After Shaping, the articles shaped are dried for a particular time schedule in closed chamber driers using the waste heat from the kilns. After drying, the wares are fired. Firing forms one of the most important steps in the manufacture of ceramics. Sanitary wares are generally fired in a 10-16 hour firing cycle in a […]

 
General problems encountered in Casting – Casting Defects:
Cracks: These are often related to the pressing cycle. Cracks are generally formed when the entrapped air expands. Cracks may be visible just after shaping process or may become visible even after firing. Thus cracks formed during firing could also be due to the shaping problem. To prevent […]

General problems encountered in Casting – Casting Defects:
Shrinkage Problems: One of the most common issue that takes notice in Casting.. The casting process should consider the shrinkage of ceramic ware during drying and firing stages. The ceramic ware has to be formed keeping in mind the shrinkage factor and the product should be given dimensions […]

General problems encountered in Casting – Casting Defects:
If the moisture content in the clay is not correct, then the dimensions of the product will vary during drying and hence a correct dimension product will not be available for firing. Hence the clay has to have correct amount of moisture in it for proper forming, and […]

General problems encountered in Casting – Casting Defects:
In dry pressing method, binders are an important element and casting defects can arise due to wrong or incorrect use of binders. Hence it is essential to test and experiment the binder to be used in the process and then make it available for commercial production. Binders with […]

General problems encountered in Casting – Casting Defects:
It is important and highly essential that the caster understands the importance of addressing the problems raised during casting be addressed while casting the ceramic ware itself. Few aspects when taken care can actually prevent defects and thereby prevent loss. For example if the dry pressing method uses […]

General problems encountered in Casting – Casting Defects:
Casting is one of the most important step in the ceramic article manufacturing. A number of defects in the ceramic ware can be formed due to improper casting methods and techniques. Defect in ceramic ware is a direct loss on profit margin. It may be true that all […]

Comparison of different methods
The average moisture before shaping is highest in slip casting of about 28 weight % whereas in dry pressing method it is only 5 weight %. The average moisture after shaping is again highest in slip casting of about 18 weight % whereas the moisture content after shaping does not […]

Slip Casting
Pressure Casting in Polymer Moulds
Sanitary ware manufacturers are increasingly turning to pressure casting in polymer moulds. High productivity is one benefit of this method as more pieces can be cast per day. Some plants producing water tanks have established operating parameters that allow them to turn the casts over about […]

Slip Casting
Battery Casting in Plaster Moulds
Battery casting is a better method when compared to Bench Casting. The productivity in this method is greater and can be achieved with relatively low mould cost. The space requirement for this method is lesser. More pieces can be produced within the space available, which reduces […]