid for the firing. Up to 1 square meter of ceramic tiles were fired at a time, each firing cost 1,200 rubles.
The girls picked up the fired tiles after 2-3 days. At home, Olya applied glaze to the tiles and took them back for re-firing. Sometimes it was possible to negotiate and apply the coating on site immediately after firing.
Other productions did not particularly monitor the process and their oven settings often went wrong. If the tiles were fired in a kiln heated at least 10 degrees above 1170 °C, the product would deteriorate. If the products were left in the oven for an hour longer than necessary, then they also had to be thrown away. Girls received about 20% of rejects when the norm was 5-7%.
After the friends rented the premises, they began looking for a stove for their own production. Finished stoves from St. Petersburg cost 300 thousand rubles, and from Germany, from market leaders, 400 thousand. There was no such money, so through friends they found a local craftsman who made the stove for 110 thousand. The stove was without a passport, quality certificate or warranty card and looked less elegant. But a kiln from a Russian master solved the same problems as an imported one, and the quality of firing did not suffer. Unlike rented stoves, defects were no more than 8%.
110,000 R
spent on a kiln
In case of a breakdown, the technician promised to come and fix the problem within an hour after the call. The girls used this service twice when the oven was reset. In both cases, the repairman really arrived very quickly and fixed everything right away. German stoves would have to be sent to the manufacturer's factory or wait for a visit from a technician.
Products
The company currently produces ceramic tiles in 11 shapes and 48 colors. A square meter costs an average of 13,000 rubles.
Olya is responsible for the production of ceramic products. Her art education helps her come up with new tile shapes, colors and combinations thereof.
Most of the girl's forms were seen from Spanish manufacturers that set trends in the market. Complex shapes are popular: polyhedra, hexagons, rhombuses, triangles.
Another source of inspiration - design projects. Often friends are asked to make custom tiles. Olya makes a new mold, selects the glaze and temperature conditions for firing, and then this model remains in the company’s assortment.
Clients and promotion
The girls received their first order 10 months after registering a legal entity. It took so much time to find premises, experiment with stoves, create several collections and search for clients.
Today, the main clients are ceramic tile stores and designers. Former marketer Ksenia is looking for clients and negotiating. She uses cold calling and promotes the studio on Instagram and Facebook. On social networks, girls talk about new tile shapes and glaze colors, and publish photos of completed projects. Ksenia leads groups independently, and advertising costs 15,000 rubles per month.
So that clients could see the shapes of the tiles and colors, the girls made a website themselves. The experience of Lena, who had previously developed and promoted websites, helped with this. A domain name and hosting payment for 1 year cost 1,200 rubles. In addition to the website, products can be viewed in the company’s catalogs and in the workshop.
The girls do not do the delivery themselves - they have agreed with courier services and offer clients different options depending on the budget.
Market Features
The premium ceramic tile market is not familiar with domestic manufacturers. Ceramic tiles from Spain cost 2-2.5 times higher than Russian manufacturers. Delivery takes twice as long. But the client is ready to overpay only because he does not know the company from Russia.
To solve this problem, Ksyusha finds partners among ceramics stores. Over the course of a year and a half, she reached agreements with stores in 9 cities: Yekaterinburg, Moscow, Naberezhnye Chelny, Novosibirsk, Samara, Sochi, Rostov-on-Don, Tula and Ufa. They offer clients Mira Ceramics tiles at full price, and they themselves order them from the girls at a discount. The size of the discount for each partner is agreed upon during negotiations. The figure depends on competition in the city and potential demand for premium ceramics.
Another feature of the market is that customers take a long time to decide on a purchase - from 2 to 10 months. First, the designer shows the tiles to the customer in a kitchen or bathroom interior project, after approval, agrees on the cost and delivery time, and then forms an order. Because of this, it is difficult for girls to predict sales. It happens that they receive 5-7 requests from clients a month, and sometimes they receive none.
results
The company's turnover is inconsistent. In one month, girls can receive orders worth 20,000 rubles, and in the next - for 500,000 rubles. This is due to poorly forecasted demand for tiles.
Profit averages 156,000 rubles per month. The girls divide the money among themselves and leave part of the funds in the account to pay rent and utilities(27,000 rubles) in less profitable months.
