In sanitaryware production, laboratory testing forms the foundation of process stability and product consistency. From raw material evaluation to slip control, plaster mold monitoring, glaze verification, and final performance testing, each analytical step supports a predictable and efficient manufacturing workflow.
1. Testing of Plastic Raw Materials (Ball Clay, Kaolin)
These materials govern plasticity, forming behavior, drying strength, and dimensional stability.
• Moisture Content
Indicates storage stability and the required adjustment during batching.
• Alkali Demand
Defines electrolyte dosage to maintain slurry thixotropy.
• Residue Test
Prevents defects such as specks and inclusions caused by coarse particles.
• Drying and Firing Shrinkage
Essential for dimensional control.
• Loss on Ignition (LOI)
Reflects volatile content and mineral composition.
• Modulus of Rupture (MOR)
Evaluates green and fired strength stability.
2. Testing of Non-Plastic Raw Materials (Quartz, Feldspar)
These raw materials influence thermal expansion, vitrification behavior, and firing density.
• Iron Content (Fe₂O₃)
Critical for achieving the required whiteness and glaze clarity.
• Moisture Test
Ensures consistent batching.
• Cone Fusion Test
Judges fluxing characteristics of feldspar.
• Residue Test
Controls particle size distribution for optimized drying and sintering.
3. Slip Testing (Slip Rheology & Casting Performance)
Slip quality directly affects casting speed, mold cycle time, and body uniformity.
• Density / Specific Gravity
Controls casting rate and drainage behavior.
• Viscosity & Thixotropy
Ensures stable flow during mold filling and water absorption.
• Flow Test
Prevents slow casting, mold blockage, and inconsistent wall thickness.
• Shrinkage and Warpage Check
Predicts production deformation risks.
• Permeability
Directly influences the casting rate and demolding time.
4. Plaster Mold Testing
Plaster molds determine casting efficiency and product consistency.
• Setting Time
• Exothermic Peak
Indicates reaction quality during molding.
• Modulus of Rupture (MOR)
• Absorption Rate
A key determinant of casting performance.
5. Glaze Slurry Testing
Glaze behavior determines surface luster, whiteness, smoothness, and chemical durability.
• Density / Viscosity
• Drying Time
• Color Matching
• Particle Size Distribution (PSD)
6. Fired Product Testing
Final tests validate the functional and aesthetic quality of sanitaryware.
• Water Absorption
Indicates vitrification level and body density.
• Crazing Resistance
Evaluates glaze–body fit under thermal stress.
• Thermal Shock Resistance
• Chemical Resistance
Conclusion
A well-structured testing framework across raw materials, slip preparation, mold performance, glaze formulation, and fired properties ensures production stability, improved efficiency, and consistent compliance with global sanitaryware standards.