Karara Ceramics

Manufacturing

We ensure only the best for your spaces, which is why our tile manufacturing goes through a lot of processes to maintain the highest standards and obtain the final product.

Raw Materials

For our tiles, we use the raw materials that consist of clay minerals mined from the earth’s crust, natural minerals such as feldspar to lower the firing temperature and chemical additives for the shaping process. The minerals are often refined or beneficiated near the mine before shipment to the ceramic plant.
The raw materials are then crushed and categorised according to particle size. Primary crushers are used to reduce large lumps of material. Either a jaw crusher or gyratory crusher is used, which operates using a horizontal squeezing motion between steel plates or a rotating motion between steel cones.
Secondary crushing reduces smaller lumps to particles, for which Hammer or Muller mills are often used. A muller mill uses steel wheels in a shallow rotating pan, while a hammer mill uses rapidly moving steel hammers to crush the material. Roller or cone type crushers can also be used for the process.
After the secondary crushing, a third particle size reduction step may be necessary. Tumbling types of mills are used in combination with grinding media. One of the most common types of such mills is the ball mill, which consists of large rotating cylinders partially filled with spherical grinding media.
Screens are used to separate particles in a specific size range. They operate in a sloped position and are vibrated mechanically or electromechanically to improve material flow. Screens are classified according to mesh number. The higher the mesh number, the smaller the opening size.

Glaze, a glass material designed to melt onto the tile’s surface during firing, adheres to the tile surface during cooling. Glazes provide moisture resistance and decoration, as they can be coloured or produce unique textures.

Our Process

After processing the raw materials, numerous steps take place to obtain the finished product. These include batching, mixing and grinding, spray-drying, forming, drying, glazing and firing. Many of these steps get accomplished using automated equipment.

The final output

After firing and testing, the tile is ready to be packaged and shipped. With such rigorous process and testing, what our customers receive are the world-class, Italy-inspired tiles that create exquisite marvels when incorporated into your interiors.
1002p
Product has been added to your cart