156,000 R
average profit per month
In 2017, friends sold 23 m² of tiles per month. By the end of 2018, they want to sell 70 m² monthly and increase turnover to 900,000 rubles.
conclusions
Before starting, it is important to create a personal “safety cushion”. It is worth setting aside funds for 4-5 months so that there is no temptation to give up without having yet received a profit. In the first months, the studio did not bring any income to the girls, and money continued to go away: for rent, utility bills, and the purchase of materials. The friends thought about closing the production several times, but it helped that Ksyusha was supported by her husband, and Olya and Lena worked part-time.
To avoid conflicts within the team, you still need to agree “on shore” who is responsible for what. It is better to make a list on paper, have everyone sign it and hang it in a visible place. At Mira Ceramics, Ksyusha develops a partner network, Olya expands the range, and Lena monitors the fulfillment of orders.
To understand at the start what to improve or fix, an entrepreneur can go through all stages of the purchase himself. Ksyusha became one of the first clients of World of Ceramics. After this, the girls extended the tile production time in the contract by 2 weeks. Additional time will be needed if you have to eliminate defects or wait for the delivery of glaze.
If turnover is small or inconsistent, there is no need to hire full-time employees. It is more profitable to work with outsourcing companies or under a contract: specialists solve the assigned tasks, and the entrepreneur pays for the result. The friends agreed that as soon as the company’s turnover reaches 500,000 thousand rubles a month, they will hire an accountant, a loader, a marketer and an office manager. The girls will focus on global development tasks, and the turnover will shift to full-time employees.
Where to buy raw materials for tiles?
State assistance in business in this area.
Organization of a mini business, how to open a workshop:
Line for the production of ceramic tiles.
Personnel for mini production.
Finance and development:
Financial plan.
Profit and payback period.
Development and improvement of this business.
The production of ceramic products can be considered one of the most ancient crafts. And tiles remain one of the most popular ceramic products. The demand for this product is not decreasing at all long time, not only for its attractive appearance, but also for such properties as hygiene, increased wear resistance, strength and fire resistance.
Despite the centuries-old history of this product, the basics of making tiles are practically the same for each manufacturer. The only difference between a cheaper and more expensive product is the quality of the raw materials themselves. To figure out what type of materials were used to make the tiles, it’s enough to look at the finished product.
If there are small dots on the surface, single foreign inclusions, inhomogeneity of color and vagueness of the pattern, then for production of this sample tiles used materials of lower quality.
The main raw materials for the manufacture of ceramic tiles are the following elements:
1. Kaolin and clay are the main raw materials for making tiles;
2. Quartz sands - added to the main raw material to obtain the shrinkage effect;
3. Slags, nephelines, feldspars are fluxes that are used to obtain the effect of reducing the sintering temperature;
4. Superficial active substances, thinners, mechanically activating substances - these are special additives necessary for the manufacture of tiles.
The entire list of raw materials described above can be divided into the following groups:
1. Carbonate raw material - gives the fired product a glassy structure;
2. Quartz components - contribute to the formation of the “skeleton” of the tile;
3. Clay components - impart special plasticity to the mass, which makes it possible to subsequently obtain formed products.
Depending on the type of clay components used, the body of the manufactured tile may differ. It can be white, red or completely colorless. Ceramic tiles that have a red or brownish body are made from a special type of red clay. White tiles are obtained if you use kaolin. If you use several types of clay at the same time to make tiles, you can get a body with a gray tint.
It is important to note the fact that the color of the raw materials does not affect the quality of the final product at all. Of course, the cost of a tile with a white body may differ from the cost of a product with a red body, but only for commercial reasons. Namely, from the place of extraction of the product itself and the cost of its delivery. The only difference between the white case and the red one is that the former is made with more precise geometric dimensions.
If we talk about glazed tiles, the color is completely invisible under the glaze layer. But with an unglazed product, things are a little different. This tile is one color throughout its entire thickness. Therefore, the aesthetic properties of the final product directly depend on the quality of the selected raw materials. Therefore, special dyes are used to obtain the color of the tiles.
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Where to buy raw materials for tiles?
You can buy raw materials for making tiles both in our country and abroad. For example, kaolin is mined mainly in the UK, France and Germany. The quality of such material is, of course, excellent, but this will directly affect the final product and it will be more difficult to find a consumer. There are also clay deposits within our state. Which allow us to supply all production with high-quality raw materials, which are practically not inferior to their foreign counterparts. And its cost is much cheaper for both the manufacturer and the end consumer.
