Article

We Will See Top 10 Tile Brand Companies In India. And the tiles they Producing and supplying to the Market. Find which tile Company is best For your need.
Here is the list Of Best/Top Tiles Brands Companies in India.

H R Johnson India Limited

Johnson tile is one of the leading manufacturers of supplying a wide range of tiles. It is one of the divisions of Prism Cement Limited and a pioneer in ceramic tiles. The company was established in the year of 1958.The corporate office was located at Mumbai. The type of products sold by this company is tiles, sanitary ware, bath fittings and kitchens.

The type of tiles produced by this company is: Ceramic floor tile, Ceramicwall tile, Vitrified wall tile, Vitrified floor tile, Glazed vitrified tile and Marble and quartz.

Some of the wall tiles are MAGNAPINE, ALASKA, BRASSIE GLOSS, COZYWOOD MOSAIC and GRACE PAPIER BRIGHT; floor tiles are Alaska crema hard mattt, Bermuda rose hard matt, Birch wood hard matt, Sandume beige hard matt and Torrenceash wood hard matt. The manufacturing production capacity per year is 68+ Million m² per annum capacity. The brands owned by this company are: Johnson tiles, Johnson Marbonite, Johnson Endura, Johnson Porselano, Johnson Marble and quartz, Johnson Bathroom.

The innovations so far taken by this company are: Anti –skid tiles for Bathrooms, Water repellant Tiles for Bathrooms, Rectified wall Tiles, Industrial and Pavement Tiles, Vitrified Wall and Floor, Scratch Free Tiles, Stain Free Tiles, Joint Free Tiles, Anti Static Tiles, Large Format Tiles, Digitally Printed Wall and Floor Tiles, Germ Free Tiles, Tac Tiles, Intellimate-intelligent toilet and Germ-Free Sanitaryware

H& R Johnson India Limited has been certified by All plants ISO 9001, All plants ISO 9001,All plants ISO 14001and All plants OH SAS 18001. This company has been awarded by Reader’s Digest Trusted Brand Award in Gold category (2008, 2010, 2011, 2012, 2013, 2016, 2018 ), Top 100 Brands title awarded to Johnson (2015), Most Admired Brand (2014)and Gas conservation Award (GAIL).

HSIL (Hindustan Sanitaryware & Industries Limited) Ltd

HSIL (Hindustan Sanitaryware & Industries Limited) Ltd is the largest sanitaryware production in India. It is also well equipped with latest technology to ensure superior quality and this is the first company to manufacture vitreous china sanitary ware products in India.The establishment of this company in the year of 1962. The corporate office was located at Haryana.

This company is operated in two divisions namely building products and container glass. Building products includes water closets, wash basins, pedestals, squatting pans, urinals and bidets. Accessories like PVC cisterns and fittings/ seat covers. Faucets like showers, kitchen faucets and bathroom faucets. Container glass includes beverage, food, liquor, pharmaceuticals, beer and chemical industries.

Here the annual production is as follows: Upto 4.2 million pieces sanitaryaware, 1600tonnes per day glass containers, 3 million pieces faucets, 14000 tonnes plastic  pipes and fittings, 10166 tonnes PET products, 275 million pieces security caps and closures. HSIL leadership in India are leading sanitaryware player, leading faucet players, one of the most significant glass container manufacturers and top 3 players in the kitchen chimney segment. Their mission is to adopt comfortable, luxurious and sustainable lifestyles.

HSIL has been certified by ISO 9001:2008 – Quality management system, ISO 14001:2004 – Environmental management system, OHSAS 18001:2007 – Health and safety management system, Platinum certification by Indian Green Building Council (IGBC) for pieces and security caps and closure manufacturing facilities,ISO 15378:2011 – Quality management system to provide primary packages materials for medical productsand FSSC 22000- Food safety system. This prestigious company has been awarded by Moonbow by hindware, TRUFLO by hindwareand Zavio –Auto clean kitchen chimney.

KAJARIA CERAMICS LIMITED

Kajaria ceramics limited is the largest ceramic tile producer and manufacturer of ceramic/ vitrified tiles in India. This company  was established in the year of 2004. Its corporate office was located at New Delhi. Noticed that application of robotic car, 0% for human error are the few reasons to make this company number one in the industry. They adopted new production technique to intensify the quality of products.

Kajaria ceramics offers  a wide range of products with more than 2600 varieties of vitrified and ceramic tiles, thus making the company as  the largest tile manufacturer. The products produced by this company are: kitchen, bedroom, bathroom, living room, exterior and commercial spaces. Some of the wall tiles are ACERO DÉCOR, ACERO CRIS, ARENA STONE COPPER, ARENA STONE CREMA and BAHMAS DÉCOR. Floor tiles are: K6000, K6002, K6008, K6010, K6014.

The capacity of annual production is of 68mn.sq.metres. It has increased capacity from 1mn.sq.metrs to 68mn.sq.metres in the past 3 years. They offers more than 2800 alternatives in ceramic wall tiles, ceramic floor tiles and designer tiles.

Kajaria ceramics has been certified by SA-8000 For implementing of Social Accountability Standards for the Manufacturing of Ceramic Tiles, ISO-14001 For implementing an Environmental Management system for the Manufacturing of Ceramic Tiles, ISO-22000: 2005 For implementing a Food Safety Management System for the Manufacturing of Ceramic Tiles, ISO-50001:2011 For Establishing, Implementing, Maintaining and Improving an Energy Management System for a Systematic approach in achieving continual improvement of energy performance, ISO 9001-2008 For implementing a Quality Management System for the Manufacture and Supply of Ceramic Tiles and OHSAS-18001 For implementing an Occupational Health and Safety Management System for the Manufacturing of Ceramic Tiles. This company has been awarded by Indian Green Building Council, Trusted Band Gold Award, Asia’s Most Promising Band, Super brand and Capexil Award.

Nitco Ltd (Northern India Tiles Corporation)

Nitco ltd is the largest manufacturer of floor tile in India. It is among the top superior quality tile companies in India. The establishment of this company in the year of 1966 and its corporate office was located at Mumbai.

The products offered by this company are ceramic floor tiles, ceramic wall tiles, glazed vitrified tiles, vitrified DCH tiles, vitrified heavy duty tiles and vitrified SST tiles. A part of ceramic floor tiles are AUSTIN ATRO, BRETON STONE AVANA, COTTO BRONZE; ceramic wall tiles are AL COR 25, ALLURA GREEN and BIANCO MARFIL; glazed vitrified tiles are AURISINA ROMA and BRECCIA AVORIO; vitrified DCH tiles are AMAZONE ICE NEW, DESSERT ASH GRAY and GREEK WHITE; vitrified heavy duty tiles are ANTIQUITY DÉCOR, ASTERIX DÉCOR and BLOOM DUST; vitrified SST tiles are ASHTON, BRILLO IVORY and CAPRI. Other products include marble and mosaic. Marble: Natural Marble and engineered marble, Mosaic: Signature collection, Flame collection, step risers and skirtings.

The production of this company is 6Windmills with a total capacity of 5.5 MW at Dhule in Maharashtra. Rectangular wooden strips, reconciling wood textures and colors, super gloss scratch-proof tiles (resistant to dirt and bacteria), matte finished tile possess anti-skid properties, digital tiles and attractive eye-catching designs are the innovations made by this company.

Nitco has been certified by ISO 9001-2008 For Quality Management, ISO-14001:2004 Environment Management, OHSAS 18001:2007 Occupational Health and Safety Management and corporate office has been certified for  ISO 9001-2008 For Quality Management. It has also been awarded as Capexil awards for innovation and design and two Construction World Awards.

Orient bell Ltd

Orient bell limited is one of the largest manufacturers of ceramic and vitrified tiles as well as the first to manufacture ultra-vitrified tiles in India. As a result of new product design and its development, it has immense range of tiles with miscellaneous finishes and textures. This esteemed company was established in the year of 1970. Its corporate office was located at New Delhi.

