How Ceramic tiles are Made: 5-step Process

Tiles are an intrinsic part of our interiors. They can uplift any space out of its mundanity, be it your residential or commercial spaces. We can see them all around us; your bathrooms, kitchens, living spaces, floors, walls & decor.

You might be surprised to know that tiles have been around us since the Egyptian period. The first glazed tile was used in the Step Pyramid in Egypt, which was built around 2600 BC. Since then, tiles have found their way through the Roman, Turkish, and Victorian eras to today’s modern world.

So, what are Ceramic tiles?

Ceramic tiles are made from raw minerals like kaolin, bentonite, sand, feldspar, and glass. They are visually appealing and are highly functional too. They are durable and resistant to fire, scratch and moisture along with being a natural & sustainable material.

There are two types of tiles: glazed and unglazed. Glazed tiles receive a coloured surface when fired. Unglazed tiles get their colour from either the clay itself, or from additives such as dye, pigment, or oxides.

But little do we know about how they are manufactured. Knowing what goes into crafting a ceramic tile will help you make better decisions when you are choosing the perfect tiles for your projects.

There are 5 major steps in the ceramic tile manufacturing process- Raw material preparation, molding, drying, glazing & firing. Let’s understand each step in detail:

1) Raw material Preparation: The journey of a tile begins with raw material preparation i.e. clay. Clays are natural materials which may vary based on the regions of extraction. The type of clay used impacts the workability, color, texture, density, and porosity of tiles.

The clay mineral is mined and other minerals like feldspar, bentonite & glass are also added to it.

The raw clay is further ground into finer particles through a wet milling process. Water is added to the mixture and a slurry-like material is formed. The water is removed followed by spray drying.

The final raw material is clay granulate, and is called atomized clay. It has a fluid consistency as compared to raw clay.

2) Molding: The atomized clay powder is loaded into molds (here is where the ?uidity of the atomized clay plays an important role) and it is pressed by large hydraulic presses to form what is called the bisque. The physical dimensions of the tile depend on the characteristics of the mold used.

3) Drying: The bisques are quite fragile and should undergo further drying. This process is usually carried out in either vertical or horizontal dryers (small kilns).

4) Glazing: The bisque or ceramic tile is then decorated in the glazing lines. Glazing lines can contain more than 50 different machines and can be up to 50m long, sometimes even more.

But what is Glaze?

A glaze is a substance made of glass that is intended to melt onto the tile's surface during firing and bind to the tile's surface after cooling. They add various colours or create unique surfaces on the tiles and are used for decoration.

With modern technology, glazing printers can print ceramic tiles with a large array of colours, patterns and decorations. The different glaze applications determine the style, colour, surface and characteristics of the tile.

There can be tiles that do not go through this process and are unglazed.

5) Firing: The tiles are subjected to intense heat to strengthen them and give them the desired porosity. This is done through single kiln firing.

Kilns are large horizontal ovens with usually a single plane of rollers that move in one direction. Each type of clay and tile follows a different temperature curve inside the kiln. The temperature at which tiles are fired impacts the color and hardness of the produced tile. A hardened and ?nished tile is formed after several physical and chemical reactions inside the kiln. Most notably, the glaze fuses and hardens on top of the tile.

Ceramic tiles have a rich history and still are a popular choice to build exquisite residential & commercial spaces. A wide variety of colors, designs, affordability, brilliant aesthetics and improved functionality such as anti-skid or stain-resistant tiles have made it a top material choice for interior designers and architects across the world.

The world of tiles is vast and we at Aryan Tiles are here to navigate you through all your queries. Connect with us to explore various tiles, designs, colors, and textures and get exclusive prices for your projects now!