Clay conditioning without souring

By Jonathan Savage 20. July 2017

The first process required to begin the production of clay bricks or roof tiles is to make available the raw materials required for the process. The major material used in manufacture are clays and as such brickworks will have been built as close to a clay quarry as possible although some clays are still trucked in to aid in varying colours and technical characteristics.

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Temaer: Structural

Clay formulation improvement for a better decorative tile production

By Miguel Ten 13. July 2017

Clay body formulation has been in a continuous evolution since the modern-day tile industry trended towards large and more aesthetic in appearance. This evolution is calling for adjustments to achieve required performances whilst optimizing production costs.

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Temaer: Decorative

How to reduce breakage and rejection in the manufacturing of bricks and rooftiles

By Jack Pongdet 6. July 2017

Breakage and rejection are two of the most common problems in ceramic manufacturing processes and It can come from a wide range of issues. Most  ceramic manufacturers try to reduce  their breakage and rejection as low as possible because small defect in a ceramic product can devalue the  product by more than 50% or even mean a loss for a premium grade producer.

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Temaer: Structural

Porcelain tile manufacturing: How to reduce breakage

By Yaiza Paños 29. June 2017

The video underneath shows an Indonesian factory producing large porcelain tiles. These white body tiles measure 120cmx60cm and, as you can see, due to its large size and thinness, they break easily during the production process, especially in those plants where layout imposes direction and/or level changes. Breakages and cracks are usual and happen for several reasons. The good news is that there are also various ways to deal with them. In the video, adding additives was the most effective way to mitigate this breakage rate.

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Temaer: Decorative

Eliminating cracks in your brick production: not as difficult as you think.

By Bill Daidone 22. June 2017

Drying is one of the most critical parts of making quality brick. There are a number of things that can be done to improve drying and reduce drying defects. In order to reduce cracking there needs to be an understanding of the drying process and understanding of the brick body that is being dried. 

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Temaer: Structural, Refractory

Decorative tiles from low plasticity clays: How to overcome challenges and keep high quality?

By Miguel Ten 15. June 2017

The clay does not last forever and, with limited deposits and high market demands, the best clay is very expensive. Add to that the conflict in Crimea, where the Russian occupation has choked the supply of cheap Ukrainian high-quality clay, and you face a situation where lack of supply has caused the raw material prices to increase five times since the manufacturers started using it. This is, of course, critical for the industry, but the forward leaning manufacturers go looking for alternative sources.

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Temaer: Decorative, Plasticity, case study

How to reduce waste material during brick production?

By Jonathan Savage 8. June 2017

All brick and tile manufacturers strive for the elusive 100% yields, but in reality, the norm is anywhere from circa 50% upwards depending upon raw materials, products being produced and processes. These losses have been seen to occur in the extruding/moulding of the clay products, during the drying and firing processes and throughout all handling stages of production.

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Temaer: Structural

4 cost effective ways to improve Ceramic Green Strength

By Miguel Ten 30. May 2017

Having a less fragile clay body after the tile is pressed is not only down to buying expensive high plasticity clay. There are workarounds to increase the Ceramic Green Strength without emptying your pockets. Read on to find a solution that fits your production.

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Temaer: Decorative, Green Strength

Brick and roof tile manufacturing with less water involved

By Jonathan Savage 23. May 2017

Various amounts of water are added within brick and tile manufacturing depending upon which process route you choose. A stiff extrusion may have water content as low as 10% while a soft mud factory may be as high as 30%. With hand made and water-struck products, this water addition value may even go higher. However, although these levels of water may be advantageous for manufacturing, they still require to be driven out during the drying process to enable the products to be fired.

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Temaer: Structural, Clay additives

How to avoid tile Breakage when producing large and thin tiles

By Miguel Ten 16. May 2017

Market trends are not easy to predict, but sometimes they are even difficult to evaluate in hindsight. The popularity of large ceramic tiles was initially a result of creative Italian producers experimenting with their product. Why they became so popular is still subject to discussions, but their impact on the market means that manufacturers need to adjust their business models to be competitive.

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Temaer: Decorative

BioKeramAdditive-A

A blog from BioKeram

BioKeram is a new range of products from Borregaard, the world's leading supplier of high performance bipolymers to the ceramics industry, with more than 50 years experience in the ceramics market. With this blog we aim to share our knowledge regarding ceramic process optimization.


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