The products offered by this company are ceramic floor tile, ceramic wall tile, vitrified wall tile, vitrified floor tile, ultra vitrified tiles, kitchen tiles, digital tiles, sanitary ware, bath fittings and also includes school tiles and paver tiles. The wall tiles include Forever tiles, Plank, Gilimkar, Kerinox, PGVT, Rustisco, Sugar tiles and Wooden tiles.

Orient bell has four patent pending technologies: FOREVER TILES, GERM FREE TILES, COOL TILES and LIFE TILES. The production capacity of this company is of 750(FY14) million square metres.

Orient bell has been certified by IS 15622:2006 under licence number CM/L- 8700002408, ISO 9001:2015 For Quality Management System, ISO 14001:2015 OBL implemented Environmental Management System and OHSAS 18001:2007 Occupational Health and Safety Management System. In 2015, this company has been awarded as a member of Indian Green Building Council (GRIHA), awarded for outstanding sales pan India in 2016, received the Lorem Ipsum Award in 2017, Awarded for initiations and contributions to the world of Tile industry and  awarded has been one of the Best Tile Research industries.

Somany ceramics

Somany ceramics is the most prominent brand of tiles industry in India. This company has manufacturing plants in Khadi (Gujarat) and Kassar (Haryana). It was established in the year of 1969 by Shri H.L Somany. Its office was located at Noida. It might be seen that not only having a leading position in India and also have an ominous force in tiles sector. The possess market share in  India, Africa, South Africa, The Middle East, United Kingdom and Russia.

The widest range of products offered by this company comprises ceramic wall and floor tiles, polished vitrified tiles, digital tiles, sanitary ware, bath fittings and tile laying solutions. The essential products in the tiles are floor tiles, ceramic durastone, GVT/ Durages, polished vitrified tiles, VC shield, floor-tilebanner-new, wall tile, wall claddings, CP fittings, allied products, accessories, exclusive showers, tile visualize, tile laying solutions, seat covers, cisterns, urinals, toilets, sinks, cabinet basins, basin, sanitary ware, imported collections and faucets.

Somany has introduced high abrasion resistant floor tiles with assorted new designs, unique outcome and superior product. The production capacity of this company is of 41 million sq.meters annually.

Somany ceramics (Kadi plant) has been awarded with OHSAS 18001:2007 certification by International Accreditation of UKAS by certification body ISOQAR, also as one of the Inc. India Innovative 100 for the year 2013; Asian Brand and leadership summit Dubai 2013; Asia’s most promising brand  2013 in building materials category and Asia’s most promising Leader’s award 2012.

Cera Sanitaryware Limited

Cera Sanitaryware Limited was an Gujarat based company. The word that capture the importance of cera sanitaryware limited are: India’s fastest growing company, to satisfy the needs of modern customer in mind, CERA unlock the doorway to the world of technique. It was established in the year of 1980 and its sales and marketing was located in Ahmedabad.

The products offered by this company are sanitaryware, faucets, tiles and other products. The sanitaryware possess EWCs, wash basins, bath accessories, cisterns, urinals, seat covers, green products and electronic flushing systems. Faucets includes Single lever faucet ranges, Quarter turn faucet ranges, Half turn faucet ranges, Sensor taps, Kitchen sinks faucets, Overhead showers, hand showers, bath spouts and shower arms, special category pillar cocks and bib cocks, flush valves, flush cocks and angle cocks, health faucets, bathroom allied products, bathroom accessories and cera auxillaries. Tiles includes wall and floor tiles. Refinito, Eleganate, Eterno, Ruvido, Fiore and Lucido are the brand names under floor tiles. The essential product are listed as follows: digital tiles, floor tiles, twin charge floor tiles, digital glazed vitrified floor tiles, double charged vitrified floor tiles, vitrified floor tiles with nano technology, digital porcelain floor tiles, anti-skid floor tiles, HD digital floor tiles and parking floor tiles. The other products are wellness, kitchen sinks, mirrors, style seal, cerena and cerenity.

Modern facility is available with latest machineries like automatic CNC machines and automatic polishing and also the plant is equipped with superior technology. In sanitaryware, production capacity has raised from 2.70 million pieces to 3.0 million pieces per annum.

Cera sanitaryware limited has been certified by India’s most preferred home solutions provider, Preferred sanitaryware partner 2015-2016 by CREDAI (Confederation of Real Estate Developers’ Association of India), Bringing excellence to life (Member of the Institute of Indian Interior Designs) and India’s fastest growing bathroom solutions. This company has been awarded with CERA- The star SME of the year, CERA CMD conferred business knight award, CERA is the best mid-sized company, A+D top 100 brand award, CERA creates cerenity and thereby a new category, CERA bags power brand award, The No.1 Reflection of style, CERA bags power brand 2012 award and Asia’s most promising Brand award for the year 2012-2013.

Bajaj Tiles

Bajaj tiles is renowned tiles in India and the largest group in world of wall and floor tiles. They are equipped with latest technology to ensure the quality of products. The first established company in BAJAJ GROUP in M/S ALFA CERAMICS in 1990. Later second plant was established as M/S YASHICA CERAMICS and M/S SIGMA CERAMICS in 1996. The corporate office was located at Gujarat. The type of products  produced by this company are : Ceramic wall tiles,  Vitrified floor tile sand Heavy duty parking tiles.

Here we will see some divisions of wall tiles. The wall glossy tiles includes Nexus Sereious, Elevation glossy and concept glossy and wall matt tiles which includes Matrix sereious, Elevation matt and concept matt. At present, the production capacity is 75000 sqm per day and the manufacturing capacity is about 72 million sq.st. per annual. The annual turnover is 50-100 crore. By setting new trends and attaining global leadership position, they have attractive design, branding, quality testing and quality products.

The innovations made by this company: To satisfy customers, the objective of this company is innovative design and creativity. It has been awarded ISO 9001:2000 certified company

Sonata ceramics private limited

Sonata ceramics private limited has made her name in the list of top suppliers of tiles. The features are high scratch resistance, stain free, UV protect, lesser than 3% water absorption, eco friendly and anti-skid surface. They are equipped with latest Italian and Chinese energy efficient machineries which meets quality and production standards as per International norms. This company was established in the year of 2004 and its office was located at Himatnagar.

Sonata ceramics have a portfolio of tiles which are Porcelain Tiles, Teflon Technology Tiles, Digital HD Tiles and Vitrified Tiles. other top products are Dark series-timber brown, Light series-Rivera, Granite series- Black Granite, porcelain series-Glossy series, Light series-Glacier, Porcelain series-Dark series and Titanic series-Titenic Ivory.

The market shares are 20%, 23%, 50% and 7% respectively for wall tiles, floor tiles, vitrified tiles and industrial tiles.The production capacity of this company has approximately 680 million square meters production per annum.

Sonata ceramics has been certified by ISO 9001: 2008. The problems faced by sonata are waste management, no government support, high equipment installation and maintenance costs.

Swastik tiles

Swastik group is one of the top 10 ceramic tiles manufacturers in the country. It was established in the year of 1996 with fresh, innovative and positive outlook. Its corporate office was located in Ahmedabad. SWASTIK TILES- creating happy and vibrant environments!

The products offered by this company are: digital glazed vitrified tiles, digital gres vitrified tiles, digital wall tiles, multicharge vitrified tiles, digital parking tiles and  full body vitrified tiles.

The swastik group has a daily production capacity of 24,000 to 25,000 square meters per day. The group is present in the all three major tile segments: ceramic tiles (Akik tiles), porcelain tiles (GCL) and vitrified tiles (SCPL).

Swastik tiles has been certified by ISO 9001:2015 Quality Management System of “SWASTIK CERACON LIMITED” and also by IS 15622 under the licence of CM/L-7200052695 received.

Conclusion

In this article, we have seen the top 10 tile brands in India with their quality, types of products, certification and awards has been discussed in wise manner.

