Technological advances continue to transform tile manufacturing. From digital printing and inkjet decoration to nanotechnology-infused tiles and porcelain slabs, these new technologies offer a wide range of design possibilities and enhanced performance.
Equipment like Lamgea and Continua+, developed by two of ceramic industry giants – Sacmi and Sit B&T – eliminates format restrictions through continuous compaction and ‘on the move’ cutting stations. These lines can produce slabs of all sizes and thicknesses, decorated on surface and in-body, at far higher rates.
Digital Printing
In terms of enabling tile manufacturers to deliver the designs and visual appearances that consumers demand, digital printing is one of the most important technological advances. It may have only been introduced in the past decade, but digital technology has revolutionised how tiles are produced.
Using a ceramic printer, the design is applied to a raw tile through digital single-pass decoration. This process uses ink that is resistant to the high temperatures of a kiln and printheads with the ability to jet layer pigments at very low viscosities.
With the digital technology, a large part of the production process is automated. This can result in substantial savings of time and resources. Additionally, less tile is lost during production as compared to screen and rotary print processes.
The process also eliminates waste from excessive manual labor and extra inventory, as well as energy consumption in comparison to traditional manufacturing methods. This reduces the impact on the environment and saves money in the long term.
In the future, the capabilities of digital printing will continue to expand. For example, it will enable tile manufacturers to decorate textured surfaces – something that would not be possible with an analog printing method. And, as consumer demands change, digital technology will allow the tile industry to offer a wider range of special effects.
Nanotechnology
The technology known as nanotechnology manipulates atoms and molecules in extremely small dimensions. It’s a field that has become increasingly relevant to tile manufacturing because it allows for lower energy consumption and faster production. It’s also possible to create new materials that are more durable, insulating and easy to clean.
As a result, manufacturers are able to use less raw material and natural gas in the production process without jeopardizing quality standards. In addition, new refractory and insulation materials for kilns can reduce energy consumption.
Nanotechnology has also expanded the design possibilities of porcelain tile. For example, MSI’s Calacatta Pietra porcelain tile features sweeping lines and elegant gray and brown veins for a realistic marble stone look. Moreover, the tile is crafted using nanotechnology to help it resist scratches and stains.
Another way nanotechnology has improved tile manufacturing is through its application to ceramics and vitrified tiles. One common form of it is called double charge vitrified tiles. They’re made by applying a layer of silica to the surface of polished tiles that fills in the nanopores and makes them water-resistant.
Other uses of nanotechnology in tile manufacturing include the coating of surfaces with a material that resists dust, dirt and staining. In a recent trial at Dubai’s Noor Bank metro station, the patented nanotechnology coating reduced cleaning and maintenance costs by 35% and boosted durability of floors.
Pressing
The tile manufacturing process involves a lot of thermal energy in the form of high temperatures and long periods of time in kilns. This consumes a large amount of electricity, natural gas and water. Advances in this area are helping manufacturers cut their production costs and environmental footprint without jeopardizing quality standards.
One example of this is new technology that allows tile manufacturers to produce large slabs with very thin body materials. The result is that tiles can be made with a wide range of sizes and textures, which opens up many more design possibilities for homeowners and commercial end-users.
Once the clay powder has been mixed with sand and cement to meet specified standards, it is sent to the pressing machine where the final tile body properties are determined. Vitrified tile is pressed at low pressure, while ceramic tile is pressed under slightly higher pressure.
Among the latest innovations in this area are superfast presses, such as the System Ceramics Superfast and Series Veloce lines from Sacmi. These allow manufacturers to create a full range of formats without moulds by compressing the powder into large slabs or, as the USA calls them, gauged porcelain panels. There are a number of leading manufacturers that use these systems including Iris, Ariostea, Graniti Fiandre, RAK and Nord Ceram. These types of advanced presses also feature a scrap collection conveyor and atomized powder collector that helps to reduce energy consumption.
Drying
As the demand for tiles continues to rise, manufacturers have responded with innovations that address style and performance. These advances are helping to increase the versatility of tile as a flooring and wall surface.
The drying process is a key step in tile manufacturing that determines the final product’s quality and properties. Manufacturers are investing in large hydraulic presses that utilize innovative kiln technology, which ensure high-quality standards and reduce energy consumption and environmental impact. For example, SACMI’s Series Veloce press combines advanced hydraulic circuit solutions with cutting-edge compaction technology that maximizes productivity and eliminates format limitations.
In addition to reducing production costs, these new technologies have also improved the appearance of tiles. Digital printing, for instance, allows manufacturers to produce tiles with intricate designs and vibrant colors. Moreover, it has helped to reduce the amount of wastage that occurs during the production process.
Nanotechnology has also been incorporated into the tile manufacturing process, which has led to products with enhanced strength and durability. One such innovation is self-cleaning tiles, which feature photocatalytic nanoparticles that react to light and break down organic substances, eliminating the need for scrubbing or chemicals.
Another significant advancement in the tile industry is the use of waterjet cutting technology, which allows for more precise cuts and reduced production time. This technology has also enabled manufacturers to create tiles with a variety of textures and reliefs, which give surfaces a more dynamic appearance.