Glazed Tile Roll Forming Machine

Glazed tile roll forming machines are specialized equipment used to produce glazed ceramic tiles in a continuous automated process. This equipment revolutionized tile manufacturing, enabling mass production of tiles with consistent quality and high output volumes.

This guide provides a detailed overview of glazed tile roll forming machines, their working, types, parts, specifications, applications, advantages and more.

How Glazed Tile Roll Forming Machines Work

Glazed tile roll forming machines create glazed ceramic tiles through an automated and continuous production process. Here are the key steps:

Raw Material Preparation

The raw materials – clay, feldspar, kaolin, quartz etc. are blended as per the tile composition requirements and ground to fine powder. Water is added to obtain a homogeneous ceramic slurry.

Pressing

The ceramic slurry is fed into the roll forming machine where it is extruded between an upper and lower roller die continuously as a flat strip. The die surface impressions shape and cut the strip into individual tile blanks.

Drying

The freshly formed wet tile strips are conveyed through dryers at 150-200°C to remove moisture evenly.

Glazing

The dried tiles move to glazing where a coat of glaze slurry is applied on the top surface. The glaze provides the glossy impervious decorative finish after firing.

Firing

Tiles pass through the kiln at temperatures of 1000-1200°C to permanently harden the body and fuse the glaze layer.

Sorting and Packing

Finally, the fired tiles are sorted, inspected for defects and packed for dispatch or storage.

This continuous sequence enables high volumes of tiles to be manufactured at fast production rates.

glazed tile roll forming machine
Glazed Tile Roll Forming Machine 4

Types of Glazed Tile Roll Forming Machines

Glazed tile roll forming machines can be categorized based on design and capabilities:

TypeDescription
Single-layerProduces tiles of one uniform thickness, typically 6-10mm
Double-layerCan produce two layers simultaneously with different thicknesses
Multi-colorCapable of applying more than one colored glaze to create decorative effects
Pressing + GlazingIntegrated design that directly glazes the wet tile strip after pressing

Specialized variants like mesh-mounted tile presses are also available for making thin tiles down to 3mm thickness.

Main Parts and Components

Glazed tile roll forming machines comprise multiple sections for the various production steps. The key parts and their functions are:

PartDescription
Mixing unitBlends the ceramic raw materials into homogeneous slurry
RollersExtract the slurry and press it into the die shape to form the tiles
DieContains impressions that shape the tile body and surface
Belt conveyorsTransport the tile strips between processes
DryersRemove moisture from the formed tiles before glazing
Glazing unitApplies a coating of glaze slurry on the tile surface
KilnHardens and fires the tiles at high temperature
Sorting unitChecks tiles for defects and sorts by size/type
Packing systemPacks sorted tiles into boxes for storage or transport
Control systemAutomates and monitors the machine parameters

Auxiliary units like tile edge cutting and surface polishing can also be integrated.

Specifications and Design Parameters

Glazed tile roll forming machines are designed and built to customer requirements based on production needs. Here are some key specifications and design considerations:

ParameterDetails
Production capacity10,000 – 40,000 tiles/hour or more
Tile sizesStandard 200x200mm to 1000x1000mm; Custom sizes possible
Tile thicknessSingle layer: 6-12mm Double layer: 4-8mm + 8-12mm
Roller sizeDiameter up to 1200mm; Width 1000-2500mm or more
Roller pressureUp to 300 tons by hydraulic cylinders
Dryer length8-12m multi-zone dryers
Kiln sizeLength 25-100m; Capacity 10-100 ton/day
Conveyor beltsHeat, abrasion and corrosion resistant
Machine width5-8m typical
Machine length15m for basic; Up to 150m for integrated line
Control systemPLC based; HMI touchscreen; SCADA
Electrical load50-750 kW connected load

The machine configuration and capabilities can be customized as per the end product mix and plant requirements.

Applications and Tile Types Produced

Glazed tile roll forming machines are extremely versatile. They can produce all varieties of ceramic wall and floor tiles:

ApplicationTile Types
Wall TilesGlossy, matte finish, digital printed, rustic, textured surfaces
Floor TilesRustic, matt finish, exterior, abrasion resistant
Border TilesDecorative borders, accents, moldings
Granite-lookTiles that simulate natural stone and granites

Double layer presses can make both thinner and thicker tiles for walls and floors respectively.

Benefits and Advantages

Glazed tile roll forming machine offer significant benefits over traditional processes:

ParameterBenefit
Fully automatedLess manual labor, consistent quality
High production ratesUp to 40,000 tiles/hour. Lower costs
Continuous operationHigher output and productivity
Flexible productionMultiple sizes and types possible
Lower maintenanceCompared to hydraulic or ram presses
Compact sizeSmaller footprint than conventional processes
Lower energy useEfficient dryers and kilns available

These advantages have made roll forming the dominant manufacturing process for high volume tile production lines.