The quality of the clay is monitored by laboratories that use modern equipment in their work. That is why you don’t have to look far; all the necessary components for making ceramic tiles can be found within our state. To purchase the necessary raw materials for the manufacture of ceramic tiles, it is necessary to allocate about $6 thousand.
The process of producing ceramic tiles is quite simple. To make tiles, clay of various types is taken, with the addition of additional components, depending on its type and intended purpose. Using industrial equipment all components are pressed at high blood pressure with further firing in a special oven at a certain temperature.
Modern production involves several methods for making ceramic tiles, depending on the type of product required.
The main types are:
1. Bicottura - used for lining internal walls;
2. Monocottura - for cladding walls inside a building, for floors;
3. Monoporosis for facade cladding;
4. Clinker tiles for swimming pools, bathrooms, pilaf;
5. Cotto - for cladding facades;
6. Kiremic granite - for the floor.
The name Bikkotura refers to enameled ceramic tiles. It is classified as a low-strength product, therefore, it is most often used for interior wall decoration indoors. The manufacturing technology of this type of tile involves pressing and double firing.
During the first stage - this is pressing and primary firing - only the body of the tile is made. After this, specialists carry out linear measurements to adjust the product parameters. Samples that have incorrect parameters are sent as rejects for the production of second-grade tiles.
Tile standard sizes goes through a secondary firing stage, which helps to fix the enamel on the base of the tile. This layer not only gives the product aesthetic beauty, but also prevents destruction under the influence of moisture. The last stage of production is checking the product for defects and further packaging of the product.
Monocottura can be compared in some way to the type of tile described above, but in its production there is no re-firing stage. But this type is a more wear-resistant and impact-resistant product. To make it, a mixture of several types of clay with various necessary additives is used. The raw materials are mixed in drums to obtain a homogeneous mass and moistened. Then there is a stage of drying and further grinding of raw materials in professional vertical silos. The resulting mixture is transferred through a dispenser to a transport belt and sent to the mold. There, all raw materials are distributed over the entire area and shape of the stamping product.
The last step is to dry the tiles in a special chamber and apply a layer of enamel. Then the product is baked in an oven at a temperature of 1200 0C and the finished product is gradually cooled. After this stage, the tile acquires the necessary hardness and the enamel layer is fixed on the body of the product. All processes take place under the close control of modern equipment. After baking, the tiles are subjected to flaw detection and visual inspection. After this, the tiles are labeled and packaged.
Monoporosa is also a type of tile using a single firing step. Distinctive characteristic is the use of slightly different components in the manufacture of the product. This allows you to change the thickness of the tile and its physical properties. This manufacturing technology makes it possible to produce ceramic tiles big size and almost ideal shape and proportions.
This tile is additionally subjected to the technological process of ratification - this is the stage of additional processing of the edges of the product. It happens on special machines, where the edges of the product are cut. This stage allows you to make a product that has an ideal shape, which greatly facilitates the process of laying the product.
This type of clinker tile is made from heterogeneous types of clay with the addition of special oxidizing agents and dyes, as well as flux and fireclay. The product is formed by extrusion. This stage is carried out by pressing the finished semi-finished product through special extruders. The finished product has low porosity, due to which it acquires properties such as wear resistance and resistance to mechanical stress. The scope of application of this type of tile is floors, stairs, the bottom of pools and more.
Cotto tiles are also produced by extrusion. Its components are based on several types of natural clay. The main positive point of this variety tiles are its aesthetic qualities. Therefore, it is widely used for the reconstruction of buildings and premises, and for the construction of structures in the old style.
This type of tile, such as ceramic granite, is made from a mixture of white clay, quartz, feldspars and kaolin. This type tiles are classified as products that have increased mechanical resistance. The only thing is that the finished products do not differ at all in texture and appearance of the design. Most often, ceramic granite does not lend itself to the glazing stage. It is used for cladding facades of premises, as well as areas that may be subject to severe wear and tear during operation (floors, stairs).
Depending on the type of ceramic tiles that the enterprise intends to produce, the planned financial capital directly depends.
Video, ceramic tile production technology:
Today, polyurethane molds are widely used for the production of ceramic tiles. The growing tile industry is focused exclusively on high quality products. That is why today molds for tiles are made from polyurethane. Such forms imitate natural materials as much as possible (with the help of which tiles were previously made).