SHE ENTERED INTO THE WORLD WHO WANTS YOUR LOVE….SO NEVER LET HER SMILE DOWN…RESPECT HER———“MOTHER”

In this article, we are going to see about step by step manufacturing process of float glass. Float glass is a widely used glass which is made of sodium silicate and calcium silicate. This glass is inexpensive and also called as window glass/ flat glass/ plate glass.

Now we will discuss the entire production of float glass manufacturing in a step-wise manner.

BATCHING OF RAW MATERIALS

• The raw materials used in float glass manufacturing are silica sand, calcium oxide and magnesium, soda ash, and feldspar.
• As we know that sand (73%) is the body former in the glass. It is the primary raw material of glass; calcium oxide (9%) and magnesium oxide (4%) to reduce solubility; soda ash (13%) to lowering the melting point; feldspar (2%) to increase the hardness.
• The above-said ingredients are fine-grained, weighed and mixed to make batches to which the cullet is also added. Here, the purpose of cullet is to reduce the consumption of natural glass. The next step is melting.

MELTING

• In this melting process, the batched raw materials are then passed to a melting furnace for 50hours at a temperature of about 1500^oC where they become molten.
• The molten glass which is free from inclusions and bubbles.
• If certain metal oxides are mixed, they impart colors to the glass by giving a tint body. The cullet in melting process acts as a flux to reduce the melting point of the batching raw materials.

REFINING

• We know that the refining process is a purification process which is done at the furnace to remove unwanted elements or impurities present in the molten glass.
• If they were not removed, a grain of sand is refused to melt.

FORMING

• The molten glass is fed into the tin bath (float bath) under the controlled atmosphere of N₂/H₂ gas to prevent oxidation of tin and the glass flows onto the surface of tin at a temperature of about 1000^o
• Then it forms a solid ribbon at 600^oC with a perfectly smooth glossy surface with the even thickness which is highly viscous.
• The density of glass should be lower than that of tin. Here, some specifications are: length = 50m, width = 3-4 m, depth = 6cm
• The tin bath has three different zones separately: Heater zone, Fire polish zone, and Cooling zone.

Why tin bath is provided in float glass manufacturing?

Tin is suitable for this type of glass manufacturing, because of its higher specific gravity. It is oxidized in a natural atmosphere to form tin oxide (TiO₂). Hence, to prevent oxidation, tin bath is provided with pressure and; hydrogen and oxygen as a protective atmosphere.

ANNEALING

• The formed glass is leaving from the tin bath at a temperature of 600^oC
• On cooling the glass, some stresses are developed in the solid ribbon. After that, it is cooled down sufficiently to passed through an annealing chamber (lehr), where the internal stress is removed to improve the glass yield and also ensures the flatness of a glass. If the surfaces are fire finished, they need no grinding and polishing.
• In annealing lehr, cooling can be controlled in 4 to 8 separate zones.
• The glass is passed between rollers into different sections of lehr.
• The first section of lehr which is Ao section maintains a uniform temperature.
• The second section of lehr which is B section, the glass temperature is cooler. This section use both heating and cooling in a controlled process. Permanent stresses within the glass formation can occur at a lower temperature, below its strain point.
• For the manufacturing of float glass, the range of annealing temperature range is from 452^oC – 482^o This point is also called as stress relief point or annealing point of the glass.

WASHING AND DRYING

• Care should be taken to obtain residue free elimination of sulphide. Now it is suitable for coated glass, white glass, and float glass.
• Washing process can be done without the addition of additives.
• After washing, it undergoes a drying process to remove the undesirable moisture content present in the annealed glass.

DEFECT ANALYSIS

• Quality can be controlled by reducing the defects which are present in the float glass.
• Bubbles, knot, cord, cracks, and seeds are some of the defects which prone to spoiling the end product.
• The other defects like insects, dust are also eliminated.
• To ensure high quality of glass, the inspection must take place at every stage.
• The float glass is checked for any defect present in the glass.
• Both online inspections by computer and manual inspection are also available to enhance the quality of glass and then it is ideal for customer line satisfaction.
• Defected float glass is sent to the recycling process and used as a cullet in batching process.

CUTTING

• The cutting process is done by using a diamond cutter with stressed edges which are dictated by the computer.
• The purpose of using a computer in the cutting process is to meet the customer requirements into patterns of cuts designed to minimal of wastage.
• It is sold by the square meter.
• Individual sheets are separated and packed for further applications.

PACKING

• Based on customer requirements, glasses are packed.
• It is packed with suitable packaging in wooden box to avoid damage during transportation.

CONCLUSION

In this article, we have seen the step by step production of the float glass manufacturing/ production process. The glass manufacturing principle is overall same in different types of glass except one or two.

SELF MOTIVATION IS THE BEST MOTIVATION EVER ON WHAT YOU EXPERIENCED IN YOUR LIFE!!!

PRODUCTS LIST
Ceramic made products are around us everywhere.We will see here some of the ceramic products we use we normally use.

GLASS PRODUCTS

• Glass can be blown, bent, cut, and molded formed into many size and shape.
• There are many type of glass products are producing based on the applications
• For examples: Glass jar.

LABORATORY GLASSWARE

• It is made up of borosilicate glass.
• Therefore commonly used in chemistry, biology and analytical laborites.

PASSIVATION GLASS

• One of the key properties is a high insulation resistance achieved by limiting the alkali content to a minimum level as possible.
• It is used for the chemical and mechanical protection of discrete semiconductor and varistor surface.

SEALING GLASS
Use of sealing glasses is wide spread in the electronics industry, (i.e) producing bulb and tube light like products.

CLEAR GLASS

• By name itself it is clear and transparent annealed glass.
• It is used in doors, windows, solar applications, shelves, etc.

TINTED GLASS

• The body of tinted glass is float glass.
• It saves energy, reduces visibility across its surface due to a film that absorbs and reflects incident solar radiation.

GLASS BOTTLES

• Glass bottle made by blowing molten glass into a mould and introducing air pressure to force the molten glass into the shape of the mould.
• Gradually cooling process take place and get the product.
• It is useful for pharmaceutical application

MIRROR

• A silver glass mirror is an ordinary mirror.
• Yet glass is merely used as a substrate to hold and protect a thin metallic layer.

TEMPERED GLASS

• Tempered glass is more heat barrier when compared to regular glass.
• 90% protection to your screen from shocks.
• It can be reused many a times.

OPTICAL LENS

• The best and cheep material used to construct lens element is glass, which is good optical property and resistance to scratching.
• Lens is used for a camera, a telescope and a microscope.

FIBER GLASS

• A material made up of very fine fibers of glass.
• It is resistant to heat and fire.
• Used to make various product, such as building insulation, boat hulls, thermal and acoustical insulator.

GLASS WOOL

• It is a type of fiber with high thermal insulation and low thermal conductivity.
• Used in a furnace like cotton, this is white in color.

POP IDOLS

• Most of the solid casting idols are made up of plaster of Paris.
• It requires less time for drying process.

TILES

• A thin flat slab made with pottery body and applied glaze on the surface.
• Used for construction works.

SEWER PIPES

• A sewer is for removing waste water and generally relies on gravity.
• Sewer lines are mainly drainage pipes which connect your home and commercial buildings to sewage treatment plants.

TUNGSTEN CARBIDE CERAMIC LINED PIPES

• It is used to transport highly abrasive media.
• Tough and ductile tungsten carbide lining provides a higher level of wear and abrasion production than many legacy lining methods.

VITRIFIED CLAY PIPES

• The more advanced version of these types of pipes is VCP pipe, which is blend of clay and shale that has subjected to high temperature to achieve nitrification.
• It is reliable, stable, sturdy, able to repel corrosion, resistant to abrasion and recyclable.

POTTERY WARE PRODUCTS

• Pottery is useful or decorative household items made from clay.
• It is made by forcing the chemically bound water in clay, which is shaped into desirable form.
• Ceramic ware that is fired in high heat, vitrified and nonporous.
• Available products like pots, jugs, cups, plates and etc.