Suppliers and Pricing

There are many equipment manufacturers across China, Europe and India that supply glazed tile roll forming machines. Here are some indicative price ranges:

Machine OutputPrice Range
10,000 tiles/hour$200,000 to $300,000
20,000 tiles/hour$500,000 to $800,000
40,000 tiles/hour$1 million to $1.5 million

Prices vary based on the level of automation, customization and optional accessories chosen. Second hand and refurbished machines are also available at 30-40% lower cost.

Some leading glazed tile roll forming machine manufacturers include:

  • KEDA (China)
  • SACMI (Italy)
  • Eirich (Germany)
  • SITI B&T Group (Italy)
  • Tosilab (Spain)
glazed tile roll forming machine
Glazed Tile Roll Forming Machine 5

How to Choose a Reliable Manufacturer?

Here are tips on selecting a good glazed tile roll forming machine supplier:

ParameterRecommendation
TechnologyLook for suppliers with in-house R&D for latest designs
ExperienceMore experienced companies offer better support
Production facilitiesVisit their factory to assess production capability
Tile trialsAsk for test samples of tiles made by their machine
CustomizationSee if they offer customized solutions for your needs
After-sales serviceCheck response time, service network etc.
ClienteleEstablished suppliers have reputed tile maker clients
CostGet quotes from multiple vendors for best price

Choose a technologically capable manufacturer who can deliver high performance, durable machines with good after-sales support.

Installation and Commissioning

Installing a glazed tile roll forming machine requires careful planning and preparation:

  • Adequate space is needed for the entire production line and material movement.
  • Strong foundations are required to hold the machines weighing hundreds of tons.
  • Electrical, water and drainage connections must be provided.
  • The machine is assembled in sections which need proper alignment.
  • Mechanical and electrical installation is followed by trial runs and testing.
  • Raw materials processing units must be operational before starting the tile pressing.
  • Staff training for operation and maintenance is essential.

With systematic installation and testing, the machine can be commissioned smoothly. Manufacturers provide engineers to supervise the process.

Operation and Maintenance

To achieve optimal performance from glazed tile roll forming machines:

  • Follow the manufacturer’s instructions for operation and safety.
  • Keep the dies, rollers and other parts clean to avoid tile defects.
  • Use heat resistant belt lubricants to minimize wear.
  • Inspect rollers, bearings, belts and hydraulics regularly.
  • Monitor process parameters like pressure, speed, temperature.
  • Schedule preventive maintenance during plant shutdowns.
  • Replace worn out spares like seals, belts, rollers periodically.

Proper operation and maintenance minimizes downtime and maximizes production.

Advantages of Glazed Tile Roll Forming Machines

Glazed tile roll forming machines offer the following key advantages compared to traditional tile making processes:

  • Fully automated – Requires less manual labor leading to consistent product quality and minimal human errors.
  • High productivity – Capable of outputs up to 40,000 tiles per hour through continuous operation, reducing manufacturing costs.
  • Flexibility – Able to make wide range of tile sizes and designs with quick die changeovers. Enables diversified product portfolio.
  • Compact size – Footprint is 50-70% smaller compared to conventional tile making methods, saving space.
  • Energy efficiency – Advanced dryers and kilns available that optimize heat usage and minimize power consumption.
  • Lower maintenance – Simpler system with less moving parts than hydraulic presses. Easier to maintain with infrequent downtimes.
  • Customization – Machines can be tailored to customer needs in terms of automation features, line integration, optional accessories etc.

These valuable advantages have made glazed tile roll forming the most popular manufacturing process among leading tile makers worldwide.

Limitations of Glazed Tile Roll Forming Machines

Despite many benefits, glazed tile roll forming machines also have certain limitations:

  • High initial capital investment required. Major tile manufacturers prefer to buy, while smaller players prefer conventional machines.
  • Design complexity makes manufacturing dependent on availability of high-precision metalworking facilities. Local production in developing markets can be a challenge.
  • Limited ability to make specialized tiles like concert, terrazzo or highly textured designs. Alternative processes may be better suited.
  • Thickness is restricted to around 6mm for floor tiles and 12mm for wall tiles on a single layer press.
  • Not ideal for producing tiles in small batches for custom applications. Conventional or digital printing may be preferred.
  • Lack of trained personnel and after-sales support in some regions can hamper adoption.
  • Requires significant manual batching and glazing work for certain textured or decorative tiles.

Keeping these limitations in mind, glazed tile roll forming remains the premier solution for medium to high volume tile manufacturing for regular formats and designs.

Glazed Tile Roll Forming Vs Wet Powder Compaction

Glazed tile roll forming and wet powder compaction are two competitive automated technologies for ceramic tile production. How do they compare?