It often happens that manufacturers can produce various forms of tiles in limited quantities or produce them according to the consumer’s order. These can be either standard tile shapes (square, rectangle, square with rounded or beveled edges), or completely non-standard shapes for making tiles, made to order.
The following requirements apply to the forms:
1. Resistance to abrasives and alkalis;
2. High elasticity;
3. Resistance to fractures, deformation and tearing;
4. Possibility of carrying out a large number of technological cycles (most often more than 1000).
All the above requirements are met by polyurethane molds for the manufacture of ceramic tiles for both internal and external work. That is why tile manufacturers choose such modern and durable products.
State assistance in business in this area.
Today, many aspiring entrepreneurs can use state support. And for this, the country has provided a number of opportunities. This special programs assistance to young entrepreneurs, which includes several areas of support:
1. Subsidy;
2. Credit;
3. Property;
4. Training;
5. Export support.
Although there are many more applicants than the state assumes. Still, many have a chance to receive the desired support. You can consider support options in more detail.
First of all, this is financial assistance (subsidy or loan for small businesses). It can be used by a businessman who is already on the register of entrepreneurs (no more than two years ago). In this case, you may be a young businessman and have the right to support from the state. The amount of financial assistance for Moscow residents can be up to $7 thousand. For residents of the regions, this amount is about $4 thousand. All funds can be allocated to an entrepreneur only subject to co-financing. This means the need to simultaneously invest your hard-earned money into the project. Such funds give the right to use such as renting premises, equipping workplaces, purchasing equipment and more.
Additionally, the state offers to help with property. Most often, this is the provision of production space on a preferential basis, which is listed on the city’s balance sheet. For this purpose, the selected premises are offered to entrepreneurs on competitive terms. And rental rates in this case are much lower compared to market ones. The winner of such an auction receives the premises for use on special, preferential terms. It is important that having received the room in which you need to conduct renovation work, you can have full rights in co-financing.
The state also offers assistance in training. To understand the basics of the tile business you need professional education. And the state is ready to help. Such training can take place in the form of lectures, seminars, and legal consultations. It is important that such training is completely free and can help young businessmen master the basics entrepreneurial activity.
Additionally, government assistance may be provided to support exports. In this case, such government assistance may come in handy already at the graduation stages finished products and the possibility of its further sale. Most often, the state offers preferential terms for the export of manufactured products.
Below are real examples state aid:
1. Reimbursement of costs for participation in exhibition events;
2. Subsidy to compensate for all costs associated with paying interest on the loan and developing leasing of production equipment;
3. Subsidy to compensate for costs associated with the purchase or modernization of equipment;
4. Grants for young entrepreneurs to reimburse costs associated with the sale of goods or the provision of various services;
5. Subsidy for connection to electrical network and much more.
All of the above-described opportunities for receiving government assistance are on preferential terms.
To organize a business for manufacturing tiles, you need to rent a room of about 100-120 m2. This area will be enough to locate the necessary equipment, properly organize workplaces for staff, allocate space for storing raw materials and finished ceramic tiles, and also allocate a corner for office space. There is no need to make special requirements for the selection of this room. It's important to work well there ventilation system, and the room was dry to carry out comfortable conditions for storage of raw materials and materials.
The ceiling height can be from 3.5 to 4 meters. IN higher altitude walls are necessary. There is also a need for all communications: water, heating in winter, sewerage. It is important that the power line can withstand a voltage of 380 W for normal operation of the equipment.
There are also several mandatory requirements to the production premises where the production of ceramic tiles will be carried out:
1. The presence of opening sashes or vents in window openings for ventilation in the room;
2. The presence of several exits for the possibility of evacuating personnel in case of danger to life or health;
3. The roofs of the building itself must necessarily have perimeter fences with a height of at least 60 cm;
4. Roofs must be equipped special device for removal of precipitation;
5. Floors in production and warehouse must be smooth, several and necessarily of increased strength;
6. Personnel workplaces must be equipped with heat-protective mats;
7. The covering of walls and floors must allow for regular wet cleaning of the premises;
8. Industrial premises must be equipped with fire safety equipment.
The rental cost of such premises is about $220 per month. It is better to choose a premises far outside the city or in an industrial area.
Line for the production of ceramic tiles.