SANITARY WARE PRODUCTS

• Sanitary ware is a partition of ceramic wares.
• It can with stand more than 400 kg load, excellent resistance to chemical attacks and easily cleaned.

WATER CLOSETS

• It is used for disposal of human wastage by flushing.

WASH BASIN

• Sanitary ware used for washing of the upper part of the body.

BIOLETS

• Sanitary ware used for washing the central part of the human body.

CLISTERS

• Sanitary ware used for flushing of the waste water into the water closet.

PEDESTAIS

• Sanitary ware used to support and cover pipeline attached to the waste hole of the wash basin.

SINKS

• Sanitary ware used for washing the dishes and for kitchen ware.

URINALS

• It is used for flushing away urine generated by the human being on standing position.

HELMET

• It is a productive head ware which prevent the head injures and saving the rider’s lifespan also.
• Outer shell typically made from fiberglass and some other materials.

PAVING BRICKS

• Bricks are porous form which is formed by mixing sand, small stone hardcore, dyes, cement and other materials in various amounts.
• Pavers are perfected for your driveway process.

CEMENT BRICKS

• Cement bricks is made from a mixture of cement and sand have many advantages.
• Used in the construction works
• Available in two types that is hollow bricks and solid bricks

GRINDING MEDIA

• Grinding media is the balls or pebbles, which is made up of ceramic.
• Used to grind and blend materials for use in mineral dressing process.

INDUCTION STOVE

• Cooking is done by electrical heating using magnetic induction.
• The cooking surface is made of a glass ceramic material which is poor heat conductor.

MICRO OVEN

• Microwave oven is a popular kitchen appliance that uses microwave radiation to heat and cook food easily.
• Borosilicate glass is used because material that have low dielectric loss characteristics.

BEARING BALLS

• Usually used for freewheel mechanisms.
• The surface is highly finished and hardened for a high load capacity.
• Variety of use in different industries like automobile industry, paper making industry, toy industry, etc.

AUTOMOBILE CERAMICS

• Ceramic materials are more efficient than metal and more durable than plastic, so that are made into components for automobiles.
• Ceramic materials are used in aero plane, rocket, and car, include spark plug insulators etc.

TEETH

• There are two materials that are suited to replace the looks of anterior teeth that is composite and ceramic.
• All ceramic crowns provide great esthetics and show for a long term result.

PIEZOELECTRIC SENSOR

• A piezoelectric sensor is a device that capable of converting mechanical quantities like pressure, acceleration, temperature, strain, or force by converting them to an electrical charge.
• Thin film or silicon-based device is also easy to set up, but that point is expensive.

CONCLUSION
Ceramic products are used in everywhere from traditional application to advance applications. At any rate, ceramic are excellent in terms of strength, appearance, lifespan which do not stain.

The glass plays an integral and important part in our day- to- day life. It is almost used by everyone. It is one of the most useful materials in the world. The human life will be held handicapped without glass nowadays. It has been used in the diverse and wide uses. Hence the manufacturing industry has grown to a greater extent in recent years. It plays a major role in the country’s economy. A total of around Rs. 340 million worth glass industries were found in India. It is likely to be increased in the upcoming years.

The glass production comprises of two processes namely float and glass blowing process. The former produces sheet glass while the latter produces bottles and other containers. The glass industry included under two categories namely factory and cottage industry. The top glass industries in India are crafted here.

Asahi India glass limited:

It stands as one of the largest companies in India according to market capitalization of about Rs. 3500 crores. It was initially set up as a joint venture between Labroo family and Maruti Suzuki, India. This company is unique in manufacturing products with quality, innovation and long life standing as a leading manufacturer in our country. This company exclusively offers glass, ceramic and glass products. It is special for architectural glass, solar glass, tempered glass, door glass, value added glass, laminated windshield, heat reflective glass, frosted glass, lacquered glass etc.,

Asahi India glass limited

Key facts:

• The company was established in the year 1984.
• It was initially founded by B. M. Labroo.
• The corporate office was located at Gurgaon.
• The total employees under this company include about 2000.
• The company earns a net profit of about Rs. 40 crores.
• This company stands out from the others by being driven to the market-leading innovations.
• It is a world-class integrated glass industry which has been listed in the National Stock Exchange and Bombay Stock Exchange.

La Opala Rg:

La Opala Rg is currently the tableware brand number in our country. It has become one of the leading glasses manufacturing glass in recent years. This company exclusively offers a range of decorative and handcrafted glasses and plates. The core business products include La Opala, Diva, Solitaire crystals etc., The innovation of this company continued with a wide variety of brands like crystal ware and solitaire, and is known for its impressive looks. It was initially felicitated with the Udyog Ratna. It has wide range of export to countries including USA, UK, Turkey and France. The market capitalization includes about Rs. 3123 crores.

La opala Rg

Key facts:

• The establishing year of this company was 1988.
• The founder of this company was Mr. Sushil Jhunjhunwala.
• The total employee’s of this company was 300.
• The corporate office and headquarters was situated at Kolkata.
• The chairman of this company was Mr. A. C. Chakrabarthi.
• It offers trust and quality to the customers.
• It is an ISO certified company.

Empire Industries limited:

This industry is a diverse group offering glass containers for pharmaceuticals. This is a fully automated company and a century old organization. The export market of this company includes USA, Europe, Asia, Africa and South America. This is a massive conglomerate in contact with many industries such as pharmaceuticals, food and glass. This company was initially a part of the British company during the British rule. The company deals with the diverse domains having an experience of more than 105 years. The market capitalization includes about Rs. 36 crores. This is a globally recognized company.

Empire industries limited

Key facts:

• This company was established in the year 1900.
• The founder of this company was Mr. S. C. Malhotra.
• The corporate office was located at Mumbai.
• The total employees include more than 2000.
• The main production is the glass containers.
• The daily production of this company includes about 1.5 million.
• This company has a strong customer trust with a long journey of years through a focused approach and a continuous quest of quality.

Hindustan National glass and industries limited:

This company is one of the oldest glass manufacturing companies in our country. It is also one of the leading producers of glass in India. It was mainly associated in the field of float and safety glasses. It has a market capitalization of Rs. 1013.13 crores. This company has been specialized in light weight glass containers. This has been marked as a famous company in South East Asia for its fully automated factory. Additionally this was the first automated glass manufacturing unit of the country. This company has a market capitalization of about Rs. 786 crores.

Hindustan national glass and industries limited

Key facts:

• The establishing year of this company was 1946.
• The founders and promoters of this company are Somany brothers.
• The corporate office was located at Kolkata.
• The total number of employees is 2000 to 3000.
• The net profit includes Rs. 218 crores.
• This company has been listed in the NSE (National Stock Exchange).
• This has a market share of 65% and continues its growth.

Borosil glass works limited:

This company has been marked as one of the fastest growing glass companies in India. This company is a believer of green technology and is a sponsor of save the tiger campaign. They have a market capitalization of Rs. 480.96 crores. They have strived hard with their experience and presence in the glass industry. The products from this company have been exported to all the developed countries across the world. This was literally the first producer and manufacturer of solar glasses. This proves to be the leading producer and produces a wide variety of laboratory glassware. In addition, it also manufactures kitchen wares, industrial glass wares etc.,

Borosil glass works limited

Key facts:

• This company has been exclusively established in the year 1962.
• This company was founded by P. K. Kheruka.
• The corporate office was located at Mumbai.
• This company was headquartered at Kolkata.
• The total number of employee includes about 1000.
• This company sounds unique for its special production of low iron solar glass.
• It is an ISO certified company.
• The net profit of this company was Rs. 37 crores.

Saint Gobain Sekurit limited:

This company has been marked as one of the most popular glass manufacturing industries not only in India but also across the globe. It exclusively plays a key role in marketing its brand name thus branding its products. This company serves worldwide. This has a long journey of about 350 years with its immense experience. This company produces well known brand used mostly in the automobile industry and it is also the preferential partner of automobile industry. The market capitalization includes about Rs. 360 crores.

