Karara Ceramics


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​

Here is how we source our raw material

For the production of our tiles, we meticulously source raw materials that comprise clay minerals extracted from the Earth’s crust, natural minerals like feldspar to optimize firing temperatures, and chemical additives for shaping. These minerals undergo refinement or beneficiation near the mining site before being transported to our ceramic plant.
The raw materials undergo a methodical process involving crushing and categorization based on particle size. Primary crushers, such as jaw or gyratory crushers, play a crucial role in reducing large material lumps through horizontal squeezing or rotating motion between steel plates or cones.
Following primary crushing, secondary crushing further refines smaller lumps into particles, often employing Hammer or Muller mills. Muller mills utilize steel wheels in a gently rotating pan, while hammer mills deploy rapidly moving steel hammers to crush the material. Alternatively, roller or cone-type crushers may be employed for this process. This comprehensive approach ensures the quality and consistency of our tile production.
Following secondary crushing, a third step of particle size reduction may be necessary. Tumbling mills, coupled with grinding media, are employed for this purpose. Among these mills, the ball mill is a prevalent choice, featuring large rotating cylinders partially filled with spherical grinding media.
In the subsequent stage, screens are utilized to segregate particles within a specific size range. Positioned in a sloped manner, these screens undergo mechanical or electromechanical vibration to enhance material flow. Classification of screens is based on mesh number, where a higher mesh number signifies a smaller opening size.
The final stage involves the application of glaze, a glass material designed to melt onto the tile’s surface during firing. This molten glaze adheres to the tile surface as it cools, delivering both moisture resistance and aesthetic embellishment. Glazes, available in various colors or textures, contribute not only to the functionality but also to the visual appeal of the tiles.

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.


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