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How Are Ceramics Made? JOMOO Factory Gives You the Answer!

Tue Aug 17 16:05:53 CST 2021 130Hits

Wash basins, toilets, bathtubs, you probably use those things every day. Have you ever wondered how on earth are those shiny, silky ceramic products made?” If you have, now it is time to reveal the answer. Let us dive into JOMOO Smart Ceramic Sanitary Ware Factory and see how ceramics work!


JOMOO Smart Ceramic Factory, one of the leading smart factories in the industry. Intelligent production is incorporated with the Internet of Things, Cloud Technology and Big Data. The company takes pride in its 5G cloud system that manages and keeps tracks of all stages of the production process, statistics, logistics, quality control, and packaging. 


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In total, there are 28 processes (we are not going to specify each one of them here), and it all begins with this - a powdered clay, which is a mixture of 13 kinds of raw materials. Key components are quartz, known for their good chemical and thermal stability. These raw materials provide special smoothness of the products, low water absorption, and make an excellent glaze, which makes toilets impermeable.

 

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The water is added to the powder mix and then stirred together in these large cisterns. The mixture is then sent to the next stage, where the bigger particles are being separated through industrial sieves, and the clay is stirred again until it's completely homogenous.

When the clay is ready, it is transported to the molding machines by a pipeline. The factory's layout was designed in the most efficient for the production line way.

The toilets come out of the molds and each piece is carefully checked. At this state their moisture content is quite high and the product is very pliable. It is air drying that hardens them, so they are placed in special chambers for 40 hours until the moisture level is low. They are manually checked after drying too.

 

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Robots transport the toilet bodies to the glazing area. The glazing is done automatically by these self-learning robots. They learn the movements off the human sprayer. They spray on the glaze on the toilets' surface top to bottom, in several layers. But not only the outside of the toilet gets glazed, the inside traps gets glazing too! It makes the inner surface smooth which enhances flushing system efficiency.

 

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Now we reached the Smart Cloud Warehouse. The entire warehouse resembles a vertical parking lot. It automatically issues tasks according to delivery requirements.

 

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Thenn the toilets go to the kiln, which is basically a firing tunnel, with a total length of 138 meters. Too much heat too soon would distort the glaze. So it’s first gently warmed up, then it’s blasted with 1280 °C that melts that exterior glaze, which becomes rock solid and glossy, and then it cools down at last. The higher the temperature, the lower the water absorption. 

 

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Now those almost ready toilets are on their way to the Final Assembly Department. The assembly factory originally required more than 100 people, but now it only needs 28 people to operate. The transport robots are doing the delivery. The route of the robot can be set flexibly and the sensors in the robot give them information about their surroundings.

 

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And the final step - after firing, each unit is tested to ensure that it meets the fast flushing standards. Divided into 2 levels, the first one is to inspect 500 mm trapway to ensure sufficient suction. The second is the flushing function. To test it, workers use 100 pp balls and red ink. Having pipes with a larger diameter, it nearly instantly cleans off waste. In addition, the life expectancy has exceeded international standards.


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 Then the toilets are ready to be carefully packaged and delivered to our warehouses.


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