ParameterGlazed Tile Roll FormingWet Powder Compaction
Pressing methodExtrusion between rollersCompaction by vibration and pressure
Production rateUp to 40,000 tiles/hourUp to 33,000 tiles/hour
Thickness range4mm to 12mm3mm to 12mm
Size flexibilityLimited for very large or small tilesHigher flexibility in sizes
Process complexitySlightly lowerMore complex material preparation
Investment costLower by 15-20%Higher
Running costLower energy usageSlightly higher energy
Product consistencyVery highHigh
Type of tilesAll standard formatsLower suitability for specialized tiles

Glazed tile roll forming scores in terms of higher throughput, lower cost and flexibility for regular tiles formats. Wet powder compaction offers ability to go thinner and make some special sizes. For most applications, roll forming is preferred, but powder compaction is a good alternative.

Glazed Tile Roll Forming Vs Dry Powder Pressing

Here is a comparison between glazed tile roll forming and conventional dry powder pressing:

ParameterGlazed Tile Roll FormingDry Powder Pressing
ProcessAutomated continuousBatch type press cycles
Production rateMuch higher upto 40,000/hourLower around 15,000/hour
LaborLower since automatedHigher labor for pressing and handling
Power usageMore efficient dryers and kilnsHigher power consumption
MaintenanceLower with fewer moving partsHigher on hydraulic components
Size flexibilityLimited for very large or small tilesHigher flexibility in sizes
Product consistencyExtremely highModerate, depends on manual supervision
CostHigher capital investmentLower capital cost
Running costLower due to higher throughputHigher due to lower productivity

Glazed tile roll forming offers superior productivity, efficiency, consistency and capability for mass tile production. Dry powder pressing is suitable for smaller batch volumes or specialized tiles.

Glazed Tile Roll Forming Vs Ram Extrusion

Glazed tile roll forming machines and ram extruders are the most common machine choices for glazed wall tile production.

ParameterGlazed Tile Roll FormingRam Extrusion
Pressing methodRollersHydraulic ram
Production rateHigher upto 40,000 tiles/hourLower around 25,000 tiles/hour
Tile thickness4mm to 12mm7mm to 12mm
Size rangeLimited for very large or small tilesWider range of tile sizes
MaintenanceLower on rollersHigher on hydraulic components
Power consumptionMore optimizedHigher due to friction losses
Product consistencyExtremely highModerate, depends on supervision
AutomationHigher degree of automationLower automation levels
CostHigher capital costLower capital cost

Glazed tile roll forming is superior in output, efficiency, automation and product consistency. Ram extrusion tiles lines have lower investment costs but require more supervision.

Conclusion

Glazed tile roll forming machines deliver high productivity, superb quality consistency and design flexibility at optimized costs. The automated process allows tile manufacturers to produce large volumes cost-effectively with minimal manual intervention. Although the initial investment is higher, the advantages of much greater throughput and lower operating expenses make glazed tile roll forming the ideal choice for large scale tile production. Leading tile makers around the world have adopted this technology for their core manufacturing needs. With continual advances and new developments, glazed tile roll forming machines will consolidate their dominance as the premier manufacturing process for the global ceramic tile industry.

glazed tile roll forming machine
Glazed Tile Roll Forming Machine 6

FAQs

Q: What is the typical production capacity of glazed tile roll forming machines?

A: Standard production capacity ranges from 10,000 to 40,000 tiles per hour. Higher custom capacity machines are also available.

Q: What tile sizes can be made on these machines?

A: Common tile dimensions from 200x200mm up to 1000x1000mm can be produced. Custom sizes are also possible.

Q: What types of tiles can be made?

A: All kinds of wall tiles and floor tiles with glossy, matte, textured, rustic, stone-look and other finishes can be manufactured.

Q: How to choose between single layer and double layer tile presses?

A: Single layer is suitable for most tile thicknesses from 6-12mm. Double layer allows combining thinner and thicker tiles on the same machine.

Q: How are different tile colors and patterns achieved?

A: Multi-color glazing, digital printing and customized die shapes enable a range of decorative designs.

Q: How to reduce power consumption in glazed tile roll forming?

A: Using energy-efficient dryers and kilns is key. Heat recovery systems can also minimize energy usage.

Q: What is the service life of these machines?

A: With proper maintenance, the machinery will last over 15-20 years. Key parts like rollers may need replacement over time.

Q: What factors affect the price of glazed tile roll forming machines?

A: Production capacity, automation features, customization, line integration and optional accessories impact the pricing.

Q: How much floor space is needed to install a tile roll forming machine?

A: Approximately 600-1000 sq.m is required for a basic machine with ancillaries. More for integrated lines.

Q: What skills are needed to operate glazed tile roll forming machines?

A: Machine operators need basic technical skills. Process engineers oversee the production quality and parameters.

Q: How is glazed tile roll forming better than powder compaction?

A: It offers higher throughput, lower cost, and greater consistency in product quality for regular tile formats.

Q: What are the limitations of glazed tile roll forming machines?

A: High investment cost, less suitability for specialized tiles, restrictions on tile sizes, and availability of skilled resources.

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