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Melt flow test done by QC in sanitaryware plant

Sanitaryware manufacturers walk a tightrope between enough zircon to opacify and whiten but not so much that the glaze melt becomes too cohesive and stiff (which prevents healing defects and produces crawling). High percentages of Zircon are needed to stain the glaze white and opacify it enough. Melt fluidity can be observed and measured. This technician at a sanitaryware plant uses a melt flow test like this to extract a measurement that can be recorded in test records. The same glaze is being tested here - the two values are being averaged.

Melt flow test done by QC in sanitaryware plant

Related Pictures

Crawling on sanitary ware. Laydown is the first suspect.


Crawl-point in sanitaryware

This is glaze crawling and it underscores the need for attention to the details of all production parameters. This one small glaze defect makes this pedestal sink either a refire, a second or unsaleable. This is most common on abrupt surface contours but that is not the case here. The cause of this is likely several factors combining. The glaze is opaque white because it contains a high percentage of zircon opacifier. Zircon glazes tend to do exactly this so their successful use is doubly dependent on minimizing the percentage added and on attention to other details to compensate. This glaze has been applied thickly to ensure good coverage (thicker laydowns bring more crawling problems). The glaze is likely low in clay and thus the physical bond of the dried glaze layer depends on the binders being used, their percentages, the integrity of the way they were mixed in, and their shelf life. The ability of the glaze laydown to dry-bond with the body depends on the condition of the surface (e.g. water content, dry or bisque fired, smoothness, dustfreeness, quality of materials used in the body and integrity of body preparation, etc), the presence of surface contaminants (e.g. soluble salts) and the way in which it was applied and its thickness. The glaze melt's ability fire-bond and form an interface with the body that produces a smooth surface is dependent on its melt fluidity and ability to form an interface with the body.

There is another way to look at this problem: The process runs along crawling multiple tipping points: A viscous glaze melt, glaze application to dry rather than bisque ware, a thick glaze application, a large surface area intolerant of any defects and a glaze application technique (spraying) prone to irregularities of thickness. Rather than trying to identify the specific problem it might be better to simply make changes to move the process back from the tipping points.

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Glossary Sanitary ware
A type of porcelain zircon-glazed ceramic that includes bathtubs, sinks, toilets, etc.

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