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SHINTO Tile Manufacturing Process
Tile Manufacturing Process
We currently manufacture our tiles using a tunnel kiln, the standard practice for ceramic tile manufacturing.
Each session is controlled using the latest technologies.
Blended clay
Main supply unit
･Supplies and stores clay
Temporarily holds clay as it supplies clay for the next process.
Temporarily holds clay as it supplies clay for the next process.
Sub supply unit
Kneading machine
･Kneading
This is where clay is kneaded to make it uniform.
We inject steam to improve molding performance.
This is where clay is kneaded to make it uniform.
We inject steam to improve molding performance.
Extruder
･Soil kneading
By turning the air inside the clay into a vacuum, we remove it and create a form close to the product itself (called araji).
By turning the air inside the clay into a vacuum, we remove it and create a form close to the product itself (called araji).
Cutting Machine
･Cutting
The continuously fed araji are cut into individual pieces.
The continuously fed araji are cut into individual pieces.
Press
･Forming
The clay is formed into the product shape.
The clay is formed into the product shape.
Drying furnace
･Drying
Clay contains roughly 20% water, so this process removes that water.
The dried tile is called shiraji.
We use excess heat from the tunnel kiln as the heat source for this process to save energy.
Clay contains roughly 20% water, so this process removes that water.
The dried tile is called shiraji.
We use excess heat from the tunnel kiln as the heat source for this process to save energy.
Glaze
Glazing
Glaze (known as yuyaku or uwagusuri) is applied.
Firing machine (tunnel kiln)
･Firing
The tiles are fired at temperatures of up to 1120°C.
The glaze is also colored during firing.
The tiles are fired at temperatures of up to 1120°C.
The glaze is also colored during firing.
Screening inspection of all tiles
･Screening
All tiles undergo a visual inspection.
Defective tiles are removed and sent to be recycled into blended clay.
All tiles undergo a visual inspection.
Defective tiles are removed and sent to be recycled into blended clay.
Palletizer
Stretch packing
･Binding and packing
Tiles are bound in packs of four using PP bands, and loaded onto pallets in predetermined lots.
They are wrapped in film for storage.
Tiles are bound in packs of four using PP bands, and loaded onto pallets in predetermined lots.
They are wrapped in film for storage.
Finished products
The tiles are prepared for shipment in the yard.