Saint gobain sekurit

Key facts:

• The establishing year of this company in India was 1996.
• The founder was M. G. Ramakrishna.
• The net profit of this company was Rs. 41 crores.
• The corporate office was situated at Pune.
• The total number of employees was more than 2000.
• The major products of this company are laminated windshields, tempered side glasses, automotive glasses, backlites, float glasses, mirrors etc.,
• This company is an ISO certified.
• This company has a rapid growing presence in Asia.

Gujarat Borosil limited:

This company produces a wide range of glass. The production includes tinted glass, container glass, architectural glass, and automotive glass etc., The products produced and manufactured from this company are found to be of high quality. In recent years, this company has a witnessed a rapid growth rate. It has been considered as the pioneer of microwavable kitchenware and laboratory glassware in our country. This company was officially found as the first and only producer of solar glass in India. The market capitalization is Rs. 217 crores.

Gujarat borosil limited

Key facts:

• The company was established in the year 1988.
• The founder of this company was B. L. Kheruka.
• The net profit of this company was found to be Rs. 8.29 crores.
• The corporate office was situated at Gujarat.
• It has more than 1000 employees.
• This company stands unique in offering products with premier quality.
• This was the largest exporter of sheet glass in India.

8. Binani industries:

This company is a part of Braj Binani group. This company has a wide business portfolio of cement, zinc, glass- fibre etc., In glass melting, it uses an unique technology of oxyfuel combustion. This company was currently found to be the leading producer of fiberglass used in various industries. It has established its many operations in many countries around the world. This company is about 143 years old. The market capitalization was Rs. 281 crores.

Binani industries limited

Key facts:

• The establishment of this company was in the year 1872.
• The headquarters was located at Mumbai.
• The corporate office was located at Kolkata.
• The founder of this company was Braj Binani.
• The number of employees was about 500.
• The net profit was about Rs. 19.60 crores.
• This company was a leader in fiberglass with the supply of fiberglass and other related products.
• This company was the major exporter of its products exporting it to more than 25 countries around the world.

Haldyn glass limited:

The Haldyn glass limited was promoted by Haldyn corporations limited. This company produces food and beverage bottles. These bottles find its major use in many sectors such as food, pharmaceuticals, cosmetics, liquor and beer industry etc., It is also involved in the manufacturing of soda lime flint and amber glass container. With the help of two melting furnaces, it daily melts about 320 tons of glass. The major and the greatest client of this company was Amul. This company was very famous for its creative and prolific designs. The market capitalization was Rs. 165 crores.

Haldyn glass limited

Key facts:

1. This company was established in the year 1964.
2. This company was founded by N. D. Shetty.
3. The corporate office and headquarters was located at Vadodara, Gujarat.
4. The manufacturing plant was located at Baroda, Gujarat.
5. The administrative office was located at Gorgean East, Mumbai.
6. This company contains about 1500 employees.
7. The net profit was about Rs. 18.41 crores.
8. This company installed integrated quality management system comprising ISO 9001: 2001 and 14001: 2004.
9. This company facilitates consistent supplies with an environmental focus.

This company is a public company. This is a manufacturing company. This majorly manufactures carbon steel glass lined equipment. This manufactured product finds its wide usage in various industries such as reactors, storage tanks, columns, dryers, valves, agitators, etc., this company especially caters to all the needs of various industries such as food processing, pharmaceuticals, agrochemicals, allied industries etc., the production capacity of this company was 8000.

Key facts:

• This company was established in the year 1991.
• The annual turnover of this company was Rs. 52 crores.
• The market capitalization was Rs. 168.95 crores.
• The headquarters of this company was located at Vithal Udyognagar in Gujarat.
• This company produces trustworthy products.
• The total number of employees was about 2000.

Nile limited:

The Nile limited produces glass in addition to lead and lead alloys. Though it is a leading manufacturer of lead, it also produces quality and trustworthy glasses. For its perfection in products, it has been widely appreciated by its clients. This is primarily engaged in the secondary manufacturing. The capacity of this company is 82000 tons.

Nile limited

Key facts:

• The major production of this company regarding glass is the glass lined equipment.
• The headquarters was located at Hyderabad.
• The net profit was Rs. 15 crores.
• The establishment of this company was in the year 1984.
• The key person includes Sandeep Ramesh who is the executive director.
• This company is an ISO certified.

Schott glass India private limited:

This company has been witnessed as an international manufacturing group of glass and glass ceramics. This company exclusively produces glass ceramics even with low thermal expansion coefficient. In addition to glass and glass ceramics, it also produces crystalline photovoltaic cells with 15MW. This company operates overseas at China since 2011.

Schott glass India private limited

Key facts:

• The company was headquartered at Mumbai, Maharashtra.
• The company was established in India in the year 1989.
• The key person of this company was Murali Viswanathan who is the managing director.
• The net profit was about Rs. 5.6 crores.
• The total number of employees includes about 15,100 in 35 countries.
• The overall chairman for the managing board is Dr. Frank Heinricht.

Piramal glass private limited:

This company has been marked as a global specialist in design, production and decoration of premium glass packing. This company was formerly known as Gujarat glasses. This renders its service to various industries such as pharmaceutical, food, beverage and perfume. This was one of the most leading Indian glass packaging companies. These have been listed as the Bombay Stock Exchange (BSC: 532949) and National Stock Exchange (NSE: PIRGLASS).

Piramal glass private limited

Key facts:

• This company was established in the year 1984.
• This company was headquartered at Mumbai, Maharashtra.
• This company serves all the area worldwide.
• The key people include Ajay Piramal (Chairman) and Vijay Shah (Managing Director).
• This company is a type of containers and packing industry.
• This company is a world leader with 50% market share.
• This company has won its fourth consecutive Gold award in the large industry segment in ceramic sector at the 21^st Annual NCE awards ceremony.

Pragati glass private limited:

This company is known for its manufacturing of a wide range of clear glass bottles and tumblers. Through the above such quality, this company has earned an enduring international fame. Thus it has raised its standards and methods of production over the last two decades bringing its products to an international standard. It is primarily involved in the manufacturing of glass and glass products. The authorization share capital and paid up capital are Rs. 100,000,000 and Rs. 59,887,600 respectively.

Pragati glass private limited

Key facts:

• The company was established in the year 1982.
• This company renders its service to a wide range of customers, without considering their quantities.
• The board of director includes Rajeshbhai Ishvarlal Shah, Dineshkumar Gupta and Ashish Dinesh Gupta.
• The headquarters was located at Mumbai, Maharashtra.
• This company provides an advantage of multifunctional technology to its customers of all sectors.
• The Corporate Identification Number (CIN) is U26100MH1981PTC200311.
• The registration number is 200311.

Gurind India private limited:

• This company is one of the leading glass processing enterprises in India. In addition, it also ranks as one of the top glass manufacturing glass companies in our country. This offers various types of glasses such as architectural glass, industrial glass, mirror products and aluminium composite panels. Presently, it consists of three production units spread over 150,000 sq.ft. The manufacturing area includes two states. This company offers a state of the art glass processing facilities in Srilanka and Noida. The authorized share capital and paid up capital are Rs. 5,000,000 and Rs. 3,774,000 respectively.

Gurind India private limited

Key facts:

• This company was established in the year 1986.
• This group of company has an illustrious history to acquire its current position.
• This company is a prime and leading manufacturer of aluminium composite panels.
• This company was established in the year 1987.
• The Corporate Identification Number (CIN)is U74899DL1987PTC0028060.
• The registration number is 28060.
• The board of directors includes Arti Singh, Karan Singh and Gurmeet Satwan Singh.

HNG Float glass India private limited:

This company has been marked as one of the major producer of container glass in India. This is the manufacturer of clear float glass, tinted float glass, reflective glass, low iron glass and cool insulating glass. The authorized share capital and paid up capital are Rs. 3,300,000,000 and Rs. 3,079,160,060 respectively. This is primarily involved in the production of glass and glass products.

