Sanitary ware plays a vital role in kitchens and washrooms. The sanitary wares fulfill our basic and daily needs. It would have been impossible to have high-quality toilets without sanitary wares. Sanitary wares are nothing but appliances used in kitchens and washrooms.
About the Sanitary ware Manufacturers
The Sanitary ware company India produces products that comply with international standards such as ISO 9001:2008. The best manufacturers concentrate on the quality parameters from raw material selection to each process to provide the best quality sanitary wares.
The raw materials used in the production process of sanitary wares are China clay, felspar, ball clay, quads, white prepared pigments, and more. The glaze is also prepared using high-quality raw materials to get pure snow-white colors with the best texture.
The Sanitary ware Company India uses equipment in the production processes like high-speed blenders, body slip storage which provides more plasticity naturally, and others.
The working molds are made using high-quality VOP material from raising mother molds which provide sharp edges and good finishing quality. Along with the traditional batch casting, they have battery casting lines that provide green casting. All working molds must be carefully prepared and inspected daily.
But, have you ever wondered how these sanitary wares are made and what all the processes are involved in making sanitary wares?
The sanitary wares are made from a mixture of clay and other minerals like granite, sand, white clay, Ball clay, and various other minerals.
There are eight steps in the Sanitary ware Manufacturing Process,
1. Minerals mixed in Rotating Mills
The minerals are mixed in rotating mills in carefully controlled amounts. The raw materials are still rough at the initial stage—an ascent to large rotating mills where water and other minerals are added. As the vast mills turn the particles and are ground up into an excellent powder, a watery liquid clay mixture is produced.
2. Huge tanks
These huge tanks are bottomless and store the liquid clay mixture used to make the sanitary appliances. These machines are automatic, and they utilize high-pressure casting technology, which reduces the size of sanitary appliances.
3. Molding process
The pieces of the resin mold are closed and held in place with hydraulic pressure as the top section fits into the rest of the mold, and an airtight joint is created. The ceramic liquid is being prepared in the vast tanks drawn from the storage tanks or huge tanks.
It is sent to the molding machine through a series of pipes and pumped into each mold. The molding process is entirely computer-controlled.
Inside the mold, the water is forced from the liquid clay through the porous Risen mold leaving behind the solid material. As this process proceeds, the layer formed on the mold surface increases in thickness.
Once the required wall thickness is achieved, the excess liquid is drained and recycled to the storage tanks. Next, air at high pressure is used to drain water from the continuous layer in the hardening phase.
4. The casting process
The casting process is computer-controlled, with different settings being entered into the computer for the various appliance designs and sizes that the company produces.
The casting machine is opened, and the sanitary appliance can be seen. It is soft at this stage, and it is handled with great care. As it is removed from the mold, the mold is washed and cleaned in an entirely automated process.
These techniques are used to manufacture ceramic sanitary appliances that are in demand all over the world.
5. Suction Action
A suction action occurs within the machine that holds the products firmly in place when the machine opens to not fall out of the place and be damaged. The worker in the company can switch off the suction, and the molded piece can be removed. After removing it from the machine, the products are soft as the clay and are still wet.
6. Drying tunnel
Then the products are left to air dry about 10 hours before being stacked onto a trolley and fed into a drying tunnel. They spend 12 hours in the dryer, where they are dried at a temperature of 65 degrees Centigrade to remove moisture from the clay.
7. Processed in a pneumatic lift
Since the products are heavy, the company is fitted with a pneumatic lift to enable the workers to move the product around with minimal effort. The entire unit is smoothed off using a scouring pad to remove any rough edges and create a perfectly smooth surface.
This process is done in a unique vacuum workstation. The vacuum at the top of the unit draws the dust away from the work surface. When the technician is satisfied that the product is perfect, he blows off all the excess dust removed by the vacuum.
8. Blazing stage
The products are now ready to pass into the blazing stage, where they will be sprayed with a liquid glaze that will eventually provide a glass-like structure, which is extremely hard and smooth.
Glazing occurs in two stages – in the first stage, a robot applies glaze to the product, and the excess clay is drained. Then it moves to the next stage, where a spraying robot sprays the outside of the piece.
The spray robot is a self-learning robot. The products are sprayed on my hands, and the robot learns the movements of the human sprayers. These movements are consistently repeated for each unit to ensure consistent results.
The units are loaded into cone cars and made ready to move into a second firing tunnel. Each car will spend 12 hours in the kiln, where the units will reach a temperature of 1200 degrees centigrade to melt the glaze and rectify the ceramic body. The ceramic units come out of the other side of the tunnel with a gleaming appearance and a tough finish.
Thus, the sanitary wares are now ready to the marketplace and supplied as separate units or complete sets.
Conclusion
We hope you would have understood the manufacturing process of the Sanitary wares. It is also essential to know about the manufacturing process before using it. Thus, Sanitary ware Company India uses various things to provide us with the best quality products.
