How Vitrified Tiles are Made?

 Creating vitrified tiles requires highly specialized and painstakingly precise equipment and processes, but the results are well worth it. These tiles are created by melting, cooling, and re-heating ceramics at incredibly high temperatures without allowing oxygen to get inside the material, which gives them their special durability and strength.

Making vitrified tiles is a complicated process. It requires many steps, and there’s lots of room for things to go wrong along the way. To ensure that your tiles come out properly, you need to be especially careful throughout every step of production.

Clay composition

clays contain a high percentage of silicon, which will expand when heated. In addition to silica compounds, clays also contain variable amounts of aluminium, iron and other materials. As an example, sodium is a component of common clay rocks such as kaolinite. Aluminium occurs in many forms such as brucite or gibbsite.

Kiln

A kiln is a heated chamber with an opening to allow heat and material in, and a similar opening to allow products out. It also has controls that monitor and regulate temperatures. A typical kiln operates between 1500°F (815°C) and 2250°F (1260°C). Most vitrified tiles are made using a kiln of some sort, often an electric or gas-fired one.

Grinding and sieving

The first step in vitrification of tiles is grinding. The powder is sieved to remove any large particles, then it is mixed with a binder solution. It is then pressed into moulds and dried using heat or air. The process finishes by applying surface treatments that enhance their appearance. This may involve painting, polishing or coating with materials such as glaze, ceramic colours or metal oxides.

Drying

After any excess liquid has been removed from your porcelain tile, it’s ready to dry. This is done by placing your tile on wooden pallets and leaving it in a well-ventilated area for a few days. Because of its high level of natural moisture, avoid placing wet tile near an air conditioning unit; doing so can result in condensation, which will eventually freeze and shatter your tile upon defrosting.

Smoothing and polishing

The smoothing and polishing of vitrified tiles is relatively easy, as they have already been ground smooth in a granite-crushing plant. However, polishing should still be done thoroughly to ensure that scratches or defects don’t appear over time. Companies typically polish their own tiles for aesthetics, although some professional tile installers offer these services as well. Before you buy vitrified tiles, ask your supplier how smooth their tiles will be after polishing.

Finishing with enamel glaze

Once tiles have been vitrified and fired, they will be glazed with an enamel. Enamel is a hardened material that prevents water from seeping into and damaging tiles or their grout. It can also add color to your tiles, in addition to protecting them. Enamels come in many colors, including white, black, blue and yellow. Red and green enamels are also available but will wear off more quickly than others do due to chlorine content in swimming pools.

Cutting to shape

First, a clay mould is made of a thin sheet of fibreglass and polyester resin. The clay mould will be used to shape or form a thin sheet of ceramics that is an exact replica of what will eventually become a vitrified tile. Once it’s formed, holes are cut into it, so liquid can be poured in. At about 1200 degrees Fahrenheit, solid tiles are then removed from each hole. Excess material is melted down and reused; vitrified tiles undergo minimal waste once they’re created.

Quality control

The quality of your tiles depends on several factors including raw materials, pigments, technology and production processes. Quality control is a very important part of tile manufacturing process as it ensures that each tile meets industry standards. There are two different types of quality control tests performed in tile manufacturing plants – final inspection and internal inspections.

If you are looking for tiles manufacturer in India, consider Wintel Vitrified.