Manual vs Carousel vs Robot Glazing in Sanitaryware Industry

Glazing is an important stage in sanitaryware manufacturing. In this section, dried greenware is inspected first, then glaze is sprayed before firing. This combined area is commonly called control and spray.

Manual, Robot and Carousel Glazing

In this article, we will see three common glazing methods used in sanitaryware production. We will compare manual spraying, robot spraying and carousel spraying based on cost, production rate, maintenance, breakdown, quality and manpower.

Manual Spraying

In manual spraying, dried greenware is inspected in one booth and then moved to the spraying booth. The sprayer applies glaze manually. After spraying, the piece is moved for logo stamping and then sent forward for kiln loading.

Robot Spraying

In robot spraying, the inspected piece is loaded on a conveyor, turntable or robot table. The robot sprays the glaze based on the selected program. After spraying, the piece is unloaded and logo stamping is done.

Carousel Spraying

A carousel is a round or square conveyor system with turntables fixed at regular intervals. The piece moves through loading, polishing, inspection, spraying, logo stamping and unloading stations. Each person handles one part of the process.

Installation Cost

Manual booth setup cost is lower than carousel and robot systems. Carousel cost is higher than manual booths, but it is normally lower than a robot system when we compare production capacity. Robot glazing has the highest initial investment because of automation, sensors, electrical parts and programming.

Production Rate

• Manual booth spraying takes around 3 minutes for one WC.
• Carousel spraying can take around 20 seconds for one WC.
• Robot spraying can take around 2 minutes for one WC.

We cannot compare only the time directly because manpower is different in each method. Manual booth uses fewer people. Carousel uses more people. Robot normally uses fewer people, but production depends on program, loading and unloading time. Still, for high production, carousel has a clear advantage.

Maintenance Cost

• Manual booth maintenance is low because the system mainly has a blower and simple booth arrangement.
• Carousel maintenance is moderate because chain, motor and gearbox need attention. Most maintenance can be handled by the factory engineering team.
• Robot maintenance is high because it has electrical, mechanical and programming-related parts. Major problems may need support from the robot supplier.

Breakdown

Manual booths have very low breakdown risk. Even if the blower has a problem, spraying may still continue for some time with control.

Carousel breakdown can happen due to chain, motor or gearbox issues. Normally, maintenance time can be planned, but old carousel chains may need more attention.

Robot breakdown is more difficult because fault finding itself may take time. Small issues like spray gun blockage can be solved quickly, but major robot or zero-point issues can stop production.

Quality of Spraying

• Manual spraying depends fully on sprayer skill. So variation and mistake chances are higher.
• Robot spraying gives repeatability, but issues like gun blockage or zero-point error can create defects.
• Carousel spraying reduces individual mistake because more than one sprayer applies coating in stages.

Manpower and Production Capacity

• Manual spraying normally needs 3 people: inspector, sprayer and logo stamper or unloader.
• Carousel may need around 13 people depending on speed and workstation design.
• Robot spraying normally needs 2 to 3 people: inspector, operator and unloader.

Labour Skill Requirement

Manual spraying needs a skilled sprayer because the full coating quality depends on one person. Carousel spraying needs average skill because each sprayer gives only one coating. Robot operation does not need high spraying skill, but programming and troubleshooting need a skilled technician.

Other Practical Points

For a new model, robot spraying needs program creation. In some WC designs, the robot cannot spray the trap or bowl area properly, so manual trap glazing may be required before loading into the robot.

Conclusion

We cannot say one method is best for all factories. Manual, carousel and robot glazing all have their own advantages and limitations. But when we compare production rate, quality control and practical factory operation, carousel glazing gives more advantages for many sanitaryware plants.

I hope I have provided enough information about manual, carousel and robot glazing in sanitaryware production. If you want to know anything more or share your thoughts, please share it below in the comment section.