Slurry molding is the core forming process. The performance of the slurry directly determines the quality of the green body, the occurrence rate of defects, and the stability of the production process. Through a systematic performance evaluation of the slurry, it can be ensured that the behavior of the slurry in the gypsum mold meets expectations and ultimately guarantees the quality of the product after firing.
Space and layout requirements:Space requirements: Detail the minimum floor area required for each department (e.g., Casting Shop, drying, glazing, etc.) and the total floor area of the factory.Factory layout: Provide a floor plan including workshop heights, floor levels, and equipment placement.Warehouse planning: Determine the storage space requirements for raw materials, green bodies, finished products, and packaging materials.Project execution plan: Develop a detailed stage-wise factory construction schedule, including equipment procurement, installation (erection), and commissioning.Packaging material specifications: Define the specifications of packaging materials required for the final product.
The overall production cost of sanitary ware manufacturing covers nine basic sub-factors (body raw materials, glaze raw materials, gypsum cost, labor, fuel, electricity, consumables, maintenance, and water fees). Continuously analyzing and optimizing these nine factors is the foundation for maintaining market competitive advantages and improving the factory's long-term operational efficiency.
When formulating the investment budget for a new bathroom factory, it is essential to have a long-term strategic vision, and allocate the budget reasonably to areas that support the two core objectives of high quality and low cost. Only in this way can the factory achieve long-term survival and development in the fierce market competition.
Three key indicators must be evaluated in a coordinated manner and cannot be viewed in isolation. The most efficient bathroom factories will continue to demonstrate a combination of the following characteristics:Average weight (indicating the ability to handle the manufacturing of complex products).Global qualification rate (indicating low waste and rigorous process control).Production cost per kilogram (indicating optimal control of resource utilization).
The indicators of casting yield rate, green body yield rate, glazed green body yield rate, firing yield rate, and overall yield rate collectively provide an overview of the efficiency at each stage of the manufacturing process. Sanitary ware manufacturers must continuously monitor these indicators and conduct targeted troubleshooting to ensure the sustainability of the production process and the overall profitability of operations.
The emergence of high-pressure injection technology equipment is not only a technological iteration of a single device, but also marks a fundamental transformation in the production paradigm of sanitary ceramic forming. It compresses the forming cycle from hours to minutes, achieving revolutionary intensification and liberation across three dimensions: space, labor, and time.
The modular injection molding equipment represents the high-efficiency trend sanitary ware forming processes, bringing lower space costs and higher production efficiency to businesses. It achieves semi-automation from slurry injection to mold handling before demolding, marking a key step in the upgrade of bathroom manufacturing.
Facing such complex and diverse challenges, investors do not need to explore alone. Sunlets, with years of experience in the deep cultivation of the entire industrial chain in the bathroom manufacturing industry, can provide enterprises with a one-stop solution from project feasibility studies, factory overall planning, core process package design, equipment selection and integration, to personnel training, production ramp-up, and even market channel docking. We are not only technology suppliers but also strategic partners who walk alongside our clients, committed to transforming systematic professional knowledge into our clients' stable competitiveness and tangible benefits.
Shrinkage glaze, as a common and challenging surface defect in ceramic sanitary ware production, profoundly reflects the subtle balance between the body, glaze, process, and environment during the manufacturing process. Its causes are not isolated but rather the result of the interweaving of multiple stages such as the state of the body, the characteristics of the glaze, the application of the glaze, and the firing system.
Each glazing technology serves a distinct purpose. Manual Glazing is suitable for low-volume, high-mix, or geometrically complex production. Robotic Glazing excels in flexible automation, high-precision consistency, and medium-to-long-term labor cost control, positioning it as a key direction for smart manufacturing upgrades. Carousel Glazing demonstrates significant cost and efficiency advantages in large-scale production dedicated to maximizing output for specific product types. The optimal choice requires a comprehensive evaluation of the company's product portfolio, capacity goals, investment budget, and technical team capabilities.
Firing is the core process that transforms ceramic bodies into high-performance sanitary ware. A thorough understanding and precise control of the entire process of physicochemical changes are key to achieving high-quality, low-cost production. This article provides a systematic analysis of firing technology for professionals in sanitary ware manufacturing and welcomes further discussion on the viewpoints presented.
In today's global competition and accelerated technological iteration, cost control and efficiency improvement in the sanitary ware manufacturing industry are no longer optimizations of a single link, but an all-round systematic project that runs through design, production, management, and talent. The ten technical approaches proposed in this paper—from systematic loss control to the establishment of a preventive maintenance system—collectively form a dynamic and sustainable cost reduction and efficiency improvement framework.
By continuously optimizing raw material control, process parameters, and production management, sanitary ware manufacturing enterprises can not only significantly reduce defect rates and save costs, but also fundamentally improve product consistency and reliability, establishing a solid quality moat in fierce market competition. The path to quality improvement is endless, and scientific, systematic analysis and prevention is the necessary route to excellence.
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.
Accurately evaluating the dispersion of ceramic slurries is crucial for ensuring the final product quality. From basic particle size analysis and rheological measurements to advanced ultrasonic monitoring and multiple light scattering techniques, various testing methods reveal the dispersion state and stability of the slurry from different dimensions.
By systematically comparing the effects of different dispersants on the viscosity of ceramic slurries, it has been confirmed that high-performance polymer dispersants significantly outperform traditional small-molecule dispersants in reducing viscosity and maintaining stability. The efficacy of dispersants is jointly constrained by multiple factors such as their stabilization mechanisms, optimal concentrations, powder characteristics, and additive compatibility. In-depth understanding of the interactions among these variables, and determining the optimal dispersing solution for specific systems through experiments, is crucial for achieving the ideal rheological properties of ceramic slurries and subsequent forming processes.
The compatibility between dispersants and other additives in ceramic formulations is key to achieving stable slurry and high-quality products. Interactions such as the adsorption competition of binders, the functional counteraction of flocculants, and the charge neutralization of surfactants can all disrupt slurry stability and lead to product defects.
High-solid-content ceramic slurry, due to its high particle density and small free volume, poses stricter requirements for dispersants. Successful dispersion solutions rely on dual stabilization mechanisms combining electrostatic repulsion and steric hindrance, and maintain slurry stability in a dense particle environment through the strong anchoring effect of high-molecular-weight polymers and the barrier effect of long chains.
Dispersants play a dual role in ceramic production, saving energy and reducing consumption while improving quality. By optimizing the rheology of the slurry, they can significantly shorten grinding time, lower firing temperature, and promote the effective utilization of recycled materials, thereby directly reducing energy consumption and raw material costs in the production process.