HNG float glass limited

Key facts:

• This company was established in the year 2006.
• The directors are Narayanaswami Sitaraman, Sanjay Somany, Mukul Somany, Jagadish Prasad Kasera, Amrit Lal Kapur, Brian Joseph Almeida, Cetin Aktruk, Reha Akcakaya, Aytac Saniye Mutluguller, Ajay Kumar Rai, Gokhan Atikkan.
• The Corporate Identification Number (CIN) is U2610WB2006PLC111182.
• The registration number is 111182.
• The company is a class of public company and a non government company.

Fuso glass India private limited:

Fuso has been recognized as the leading processor of glass products. These plants work under three states namely Chennai, Hyderabad and Mumbai. The Fuso glass India private limited supplies quality glass and glass products for a variety of architectural and building applications used for exterior as well as interior designs. This company offers a huge range of glass including architectural, automotive and specialty glasses. This company is closely associated with all the major glass customers in India. The authorized share capital and paid up capital are Rs. 60,000,000 and Rs. 52,295,660 respectively.

Fuso glass industries limited private limited

Key facts:

• This company is a brand name of complete glass solutions.
• This company was established in 1999.
• The founder of this company was Kishore Shete.
• This company is an ISO 9001:2008 certified company.
• This company is having a three star status with Saint Gobain consortium member.
• The salient features of the products from this company are efficiency, easy fitting, energy efficiency, output consistency etc.,
• The directors are Ramesh Kumar Chouhan, Tarachand Lumbchand, Champatlal Babulal Jain and Ashok Kumar.
• The net profit of this company was about Rs. 6 crores.
• The corporate office was situated at Mumbai.
• The Corporate Identification Number (CIN) is U26109TN199PTC043549.
• The registration number is 43549.

Glass wall system India private limited:

This company has been recognized as the leading façade fabricator in India. This company provides turnkey architectural façade solutions. This company is the best in providing the design, manufacturing and project management facilities. This company offers a wide range of glazing systems and custom- designed architectural metal works. The authorized share capital and paid up capital are Rs. 260,000,000 and Rs. 194,382,000 respectively.

Glass wall system India private limited

Key facts:

• This company was established in the year 2003.
• This company is our country’s leader in the field of aluminium curtain wall, doors and windows.
• The directors are Jawahar Hariraj Hemrajani, Prakash Manohar Kulkarni, Vishal Kumar gupta and Sunita Kamalesh Choudhari.
• The Corporate Identification Number (CIN) is U74999MH2010PTC207187.
• The registration number is 207187.
• This company was headquartered at Mumbai.
• This company has been awarded Glazing Excellence Collaboration award from Saint Gobain in 2011.
• Recently in 2017, it has been awarded Best Glass Façade Product Company.

Gold plus glass industry private limited:

This company is specialized in processing, trading and manufacturing of glass. This company is a manufacturer of a wide range of glasses including float, architectural, automotive and specialty glasses. This company is a non- government and public company.

Gold plus glass industries limited

Key facts:

• This company was established in the year 2005.
• The directors are Viney Kumar, Rajesh Ramaiah, Vivek Dubey, Ashok Khurana, Jimmy Tyagi, Neha Tyagi, Maheswar Sahu and Suresh Tyagi.
• The headquarters of this company was situated at Delhi.
• The Corporate Identification Number (CIN) is U26109DL2005PLC143705.
• The registration number is 143705.

Jai Mata Rolled glasses:

This company is a leading producer of designer glass in our country. This company offers a range of glass and glass products. This company offers its best in bringing the technology together from around the world. This company provides its unmatched range which is the preferred choice for interior designs and architects to offer the very best to their clients. This company has a small market capitalization of Rs. 2.50 crores.

Jai Mata rolled glasses

Key facts:

• The establishing year of this company was 1981.
• This company was founded by C.M. Marwah.
• The corporate office was situated at Delhi.
• The net profit was about Rs. 0.35 crores.
• The total number of employees was about 1000.
• The core business products include figured and wired glass.
• The directors include Ambarish Chatterjee, Sanjay Kumar Sareen and Anu Marwah.

Sejal glass:

This company is one of the preferred processors of glass in our country. This mainly caters for the huge demand for architectural glass in our country. It also analyzes and satisfies the needs of customers and provides them consistency. This has acquired the strength and trust of customers and clients both nationally and internationally. This company stands unique in following the best practices. The market capitalization was Rs. 18.65 crores.

Key facts:

• This company was established in the year 1991.
• This company was founded by Amrut S Gada who is currently acting as a chairman as well as managing director.
• The corporate office was located at Mumbai.
• The total number of employees was about 1000.
• The core business products include solid glass, kook glass, tone glass, fort glass, armor glass, décor glass, fireban glass etc.,
• The net profit was about Rs. 8 crores.

Triveni glass:

This company is the first to manufacture laminated safety glass for automobiles. With this unique feature, they become the pioneer of our country. The major products of this company are tempered glass, sheet glass, mirrors etc., This company especially offers better services to its customers and clients and hence improves its profitability.

Triveni glass2

Key facts:

• This company was established in the year 1956.
• This company was founded by D. N. Agarwal.
• The market capitalization was Rs. 17.67 crores.
• The net profit was Rs. 6.67 crores.
• The corporate office was located at Uttar Pradesh.
• The total employees were 500.
• The core business products were tints, wired glass, glass tubes, automotive glass etc.,

Conclusion:

The top glass manufacturing and processing industries in our country have been listed here in this article. Apart from theses, the other industries may also be found in India which produces or manufactures glass among their own locality in a small scale.

Introduction:

Ceramics are everywhere! In our day to day life definitely, we use ceramics. When thinking of ceramics most of the people say that ceramics are just used for making pottery, it is not a fact! Let us see in this article where the ceramics are really used for!

Pottery

Used to make decorative and household products, symmetric objects like plates, cup and saucer, flowerpot, pot, vessels.

pottery uses of ceramics

White wares

It is used to produce crucibles, Sparkplug, dishes, Electrical insulators like high voltage insulators and low voltage insulators and high-class potteries

whitewares uses of ceramics

Stone wares

Stone wares are mainly used to construct sewage pipes, public lavoritaries, underground cable sheathings, drainage pipes, valves and pumps in chemical industries

stoneware uses of ceramics

Tiles

As we know ceramic tiles are used for construction works. It is used to cover the surface of floor, wall, and ceilings. Nowadays tiles are also used for decorative purposes as it is utilized for the interior and exterior finishing works.
Based on the need both the glazed and unglazed tiles used.
Porcelain tiles are durable and highly resistant to water (water absorption is nearly 0.5%). So these types of tiles are preferred in indoor bathrooms and kitchens
Quarry tiles are very hard and they don’t break easily, so they are fit for outdoor uses.
Terracotta tiles are unglazed tiles which are hard and unglazed, thus they are used in both indoor and outdoor applications

Porcelain

Porcelain is used to manufacture
 Crucibles
 Electrical insulators
 Porcelain Tiles
 Used in tunnels and subway
 Porcelain enamel is used to coat water heater sinks, bathtubs, stoves, grills
 Food and agricultural industries

insulator uses of ceramics

Tableware

Used to produce plates, glasses, bowls, mugs, utensils, dinnerware,

Refractory

Refractory is used as a lining material in
– Foundries
– Kilns – batch kiln, tunnel kiln, shaft kiln, rotary kiln
– Furnace- basic oxygen furnace, electric arc furnace
– Driers
– Coke Oven
– Cement rotary kilns
– Combustion chamber lining of BF stoves
– Incinerators
– Tundish impact plates
– Slide gate valves
– Pushing blocks
– Reactors
– Slide gates for the furnace, ladle and tundishes in continuous casting nozzles
– Hearth and wall of calcium carbide furnace
– Tundish nozzle
– Roof, sidewall and hearth of arc furnace
– Sidewall and hearth of copper converter
– Boilers and heaters
– Furnace tubes
– Peephole blocks
– Continuous casting nozzles
– Port baffle blocks
– Reverberatory furnace
– Iron and steel ladles
– tundish
Used to manufacture
– Glass tank crowns
– Refractory bricks
– Glass tank walls
– The roof of open hearth furnace
– Coke oven wall
– Upper checker wall of blast stove
– Surface flame deflector systems for rocket launch structures
– Dome of blast stove
– Moulds for casting glass and metals
– Regenerators

Ceramic fibres

Used as a refractory insulating material in
– Ladle preheaters, intermediate insulation in blast furnace stove and coke oven door seals of iron and steel industries.
– Feeder channel, melter side wall, crown and refiner in a glass tank
– Bottom of kiln cars
– Ladle liners, lining launders in aluminium industries

ceramic fibre spun wool fire thermal insulation.