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To start a mini plant for the production of ceramic tiles, it is important to purchase the following equipment:
1. Concrete mixers.
This equipment allows you to evenly mix the source material for making tiles using special blades. This equipment comes in different sizes. For a mini-factory for the production of tiles, it is enough to purchase 2-3 concrete mixers costing about $560 each.
2. Vibrating machine.
The main purpose of this type of machine is to form future tiles from semi-finished products. The technological process for manufacturing tiles involves moving the main raw materials into special molds, where the product is formed under the influence of vibration. The cost of the vibrating machine is $5.5 thousand;
3. Furnaces for drying and firing the product.
The semi-finished tile is placed in a special oven for drying and subsequent removal of excess moisture. When purchasing this equipment, it is better to choose a furnace that uses hot air for drying. This stage adds strength finished product. The kilns are designed in the form of a tunnel. When ready tiles falls onto the conveyor, it is fired at more than 900 o C. The cost of the oven for drying and firing is about 1.7 thousand $;
4. Chamber for glazing tiles and applying designs.
Today, manufacturers of modern equipment offer a wide selection of special machines that are capable of applying a layer of glaze using the most various methods: bucket, cone, relief or spunbond. The choice of this equipment depends entirely on the allocated finances. The cost of such equipment starts from $1.2 thousand.
The above set of equipment can be considered the minimum for opening a mini tile manufacturing plant. But its cost is quite high - $10.1 thousand. If you want to offer consumers more unique products and make a profit not based on production volumes, then it will be necessary to purchase two more types of equipment for making tiles:
1. Upgraded sputtering chamber;
2. An additional set of stencils for applying a unique design.
In this case, another $6 thousand should be added to the total cost of the equipment.
It is important to note that it is best to choose the most automated equipment. But the cost of this will be higher. Alternatively, at the dawn of business development, you can give preference to partially mechanized labor. And only then, when you make a profit and develop your business, you can purchase more modern devices.
Video of what the equipment looks like full cycle, for the production of ceramic tiles:
Personnel for mini production.
Regarding the staff, 3-4 people are needed to organize the production process. They will be able to fully control production processes: mixing the solution, pouring into special molds, monitoring technological processes such as vibration pressing, drying and firing. Also, operators on the line will check received products for defects, reject non-standard products and package finished ceramic tiles.
There is no need to impose special requirements on operators. Experience in this field and a minimum amount of knowledge are sufficient. There is a need to hire a quality controller for manufactured products. The employee of this specification must have experience and knowledge in this field. There is also a need for a minimum number of auxiliary workers (1-2 people) to perform unloading and loading operations. For execution organizational issues You will need an accountant, manager, secretary. Wage The workforce is about $3 thousand.
The target audience for this type of business is all kinds of construction retail outlets and individuals. Therefore, to organize the marketing activities of a business in this area, you can use all advertising tools. First of all, this is creating your own web resource. An important point to get ahead of competitors is the constant promotion of the site.
Consumers can also be influenced through commercials on radio and television. Additionally, you can place advertising articles and publications in popular newspapers and magazines. Additionally, it is worth taking part in exhibitions and seminars. At such events you can not only advertise the ceramic tiles being produced, but also learn something new and interesting for your business. It wouldn’t hurt to go to similar foreign events, where you can learn about new tile manufacturing technologies and modern materials. Marketing activities should be approached with a special approach; it is even possible to entrust such work to a specialist in this industry. To promote your production as quickly as possible and get maximum profit. You must allocate at least $300 for marketing.
Sales of ceramic tiles.
There are several main consumers of ceramic tiles:
1. Individuals;
2. Companies offering construction or renovation services;
3. Construction markets;
4. Construction stores and supermarkets.
This is the main the target audience for the sale of ceramic tiles. As you know, it is most profitable to sell manufactured products to a wholesale buyer. And the higher the batch, the greater the profit for the company.
Financial plan.
To organize a mini-factory for the production of tiles, you need to invest next quantity funds:
1. Rental of production and office space- $220 per month;
2. Expenses for the purchase of equipment - $10.1 thousand;
3. Working capital with monthly payments - $3.5 thousand;
4. Permits for business development - $400;
5. Marketing activities - $300;
6. Workers’ salary - $3 thousand;
7. Raw materials and supplies - $6 thousand;
8. Taxes - $170;
9. Other expenses - $200.
The basic amount for investment is $24 thousand.
