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Amazing things that sanitaryware producers can make

These "one piece closets", shown in the background photo, weigh up to 45kg (100lb). In this factory, they fire cold-to-cold, in a tunnel kiln, in about 20 hours. Total shrinkage of the product is 12% (so the moulds are made 12% bigger). They are porcelain so dry hardness is fairly low - but they need to dry and shrink while doing so - without cracking. And, as porcelain, they have a high firing shrinkage - yet need to fire with minimal warping and no cracks - despite the weight. They also have to perform in use every day for decades (they must withstand a minimum 400 kg load). The glaze has be to durable and it absolutely cannot craze, shiver or leach. The engineers, mold makers and kiln designers that make these possible are amazing. But so are the production personnel - not just because of conditions in the plants (e.g. heat, humidity, noise) but also the need to keep costs down yet still produce a good product. That means incorporating as much local material, dry and fired scrap as possible. While some plants have pressure-casting lines, the cost is high so most still use traditional plaster molds - it is heavy and demanding work.

Amazing things done by sanitaryware makers

Related Pictures

Sanitaryware tunnel kiln control panel


In this plant (in India), they are firing a 20-hour cycle. In sanitaryware this is considered fast firing. This kiln is a combination drier and furnace, it is 96 meters long. It has a pre-heating zone, firing zone, and cooling zone. In this plant, after the firing zone ware is cooled quickly, from 1200-800C, to ensure a glossy glaze surface. Each car takes 13 hours to reach a peak temperature of 1200C. The panel displays the temperature of 24 points in the tunnel.

Tunnel kills are very energy efficient compared to shuttle kilns (not just by having the final drying stage in the kiln itself but by cars loaded to maximum density). This plant seeks to maximize efficiency by loading a kiln car with 15-24 sanitaryware pieces (small and large items are packed closely together to also encourage even heat distribution). Refractory high risers are also incorporated in the pack, these help minimize heat loss (via air flow).

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

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