Analysis of ceramic toilet manufacturing process
Time:
2025-04-10
This document analyzes the ceramic toilet manufacturing process, which includes seven main stages: raw material preparation, ball mill pulping, high-pressure grouting molding, body finishing, glaze preparation and application, high-temperature firing, and performance testing. Key steps involve precise material mixing, intelligent grouting systems, robotic trimming and glazing, and controlled firing in a roller kiln. Energy efficiency is enhanced through waste heat recovery, and final products undergo rigorous testing for flushing, water absorption, and load resistance.
Analysis of ceramic toilet manufacturing process
As the core product of modern bathroom, ceramic toilet integrates material science, process aesthetics and precision manufacturing technology. The process can be divided into seven stages, which requires more than 40 processes and takes 5-7 days to complete. This paper analyzes the key process nodes from the Angle of industrial production.
First, raw material preparation
Formula design
Kaolin (40%-50%), quartz sand (20%-30%), feldspar (15%-25%) and trace additives are used to form the body formula, which needs to meet the requirements of strength and shrinkage under high temperature sintering at 1260-1280℃.
Ball mill pulping
After the raw material is coarse crushed by the jaw crusher, it enters the wet ball mill for 18-22 hours, and the fineness of the slurry is controlled at 0.5-1.0% sieve allowance and the moisture content is 32-35%.
Second, high pressure grouting molding
Resin mold preparation
Using CNC engraving mold, turning polyurethane resin mold, cavity accuracy error ≤0.3mm. The mold design should reserve 1.15-1.18 times the firing shrinkage compensation amount.
Intelligent grouting system
After vacuum degassing, the slurry is injected into the mold under pressure of 0.6-0.8MPa. Using the pipe grouting system, the grouting time of single piece is controlled in 3-5 minutes, and the thickness of billet is monitored by pressure sensor in real time.
Third, body finishing
Robot repair
The six-axis mechanical arm is equipped with a diamond cutter, and the key parts such as blank mouth and blowdown pipe are trimmed according to the preset program, and the dimensional tolerance is controlled within ±0.5mm.
Microwave drying
The billet is subjected to gradient drying for 4-6 hours in the microwave drying room, and the humidity is gradually reduced from 80% to 15% to avoid cracking and deformation.
Fourth, glaze preparation and glaze application
Milky glaze formula
It is composed of zirconium silicate (8-12%), kaolin, frit and suspension agent, whiteness ≥85%, expansion coefficient matching with the billet (α=6.5×10⁻⁶/℃).
Robot glazing
Using a 3D visual positioning system, the manipulator sprays the bottom glaze (thickness 0.3-0.5mm) and the top glaze (0.1-0.2mm) with a precision of 0.3mm, and the glaze utilization rate is increased to 92%.
Fifth, high temperature burning
Roller kiln firing
The billet is burned in 120 meters roller kiln for 20 hours, and the key temperature zone is controlled:
Preheating zone (200-600℃) : organic oxidation
Vitrified zone (1180-1250℃) : Mullite crystal formation
Quench zone (800-500℃) : quartz crystal conversion control
Energy efficiency management
With the use of waste heat recovery system, the gas consumption is reduced to 1.2m³/ piece, and the firing qualification rate is ≥98%.
Sixth, Performance test
Flushing test: Complete ≥800 flushing cycles under 5kPa water pressure
Water absorption detection: boiling method determination ≤0.5%
Load test: static load 500kg for 24 hours without deformation
Related information
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