Today, there’s a good chance you’ll find a ceramic basin when you step into any bathroom. But why are these fixtures a favorite over other materials? The answer is simple—ceramic basins are built to last and offer a timeless appeal. That one aside, have you ever stopped to wonder how that beautiful ceramic basin in your bathroom came to be? It might look simple, but there’s a fascinating journey behind its creation.
In today’s blog post, Cleanman Sanitary Ware explains the ceramic basin manufacturing process in clear and easy-to-understand steps. Read on to learn how ceramic basins are manufactured.
Step 1: Mixing the Raw Materials
The manufacturing process begins with mixing silica, ball clay, and kaolin. These are the primary raw materials used in making ceramic basins. Each one of these materials has its own unique properties. Silica is added to enhance the overall strength and durability of ceramics. It also contributes to their glassy and smooth finish. Ball clay is highly plastic and boasts excellent moldability and workability when mixed with water. Manufacturers use it as a binding agent in the production of ceramics. Kaolin, which is a type of clay mineral, is added to the mixture for whiteness. The three components are mixed with water to form a thick, creamy foundation for the basin.
Step 2: Shaping
Now comes the fun part – shaping. There are two main methods manufacturers use to shape the thick, creamy mixture. The first method is casting, whereby the liquid mixture is poured into a mold, allowing it to fill the space and take on the shape of the mold’s interior. The mold is usually coated with a release agent to facilitate the removal of the cast piece later. After filling the mold, the slip is left to dry and form a layer against the mold surface. The drying process is carefully controlled to prevent cracking and ensure uniform thickness. The second method is pressing. The technicians use powerful machines to press the clay mixture into molds. This process is important as it ensures consistent shapes and thickness. This method is commonly employed for creating relatively simple-shaped ceramic basins.
Once the initial shape is formed, it’s time for some fine-tuning. Skilled technicians remove any imperfections and ensure the basin’s edges and curves are smooth and flawless.
Step 3: Drying Out
The freshly molded basins need time to dry. The basins are slowly dried in controlled environments to allow the moisture to escape evenly and prevent cracking. This stage also allows the clay to firm up and take on its intended shape. Patience is key here to ensure the basins are ready for the next step, which is bisque firing. Here, the dried basins are hardened in the kiln in preparation for glazing.
Step 4: Glazing
As the name implies, this is where ceramic basins get their shine. In this stage, technicians apply a thin layer of glaze, a glass-like mixture, to add a beautiful shine to the basins and make them waterproof and easy to clean. The glaze adds a smooth finish to the basins, making them resistant to stains and enhancing their overall appeal.
Step 6: Firing
After they’ve been glazed, the basins are loaded into giant kilns and fired at incredibly high temperatures. This intense heat fuses the clay with the glaze. Firing makes the basins incredibly strong and durable. This step is crucial to ensure the basins are robust, glossy, and ready to withstand the daily rigors of the bathroom.
Step 7: Quality Checks
This is the final step before the basins are released into the market. The experts inspect each basin for any blemishes, cracks, or imperfections, ensuring that only top-notch basins with flawless finishes make it to the market.
There you have it. This is the simple ceramic basin manufacturing process. If you’re looking for a trusted sanitary ware manufacturer that produces ceramic basins wholesale, get in touch with Cleanman Sanitary Ware.
