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The
Process
Uniceramic
utilizes the process known as the Single Firing process
which is the most modern, effective and economical method
used by almost 90% of international producers. The entire
process can be summarized as follows:
1- Batch weighing and grinding, is where the materials
are weighed according to predetermined ratios and then
transported to intermittent ball mills where they are
mixed with water and ground to certain physical characteristics
and turned into a slip.
2- This slip is then homogenized and aged and sent to
a Spray dryer where the slip is turned into powder with
a specific grain size and moisture content. The dried
powder is then aged and stored.
3- The aged powder is then sent to high pressure hydraulic
presses where the powder is pressed under high pressure
and formed to the required green size.
4- The pressed tiles are then dried in dryers at 120
deg C and transported to glazing lines where we apply
a coat of glaze (the glaze itself would have been prepared
in a separate section. The tiles here take on the basic
glaze desired glaze and then the tiles are decorated
using either a traditional silk screen methods or the
random NATURAL DESIGNS USING a laser engraved cylinder
method.
5- The glazed and decorated green tiles are then fired
in high temperature kilns to the desired finished product
specifications as either a wall or floor tile.
6- The fired tile is then taken to a sorting department
where it is sorted by operators for visual defects and
classified as first, second and third choice or rejects
as defects, then the computer takes over to classify
the tiles according to the caliber and planarity where
the first choice is sorted to various calibers. All
of this is done according to international standards
and in particular EN, BS, and ISO standards.
7- Finally the tiles are automatically palletized. Full
pallets are further subjected to a quality audit and
are either accepted to be sent to the warehouse or held
to be 100% resorted.
8- Uniceramic's production process is subjected to a
rigorous process control at each stage of the production
in order to guarantee a final product that conforms
with the international standards.
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