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GAYAFORES (Manufacturing Process of Ceramics (Glazing, Firing, Pressing,…
GAYAFORES
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2. Spray Drying and Pressing 
Process starts with the raw materials being atomise or spray dried. The atomise dust is use to make the ceramic base or biscuit (spherical and hollow) as water is removed rapidly in the atomiser.
Importance of spherical and hollow granules: To make them fill the mold and can be compacted during the pressing process. This is essential to attain the product with the required mechanical strength.
The atomised dust are pressed in one way ( in vertical direction with a high pressure) to compact the atomised clay.
The granules are literally broken so the original particles changed during the milling process which will be agglomerate with clay.
They start to stick to each other from the action of the press and they will in contact which acts as fluid lubricant forming a raw tiles with sufficient consistency to be transported.
The damp tiles are dried in a horizontal dryer. When a tile is emerge from the dryer, it has a residual humidity of around 0.5%. There is no further drying because fully dried ceramic tile is very fragile.
5. Sorting and Packaging
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Use a machine with artificial vision handle by an operator to inspects the design and colour tone of the tiles to eliminate visibly defective items.
Ceramic tiles must be always the same size (comply with certain standards of flatness)
They are stored and ready for distribution once the tiles are sorted into boxes。
3. Glazing and Decoration
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Englobe is the interface materials that lays between the clay base and the glaze. One layer of glaze is applied on top of the englobe to provide the base for decoration.
Main technique used is digital ink injection which can cover 100% of the tile. It is very flexible as changing the digital files in the printing system can customise decorations.
Glazing produce final product: Resistant to chemical, Non-slip surface, Easy cleaning, Provide beautility.
1. Preparation of raw materials
Selecting the raw materials (clay, feldspar, sand, carbonite, kaoline) that makes the tile.
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4. Firing
Perform in a single layer roller kiln (this kiln is fired by gas and can reach a maximum temperature between 1100 – 1200℃) using very fast firing cycles of about 45-60 minutes.
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About Gayafores
Established in the early 20th century in Onda,Castellón,Spain.
Supplying the international market with more than 200 collections of ceramic and porcelain tiles nowadays.