Bioceramics

Bioceramics are widely used in the medical field such as
 Bone replacement
 Hip replacement
 Joint replacement
 Spinal surgery cages filling
 Metaphysical fractures
 Dental implants
 Cystectomy filling
 Pulp Capping
 osteotomies
 Inner ear ossicles
 Maxillofacial surgeries
 Alveolar bone filling
 Periodontal defects filling
 Orthopaedic load bearing coatings
 Bone cement
 Acetabulum reconstruction
 Drug delivery system
 Orthodontics anchors

bioceramics uses of ceramics

Abrasives

Abrasives are mainly used for polishing, grinding, surface finishing and cutting operations.

Raw material uses:

Silica

• Since the toughness is lower, it is used in the lightweight finishing applications.
• Bigger grit gives rough finish hence used for surface grinding
• Smaller grits posses smooth finish and used for fine finishing applications.

Emery

• Emery is also known as black sand
• It is a blocky grain, thus used in polishing operations

Garnet

• Used in wood products finishing applications
Crocus
• Used for wood finishing, metal finishing and flat glass surface finishing applications

Diamond

• It is the hardest material.
• Used as a diamond cutting wheels for glass and stone cutting, ceramic tool cutting, cemented carbide tool cutting.

Silicon carbide

• Used for grinding and polishing applications.
Alumina
• Used for cutting operations, cold cutting
• Used for grinding operations

Uses of abrasive
Used in
o Internal combustion engine valve stems
o Sewing needles
o Tungsten rod for contact points
o Rice polishing
o Stack removals
o Axle shafts
o Spark plug electrodes
o Metal cutting
o Ceramic tool cutting
o Piston rings
o Copper rod for soldering guns
o Sanding operations

Monolithic Refractory

Monolithic refractories are used in
 Iron and steel making
 Blast furnace cast house
 Insulating material
 Coke Ovens
 Continuous casting tundish
 Steel ladle
 Tilting runner
 Cement Kilns
 Hydrocarbon processing
 Waste incinerators
 Municipal incinerators
 Industrial incinerators
 Anchors
 Basic oxygen furnace
 Electrical arc furnace
 Blast furnace
 Cyclones of petroleum refineries
 Boiler tube protection
 Electric furnace roofs
 Rotary kiln
 Iron and slag runners
 Thermal power plants
 Reheat furnace hearths
 Fluid beds
 Iron ladles
 Foundries
 Soaking pits
 Thermal power station boilers
 Foundry troughs
 Induction furnace

Glass

Glasses are everywhere! Mainly used in
• Construction field like Window glass, insulation, facades, shelves, tables
• For making laboratory equipment like beakers, test tubes, measuring cylinders, burette, pipette, flasks, thermometers
• Fibre optic cables
• Tube lights and bulbs
• Automobiles like Car windows, mirror, front and back lights, aircraft, ships
• Mirrors
• Appliances and electronics like oven doors, Television screen, computer screens, smartphone screens
• Crowns in glass tank furnace
• Solar energy glass and wind turbine
• Insulation purposes
• Jewels
• Optical fibres
• Eye Spectacles and contact lens
• Telescope lenses
• Solar panels
• Tablewares like dinner plates, cups, saucers, bowls
• Furniture making
• Modular kitchen

Glass Aluminium Casement Windows.

In this article, We are going to see the Tile Manufacturing/Production Process. Ceramic tiles are economical to produce because of the raw materials used are easily available mined ceramic minerals. The Primary raw material for the tile production is Clay, Quarts and Feldspar.

Steps in the Tile manufacturing Process are:

Batching:

• Batching is the initial step in the tile manufacturing process
• During batching the raw materials are included in a formulated percentage known as composition or in other the composition decides the amount of raw material to be taken to the manufacturing process.
• The raw materials are plastic raw materials and non-plastic raw materials and additives
• The plastic raw materials provide strength and plasticity to the green compact
• The non-plastic raw materials provide the liquid phase needed for verification and also provides strength to the fired body. feldspar is a non-plastic material.

WET GRINDING

• The raw materials are taken in a ball mill and them grinded with water for certain hours. The grinding media is usually alumina because it has good wear resistance and good density. This process is known as wet grinding.
• The raw material will be obtained in a slurry form at the end of the wet grinding process. The slurry is stored in a slip tank
• The slurry is continuously rotated in order to prevent the setting of the slurry.
• The slurry is taken to spray drying unit through the conveyors.

SPRAY DRYING

• In a spray dryer, the slurry is converted into powder through the atomizer and the hot air.
• The function of the atomizer is to spray the slurry into fine droplets. The basic principle behind the functioning of the atomizer is Bernoulli’s principle.
• the sprayed slurry is made to contact with hot air, during which liquid associated with the slurry gets evaporated and the remaining solid substance is obtained in a powder form
• During this process, more than 90% of the liquid in the slurry is evaporated.
• Depending upon the position of the atomizer and the hot air entry port the spray dryer is classified into three types.
• If the hot air zone and atomizer are at the same end of the dryer then it is called co-current flow dryer. It produces a lot of dust. To overcome this problem, there is a bed combined along with the dryer. This bed clumps the small dust particles to form a bigger sized particle, thereby reducing the problem with this type of dryer. The liquid gets evaporated by utilizing the heat from the hot air.
• If the hot air zone and atomizer are at the opposite ends of the dryer, then it is called counter-current flow dryer. The hot air is thrown against the direction opposite to that of the sprayed slurry, mostly the atomizer will be at the top and the hot air entry port will be at the bottom. The counter-current flow dryer has more efficiency than that of the co-current flow dryer.
• There is another type called a mixed flow dryer in which the mechanism of both co-current flow dryer and the counter-current flow dryer is combined together.
• Based on the cycle of the hot air the spray dryer is of two types. They are open cycle dryer and the closed cycle dryer.
• In an open cycle dryer, the air is withdrawn from the atmosphere. It is heated, processed and then it is let out into the atmosphere.
• In closed cycle dryer, the air is not let out, it is recycled and it is used again and again.

CRUSHING AND MILLING

• In this process, the raw is crushed and grounded and mixed together.
• There are various crushing machines which perform the crushing such as jaw crushers, gyratory crushers and pig mill.
• In jaw crusher, there will be a movable jaw and a stationary jaw. The movable jaw moves and then it crushes the raw materials against the stationary jaw.
• In gyratory crusher, the rotating cone throws the material against the shell by which the materials get crushed
  In pig mill, there is a hammer shaft and rotor. Due to the rotating oh hammer, the material is ground and gets powdered.
• There are many mills which powder to fine powder. The example is a hammer mill and muller mill
• The crushed powder is then taken to screening and it is stored in silos.

WETTING

The wetting machine is a consists of hollow structure inside. The material flows from top to bottom inside this structure. The water is sprayed by tubes to the material and thus it gets required moisture content.

ADVANTAGES OF DRY PROCESS

• • Spray dryer could be eliminated
  • Power supplied and water supplied to spray drier could be avoided.
  • Initial capital is less compared to wet process

  DIS ADVANTAGES OF BALL MILL

  • The product will be of low strength when compared to wet process.
  • The finishing will not be as good as product obtained in wet process.

  Tiles Green ware Formation:

  The Tiles green ware production usually consists of two methods.

  • Pug milling and Extrusion
  • Powder pressing

  Pug Mill:
  Clay is mixed to get a plastic state.

