The tile industry has seen mammoth growth in recent years. Its technological advancements have allowed manufacturers to develop a wide variety of designs for wall and floor ceramic tiles.
Sacmi’s Continua+ line utilizes continuous compaction technology to make large-format slabs or gauged porcelain panels. Its rollers compress slip powder to create a stronger, more durable form body.
1. Digital Printing
Tile manufacturers need to keep bringing new products and design options to the market in order to remain competitive, and digital printing has been a key element in their success. From larger tile formats such as Mega Size, to special effects for both aesthetic and practical purposes, and personalisation, digital printing has brought many advantages to the industry.
Digital inkjet printers are able to decorate tiles without touching them, meaning that they can print on textured surfaces as well as flat ones. This can help tilemakers to create more authentic and natural looking designs that customers demand.
One of the most important elements to consider when purchasing a large ceramic tile digital printer is the type of printhead. For example, Xaar’s 1001 print head was designed specifically for jetting high viscosity ceramic inks. Its TF technology means that it is inherently resistant to blockages caused by particles or bubbles. Furthermore, a continuous recirculation system keeps the ink flowing past the back of the printhead to prevent it from settling.
Pairing this technology with the ability to scan real marble, wood and stone allows Interceramic to create designs that mimic the most realistic looks of natural product. This is a crucial element in elevating tile to the level of beauty that consumers seek.
2. Nanotechnology
A huge supply industry has developed around the production of the raw materials that tile manufacturers use. These include frits, feldspars, silica, talcs and clays. There are also companies that specialize in equipment and others that only build complete tile factories. Another group provides cutting edge technology to improve the efficiencies of the manufacturing process.
All tile starts out as a clay, sand or cement-based material that is quarried and refined to meet quality and consistency standards. Once that is done, the material is then pressed into a mold at high pressures. Most manufacturers now have sophisticated statistical process control charts that help them monitor a wide range of processing parameters, including milling time and temperature, drying temperature and speed, compaction pressure and dimensions after pressing, density, etc.
The image of the tile is then printed onto the surface using special inks that penetrate and fuse with the porcelain. The result is a more realistic print that stays fresh longer and requires less maintenance. The latest technology involves adding metallic nanoparticles to the ink to create antimicrobial tiles. These have shown activity against a number of bacteria and can be used in hospitals, schools, offices and train stations as well as private homes. This is a significant step in improving public hygiene and combating the spread of the COVID-19 virus.
3. Energy-Efficient Drying
The manufacturing process requires a large quantity of energy, mostly in the form of heat. Tiles are subjected to very high temperatures, in particular in kilns, for long periods of time during the firing and drying stages. These thermal processes require a lot of electricity, natural gas and water. This has led to calls for improvements in the ceramic industry’s manufacturing process.
DREAM projects and other research initiatives have made it possible to reduce the consumption of raw materials, natural gas and water in tile production without jeopardizing quality standards. New refractory and insulation materials for kilns, for example, cut energy costs by eliminating heat transmission losses. In addition, technology like the Superfast press from System Ceramics and the Series Veloce lines from Sacmi allow manufacturers to create a full range of formats without using moulds. This way, the unfired slabs can be cut ‘on the move’ and then decorated both on the surface and in-body with powder-based digital decoration systems.
Additionally, thin porcelain tiles continue to gain popularity. Besides their clean, modern looks and reduced grout lines, these tile products are also easy to maintain. In fact, they are a strong fit for today’s germ-aware world. Unlike other surfaces, correctly manufactured tile is hard and impervious, which makes it innately resistant to bacteria, mildew and mold.
4. Robotics
Tile continues to be a versatile and durable material, but it has also become an increasingly aesthetically appealing product thanks to innovative technology. From digital printing to inkjet decoration, technological advancements are allowing manufacturers to push the boundaries of tile design and manufacturing.
Among the latest advances in tile production is robotics. Robotics is part of what’s known as Industry 4.0, a system that uses modern and smart technologies to increase operational excellence, including advanced robotics, Artificial Intelligence, the Internet of Things, Machine Learning, Cloud Computing, Data Analytics, and Cyber-Physical Systems.
For example, robotics allows tile factories to create mega-format slabs that can be cut and fabricated into tiles without the limitations of moulds or vertical ram presses. Two of the world’s biggest ceramic equipment makers, Sacmi and Sit B&T, have developed a compaction process called Lamgea that eliminates format restrictions, enabling the creation of large slabs (up to 1,200 by 3,600mm) and their sub-multiples.
Manufacturers are also leveraging nanotechnology in their tile products to enhance their strength, durability, and performance. One exciting development is self-cleaning tiles, which feature photocatalytic nanoparticles that react to light and break down organic substances, eliminating the need for scrubbing or chemicals.