How Porcelain Stoneware is Produced

How Porcelain Stoneware is Produced

Porcelain stoneware tiles are produced using noble clays

In a nutshell, porcelain stoneware tiles are produced using
atomized noble clays that are pressed and then fired at a very high
temperature (over 1,200°C)

FROM CLAYS TO ATOMIZED BODY
The first stage of the process involves the preparation of raw materials that
are crushed into powders at appropriate grain sizes.
These clays are ground by mixing them with water and obtaining,
first, the so-called ceramic slip which is then "atomized" and
which will yield a powder with grain size and moisture suitable for
pressing (so-called "atomized dough").
The resulting atomized paste has several components:
A plastic component (clay, kaolin) that aids workability;
imparts cohesion and solidity; is responsible for the shape of the new compounds
during firing; imparts coloring.
An inert component (silica, chamotte) that decreases plasticity; may
contribute to the formation of the glassy phase and new compounds; forms
the skeleton of the ceramic.
A melting and vitrifying component (feldspars, carbonate rocks) that
decreases plasticity and porosity; lowers melting temperature;
contributes to mechanical strength.

DIFFERENCES BETWEEN RAW MATERIALS
Raw materials differ from each other based on purity, size of the
particles and reactivity.
The presence of impurities affects the properties of the future stoneware tile.
These include:
- absorption and frost resistance
- mechanical strength
- resistance to breakage
- wear resistance
A very pure material also affects the aesthetics of the tile, the
transparency and depth of the glazes, the reflection of light, the quality
of the graphics and the definition of the structure. Finally, it should be noted that
the workability of the tile is also a function of the quality and purity of the
clays: cuts and holes are all the more precise and easier to make (without risk of
breakage) on ceramic products obtained from pure raw materials.