Mould Preparation Department
This department is the heart of the sanitarywares manufacturing plant. The mould is made up of POP material which is used to mould or we can say, to make shape of sanitarywares. The experienced designer invents the new designs for the market need. These designs are than approved by the upper management with required changes. After approval the special team makes master/mother mould of that design, this mother mould is than used to create moulds that are used to create sanitary wares pieces.
This is the begging process of sanitarywares manufacturing. The body of sanitarywares
is highly vitreous than the other ceramic products so the selected high quality
raw materials are procured from Rajasthan, Kutch, Bikaner clay and many other places
that are used to prepare the body of sanitarywares. The main materials that are
used in slip house are Feldspar, Quartz, Talc, China Clay, ball clay, Soda & Silicate.
These materials are mixed in the required proportion with the proper proportion of water in to the cylindrical grinding ball mills installed with ceramic lining bricks & containing ceramic pebbles which is rotated up to six hours to properly mix-up & grinding all the clays & powders with water and it forms the liquid slurry called as slip. This Slip is than sieved in double layer vibrator sieve and passed through magnets to remove any impurities and iron particles, than the slip is stored in to the underground storage tanks. There are nine storage tanks each of capacity of sixty tons, to keep stock of slip. This slip is stored about three days in storage tank this process is called as aging process. In storage tanks low speed sturers are rotating to prevent the settling of the suspended solid particles and to maintain the fluid properties of slip intact. This is required to make high quality vitreous body. After aging process the slip is pumped from the storage tank to the casting area of the unit called as Casting Department by hydraulic pump.
Casting department actually make sanitarywares to look in its actual shape from
the slip. The main process include in this department is the slip is pumped from
slip house through the pipes and than this slip is used to charge the mould of appropriate
shape. These moulds are made up of POP material which absorbs the water from the
slip to form a shape of sanitarywares. This process takes six to eight hours depending
upon the shape & size of sanitarywares. Than this green piece of sanitarywares are
detached from mould and again kept about six days to dry completely.
The casting department use two type of casting techniques one is Bench Casting & other one is Battery Casting. In bench casting method, the casting is done manually one by one for each piece of sanitarywares that require more time up to drying a green piece. In Battery Casting method process of casting is done by the pumping the slip in to the array of mould specially made for battery casting by applying compressed air. This method dramatically reduces the casting time, and consumes less labor. Battery casting method is used to take faster production, but the drawback of this method is that it can produce only selected shapes of sanitarywares. So we are using both type of method depending upon the shapes to produce. After casting the sanitarywares green pieces, it is kept for six days for dying process. Than it is moved to green piece stock department or we can say checking department.
After casting, the surface of green piece of sanitarywares is rough. In this department surface of green sanitarywares piece is smoothen with the help of dusters and finishers, the pieces are prepared for the final checking. During checking process the specially trained workers inspect the green piece for any damages, cracks or pinholes or any impurities by applying kerosene. Some defects that are visible only after firing, so this department require high accuracy to check the green pieces to reduce finished goods rejection. After checking process these green pieces are moved to glazing department.
This department internally does two separate processes that are very imported for
sanitary wares manufacturing. The first one is to prepare glaze of sanitarywares
which is nothing but the outer coating or we can say color of sanitarywares The
preparation of glaze is similar to the slip preparation but the materials are used
for glaze are of very highest fineness & costly. This is very sensitive area that’s
why all the activity on preparing the glaze is done under the continuous watch of
laboratory technicians. All the raw materials are tested according to the European
norms. The prepared glaze is than passed through the high power magnets to remove
the iron particles three or four times and stored in Stainless Steel container.
The second process is to color the green piece of sanitarywares with the glaze prepared according to the market needs. This process again very important because special trained workers can only spray the glaze on the surface of sanitary wares using the air pressure spray gun from the SS tank. The sanitarywares after glazing is ready for the final firing process.
For this process the firing, the kiln is used. This kiln is heated up to 1200 deg centigrade at the center of the kiln length and gradually the temperatures are lowered down towards the entry & the exit of the kiln. The liquidities natural gas is used as fuel for the kiln for firing. The glazed sanitarywares are placed in special trolley that is made up of refractory material. This trolley than pushed inside the kiln using automatic hydraulic pusher, it starts getting heated gradually starting from the lower temperatures like 100 deg c & above. This zone of the kiln is termed as pre heating zone. As the sanitarywares reaches the center of the kiln, it is heated at the peak temperature up to 1200 deg c. This zone of the kiln is termed as firing zone. And after the firing zone sanitarywares is once again gradually cooled down in the direction of the exit of kiln. This zone of the kiln is termed as cooling zone. The finished sanitarywares is ready as it comes out from the kiln. Now the Finished sanitarywares kept about five hour for cooling, after sanitarywares get cooled it is moved to Sorting Department.
The finished sanitarywares are sorted in prescribed grades & checked for any damages before packing. All the sorted pieces of sanitary wares are packed in corrugated boxes and grass packing according to market need, and stored in Godown item wised. Now as per the market orders the available stock is ready for loading and dispatching to the truck or container.