Profit and payback period.
The profitability of this production is about 45%. Every month a small enterprise can produce tiles worth $27 thousand. From this amount you can subtract monthly operating costs - $3.2 thousand. You also need to deduct variable costs in the amount of $12 thousand. The book profit from all sales is $13 thousand. Based on the data described above, the maximum profit of the enterprise can be $27.5 thousand. But, after deducting all expenses, the enterprise’s share remains about $8 thousand.
Based on practice, experts have proven that a mini plant for the production of ceramic tiles can fully recoup its initial investment within 12 months after the start of production. But this payback can only happen in cases of ideal circumstances. This is when all sales channels are fully functional and established from the first day of operation of the equipment. But, more often than not, young entrepreneurs may encounter a number of obstacles when developing a business in this area. This may be seasonal. After all, everyone knows that repair and construction work is most often carried out in the warm season. Therefore, it may happen that the production line may stagnate in the autumn and winter time. Therefore, to prevent this from happening to your production, it is important to start the production of ceramic tiles in spring time and invest the maximum amount of effort into developing marketing activities.
Business development.
To develop a business in this area, you can implement a project for the production of custom-made ceramic photo tiles. In total, to open the direction of manufacturing photographic tiles, you need to invest an additional amount of $4.8 thousand. This amount will include the purchase necessary equipment, raw materials and carrying out advertising activities. You can apply any design to this type of tile and instead of a regular tile you can get a bright and colorful panel. Phototiles have a number of advantages over standard tiles:
1. Possibility of applying any pattern;
2. High quality finished product;
3. Resistance of the pattern to abrasion;
4. Resistance to moisture and durability of the product.
The technology for making such tiles is quite simple. Modern tendencies allow you to apply a design by direct printing onto ceramic tiles using a special printer. Tiles are used for the future panel light shade. Its surface is cleaned and degreased. A layer of precoat varnish is applied using a spray gun.
Then the tiles are dried in an oven at a temperature of 150 °C. Next, the tile is taken to the table of a special printer. After applying the design, the product is dried again. The process itself takes no more than an hour.
To make tiles you need to purchase the following equipment:
1. Spray gun - $30;
2. Printer for printing on ceramics - $3.7 thousand;
3. Drying oven - $600;
4. Computer and special software - $450.
The company's services for the production of ceramic photo tiles require additional advertising. First of all, you can use radio advertising and create an Internet site for this.
Ideas for Business from the section:
Only subject to strict adherence to tile production technology can a high-quality product with high performance characteristics be obtained. Today, many domestic and foreign factories are engaged in the production of tiles. Despite the fact that the production of ceramic tiles is a rather complex technological process, some craftsmen make tiles at home. This is done not only for the purpose of saving, but also to obtain a unique product. We will talk about the production of tiles at home and in factories.
Necessary materials and equipment
To make ceramic tiles you will need the following materials:
- to maintain dimensions after drying, quartz sand is added to the product;
- to obtain the required viscosity of the sweep, a feldspathic and carbonate composition is required;
- an elastic mixture is obtained through the use of refractory or refractory clay;
During production tiles The following additives are used:
- Glaze is needed to improve the aesthetic characteristics of the product. Glazing the tile is also necessary to protect it.
- To increase plasticity and reduce shrinkage of the material, releasing additives are used.
- In order to reduce the melting point of clay, fluxes are added.
- The addition of engobe is needed for decorative processing ceramic product.
- To increase the porosity of the material, vapor-forming components are added.
The technology for manufacturing ceramic tiles at the factory involves the use of the following equipment:
- To seal cooked concrete mixture use a vibrating machine.
- A concrete mixer is used to prepare the clay mass and mix all the ingredients.
- The mold is needed to fill the mass and form a geometric product.
- The glaze is sprayed and the design is applied in special chambers.
- Drying of the formed products is carried out in an oven.
- Set of stencils for professional application drawing.
Attention! Some factories use multifunctional chambers in which designs and glazes are sprayed onto elements. Although this equipment is quite expensive, it quickly pays for itself.
Factory tile manufacturing technology
The technological scheme for the production of ceramic tiles implies the following stages:
- procurement of raw materials and production of mixtures;
- product molding;
- drying process;
- glazing of tiles;
- firing in special kilns;
- sorting.