  • The Pug mill usually consists of a augar blades (or) knifes in the rotating shaft.
  • It cuts and blends the clay with water.
  • In some cases, there will be a de-airing chamber before blending.
  • It removes the air from the mass which increases the plasticity of the clay mass.
  • At the end of a pug mill a plastic mass which has good plasticity is obtained.

  Extrusion:
  The shaping of plastic mass is done by extrusion.

  • The plastic mass from pug mill is taken to a extruder.
  • The extruder consists of a pressuring chamber and a die.
  • The die has a thin rectangular cross section.
  • The pressuring chamber pressurizes the clay into a die through which a flat, slafs of continuous tile green ware emerges.

  Cutting tile green ware:

  • In this process, sharp blades are used to cut the continuous greenware into a required shape. Then the shaped tile greenware is taken to the drying process.

  Powder pressing:

  • In this process, there is a hopper, mould cavity, top plunger and a bottom ejector.
  • The hopper pours the material which is in powder form into the mould cavity.
  • Then the top plunger moves into the mould cavity and pressurizer the powder present in the cavity.
  • After pressing, the bottom ejector moves up and pushes the tile greenware into the conveyor.
  • The conveyor takes the change of the tile greenware, which takes it to the drying process.

  The most commonly used process is powder pressing.

  • In this step, the powder produced by spray drying is fed into the mould cavity.
  • Then the top punch moves down and presses the powder to dry pressed tile.
  • The binding component is usually water. In some industries, chemical additives are also used as a binder.
  • The pressed tile is ejected by an ejector.
  • The dry pressed ware is then taken to the drying chamber through the conveyors.
  • Nowadays pressure glazing is a new technique followed. In this method, the powder is pressed and then the glaze which is in powder form is pressed into it.
  • The advantages of pressure glazing are glaze storage tanks, energy supplied to the rotors which will be agitating the glaze in glaze tanks, separate glaze line could also be avoided
  • The sludge which is the waste produced from glaze unit could be absolutely avoided.

  DRYER:

  • The dryer is commonly employed after pressing. The dryer reduces the moisture content. After drying, the moisture content will be 1-1.5%.
  • The dryer process also increases the strength of the green compact. The horizontal dryer or vertical dryer is most commonly used.
  • The time, temperature and type of dryer used depend upon the nature of title.
  • If drying time is high, say for 90 minutes the one can go for vertical dryer since constructing a horizontal dryer for that length is quite expensive.
  • After dryer the dried tile is taken to glaze line
  • The water is sprayed over the surface of the pressed tile.

  PREPARATION OF GLAZE

  The important method in glaze preparation is the selection of raw materials.

  • The Raw material must be selected in the way that it must fuse homogeneously at the given temperature.
  • If it is applied on the dry body then it must get fused at the temperature at which the body is fixed. If it is applied on bisque fired body, then it must fuse at low temperature.
  • Another important criteria is thermal expansion. The thermal expansion of glaze should be slightly lower than the expansion of body so that it will be in slight compression which will increase the strength of the tile.
  • If there is a big difference on thermal expansion between the body and the glaze, defects such as crazing, peeling occurs. To avoid that, the thermal expansion of the glaze should be suitable of that of body.

  The Raw materials commonly used are

  1. China clay
  2. Ball clay
  3. Zinc oxide
  4. Feldspar
  5. Calcite
  6. Frit
  1. The above raw materials are taken according to batch composition and then it is taken to ball mill. The grinding of material with water occurs in the Ball mill. The grinding media is usually alumina.
  2. After milling, certain properties of glaze has to be checked they are viscosity, density, residue and pickup weight
  3. If the determined value matches with the standard, then the glaze is passed through sieves and it is loaded on glazes storage tanks.
  4. To get coloured glaze, stains are to be added. The stain can be directly added on Ball milling.
  5. In other method desired amount of glaze is taken in drum, then stains are added to it and then it is mixed.
  6. Engobe is also prepared in the same method.

  APPLICATION OF ENGOBE AND GLAZE

  After engobe application, the glaze is applied over it.
  the following are different methods of application
  Bell Application:
  In this method, there is bell-like structure which makes the glaze to fall over the surface.  It is a predominantly used method which is used to produce defect-free glaze.
  Disc Application:
  In this method, the disc is employed to through glaze over the surface of the body.  The quality of glaze produced by this method is quite less.

  Dry glazing:

  • In this method, a wet glaze is first applied over the surface of the body.
  • Then dry glaze powder is sprayed over that wet glaze.
  • On firing, the powder and the wet glaze will fuse together which will produce beautiful designs.

  Dry Pressing:

  • As previously said, during pressing, a powder is pressed first and then dry glaze powder is pressed over it.  It reduces separate glaze line.
  • After glaze application, the raw materials are taken to the kiln for firing.

  Tiles Designing

  The decoration over the glaze makes the tile pleasing to the eye. The decoration is done by various techniques. Some of the techniques are

  • Screen printing
  • Digital printing

  Screen printing:

  • The screen printing is done with the help of screen
  • The required design is made on the screen
  • The required colourant is added on the screen
  • The rotating roller is allowed to pass over the screen
  • By the action of rollers, the colourant is squeezed or pressed over the screen and it emerges through the design
  • By this, the tiles get designed

  Digital printing:

  • This type of printing is done by digital printers
  • The ceramic ink is fed into the printers
  • Any type of design could be drawn by digital printers.
  • The digital printers prints the given design over the tiles

  KILN:

  • The kiln is the back tone of the industry.
  • The roller worth kiln is most commonly used.
  • The temperature of the kiln depends upon the nature of the tile.
  • If one wants to increase the time, the speed of the roller could be increased or vice versa.
  • The zone is
  • Pre-heating zone
  • Firing zone
  • Cooling zone

  PRE-HEATING ZONE:

  In this zone, heating is done by the heated air coming from the firing zone. The is no flame heating in this area.

  The green tile gets heated by the hot air coming out of the firing zone.

  FIRING ZONE:

  In this zone, a group of burners is employed to achieve the highs firing temperature. Verification of tiles takes place in this which provides the tiles desired strength, good finishing and also makes the tiles to be pore-free.

  COOLING ZONE:

  PRE-COOLING ZONE:

  In this zone, the air is drawn from the atmosphere, through air fans and is thrown inside the chamber. This cool air interacts with the tile and absorbs the heat. The temperature of the tile gets reduced.

  INDIRECT COOLING ZONE:

  In this zone, the air is withdrawn from the chamber using air pumps. The temperature of the tile gets further decreased. It is termed In-direct cooling because there is no air cooling is involved as in the previous step.

  FINAL-COOLING:

  It is like that of the direct-cooling zone. A larger amount of air is sucked from the atmosphere and it is distributed by cooling fans.

  The hot air obtained from this area is used as a heat source for dryer. At this end, the temperature of the tile will be in the range of 40°c-80°c

  After firing and cooling, the fired tile is taken to quality check and inspection

  QUALITY CHECK

  In quality, check is done to find whether the tile has defects or it is free from tiles

  The common defects found is

  • Lamination: Sometimes the body gets swells up. It is known as lamination. It is due to the improper moisture content in the pressed powder and improper pressing conditions etc.
  • Chipping: When some portion of the body get chipped off or broken, then it is known as chipping. It occurs due to the hitting of tile against objects such as guides on passing through the conveyor
  • Crazing: If the thermal expansion is very high than that of the body, the glaze will be in tension. Cracks will develop over the glaze surface. It is known as crazing.
  • Crawling: It occurs due to the adhesion problems. The glaze will not get properly adhered to the body. It May also occur due to the high surface tension of the glaze
  • Pinholes: The volatile substance in firing gets escaped from the body which causes small hole I the glaze. It is called as pin holes.
  • Cracks: The cracks occur at the side of the pressed compact. It is due to the high moisture content in the press powder or pressure variation during pressing.

  SORTING & PACKAGING

  The inspected tiles are sorted, packed and taken to the storage area.