Sanitaryware troubleshooting
How can I resolve common defects in my sanitaryware production?
Sanitaryware manufacturing involves multiple sensitive stages where defects can easily arise. Our teams provide skilled troubleshooting services to improve your process stability and final product quality.
Why is my drying stage generating so many rejects?
In sanitaryware production, drying is typically the stage where most rejects occur, primarily due to drying cracks. These cracks often stem from unseen defects at the casting stage, such as issues in hollow parts or joints, or from environmental factors like uneven temperature and moisture.
The Solution: Using minerals that provide better particle packing can help absorb or prevent crack generation, significantly improving yield.
Body Strength: If handling stress between de-molding and the kiln causes damage, we may recommend higher plasticity clays to increase the strength of the ceramic body.
How do I fix problems with slip and glaze preparation in sanitaryware?
Inconsistencies during preparation can lead to a variety of downstream application issues.
Slip preparation: We help resolve challenges such as difficult blunging, high residue, low density or excessive viscosity and thixotropy.
Glazing issues: Our experts help you tackle glazing problems including wavy surfaces, powdering, detachment and excessive drying time.
Sedimentation: We provide solutions for glaze sedimentation and settling for consistent application.
FAQ
If you are encountering a low casting rate, poor drainage, or issues with de-molding, our specialists can analyze your formulation to improve plasticity and reduce shrinkage in the mold.
Glaze defects such as crawling, pinholes, crazing, and shivering are major challenges for sanitaryware producers. At Imerys, we can help you troubleshoot these issues alongside other surface problems like black spots, stains, and chipping.
Many defects found during sorting after firing actually originate during the casting, drying or glazing stages. Our experts help identify these root causes to reduce firing cracks and creeping (pyroplasticity).
Sanitaryware
Ceramics
Imerys supplies high-performance mineral solutions used in ceramic manufacturing across sanitaryware, tableware, tiles and technical ceramics. Our portfolio of kaolin, ball clay, feldspar, wollastonite and talc supports ceramic body formulation, glaze performance and firing stability. Ceramic producers across Europe, Asia, Middle East, Africa, North and South America rely on Imerys minerals to improve product strength, surface quality, whiteness and manufacturing efficiency.