Preparation of raw materials and molding of tiles
As can be seen from the technological diagram, the process of manufacturing ceramic tiles begins with the preparation of the mixture and the formation of products. This includes several stages of work:
- The clay is pre-crushed. The necessary components are added to it. They are thoroughly mixed until they have a homogeneous consistency. The percentage of the constituent components depends on the required characteristics of the future product.
- Before molding, the clay mass is wetted. The degree of wetting also depends on technical indicators finished tiles.
- Next, the prepared mass is poured into special molds. The tiles are pressed under high pressure (400 kg/cm²). The result is a dense and durable product.
Drying tiles and glazing them
Pre-drying during the production of tiles is necessary to remove excess moisture. If it is not removed before firing, the steam generated as a result of strong heating will destroy the product.
Glazing allows you to give the tile the desired color or shade. After firing, the glaze layer becomes as strong as glass. It turns out that the coating performs not only decorative, but also protective functions.
Kiln firing and sorting
The technology for producing ceramic tiles requires mandatory firing in a kiln at high temperatures. As a result of chemical reactions occurring in the material at high temperatures, the tile acquires its final operational and technical characteristics.
The temperature in the oven varies from 900 to 1300 degrees. The product moves in a tunnel where the ambient temperature gradually decreases. It is very important to protect the material from sudden changes in temperature, as this leads to deformation.
Important! During the sorting process, tiles with cracks, oversized elements and tiles with uneven thickness are rejected. Only after this the products are packaged.
Making tiles with your own hands
If you make ceramic tiles yourself, the manufacturing process includes the following steps:
- kneading clay mixture;
- raw material production;
- biscuit firing;
- decoration.
Mixture preparation and raw production
It is very important to choose the right clay. Clay with medium fat content is considered the best option, since it has good plasticity, which allows you to form a product of any configuration.
Important! When choosing oily clay, fireclay, pumice or sand are added to it. This will prevent the material from tearing during firing and will reduce the refractoriness of the raw material.
Making ceramic tiles at home takes place in the following sequence:
- First, all components are mixed, and the prepared mass is wrapped in polyethylene. This is done to completely exclude the access of oxygen. This way the raw material will better absorb moisture. Wrapping with polyethylene will protect against the formation air jams in the product, which will improve its quality.
- Molding is carried out in molds made of polyurethane or other material suitable for its characteristics.
- After pouring the mass into the mold, it is carefully leveled and compacted. During this process, make sure that the thickness of the product is the same over the entire area.
- Then the raw material is dried well. The readiness of the product for the next stage is indicated by its density and color. The raw material should brighten noticeably.
Firing and decoration
To obtain durable tiles, firing is carried out at high temperatures, but at home, the maximum that can be obtained is 850 degrees. The firing process is called biscuit due to the fact that the blanks shrink, which is taken into account when determining the dimensions of the future tile.
The quality of decoration depends on the level of the master. Usually they use drawings and ornaments. In any case, the product is covered with glaze, which is applied with a spray or brush. The method of dousing the workpiece is also sometimes used. To obtain a glossy shine, the tiles are coated with enamel or varnish.
Worth knowing! When re-firing after decoration, it is important to strictly observe the temperature. Exceeding its values will lead to cracking of the product.
Business plan for tile production
Do not think that the presence large number competitors in the tile production industry will make your business unprofitable. Having set up your own mini-production, you will be able to produce tiles of the same quality, but at an affordable price. This has always attracted consumers.
Let's calculate the upcoming expenses:
- Equipment for the production of ceramic tiles will cost $5,000.
- Purchasing the necessary materials will require a cost of $5,800.
- You will also need a multifunctional camera for spraying. It costs $1500.
- To purchase a set of stencils for professional tile decoration, you will have to allocate $300. The set includes 200 stencils.
- Also take into account the rental of space for placing equipment and carrying out the production process. These costs, together with electricity costs, will amount to $585.
- To pay the workers who will be involved in the production process, you will have to allocate $1,500.
- Also, don’t forget to include money for starting a business in your expenses. The amount is $750.
All of the above expenses are divided into two types:
- disposable (they amount to $7550);
- yours monthly expenses will amount to $7920.
To calculate expected profit, you need to know production volumes. Let's assume they are 5 thousand square meters. tiles If the price per square is $3.5, then the profit for the month will be $17,500. If you subtract monthly expenses from the amount received, then net profit will be $9580.
