PREFACE

In today's modern business world is placed on a very complex and

intricate political and economic environment. The new technology is adopted
and has influenced by environmental factors. The opportunity and challenges
provided by this environment have profound importance on the business type of
product to be manufactured and marketed. The business may also be considered
as one of the essential functions of the society carried on the primary on society.

To know about more as a student of T.Y. B.Sc. Chemistry

Conducted industrial visit of DELTA TILES LIMITED. From his visit, much
knowledge of practical studies gained more than theoretical studies. Thus, I take
this project as an opportunity to make a better future this project report is the
co-operation of the company. By guide, and my hard effort. So in respect of my
practical training, I am presenting this report.
 Acknowledgment

The report for 'student through industrial visit ‘in the chemistry
department of Shri M. P. Patel & science college, Jodhpur (Nadi) as a part of
the fulfillment of the visit program.’

I am very thankful to our principal A. P. Barasara, Head of department

Y. J. Sanghani & all staff members of the chemistry department for arranging
my training in such an esteemed company and providing guidance during the
visit period.
 INDEX

No. Title Page no.

1 Company profile 01
2 Introduction 02
3 What is a vitrified tiles 03
4 Type of vitrified tiles 05
5 Raw materials 07
6 Manufacturing process 09
7 Parameter of vitrified tiles 22
8 By product 23
9 Quality control 24
10 The future 25
11 What are the characteristics of vitrified tiles 26
12 What are the advantages of vitrified tiles 27
13 What are the disadvantages of vitrified tiles 28
14 Where are vitrified tiles best suited 29
15 Features of vitrified tiles 30
16 Use of ceramic vitrified tiles 31
17 Vision 32
18 Conclusion 33
19 bibliography 34
 Company profile

Delta Tiles Limited is a Public incorporated on 08 December 2005. It is

classified as a Non-govt company and is registered at Registrar of Companies,
Ahmedabad. Its authorized share capital is Rs. 35,000,000 and its paid-up
capital is Rs. 34,980,192. It is involved in the Manufacture of non-metallic
mineralproductsn.e.c.

Delta Tiles Limited's Annual General Meeting (AGM) was last held on
29 September 2018 and as per records from the Ministry of Corporate Affairs
(MCA),itsbalancesheetwaslastfiledon31March2018.

Directors of Delta Tiles Limited are Parth Amrutlal Patel, Darshankumar

TalshibhaiSanghani,LaljibhaiAndabhaiSavsani,

Delta Tiles Limited's Corporate Identification Number is (CIN)

U26933GJ2005PLC047226 and its registration number is 47226. Its Email
address is [email protected] and its registered address is S NO. 109,
132 KVA SUB-STATION, N H-8A, AT- LALPAR TAL. MORBI, RAJKOT
GJ 363642 IN,

1
 Introduction

This project envisages the production of Ceramic Glazed Tiles which

is having a very bright prospect in bathrooms and kitchen in modern housing
and in Analytical Laboratories and toilets attached to Railway stations. Due to
the liberalized economic policy followed and encouragement by Govt. of India
future prosperity of this product in the eastern zone is obviously bright.
Moreover, there is not a single MSEs in manufacturing ceramic glazed tiles in
total Eastern Region which has a vast demand for this product.
With regards to giving your home a richly current and invigorating
look, vitrified tiles are the best alternative. These tiles are made through a
procedure called vitrification. The procedure joins 40% mud and 60% silica.

2
 What is a vitrified Tiles?

Vitrified tiles consist of a spray-dried body of selected clay, Kaolinite

minerals, quartz, and feldspar, shaped by dry pressing to form a ceramic
material that is then fired at temperatures up to 1250 degrees centigrade.
A key element of vitrified tiles is its extremely low level of water
absorption which is below 0.5%.
As a result of new innovative processes, new vitrified tiles bear a
striking resemblance to natural stones such as marble and granite.

3
4
 Types of vitrified Tiles

 Double charged vitrified tiles

 In this process, two kinds of color are fed into the machine resulting in a
very thick layer of a double-colored design on the tile. This layer of color
and design is around 3-4 mm thick. These tiles are good for high traffic
areas.
 Full body vitrified tiles
 In full body vitrified tiles while designing the color is not only on the top
but seeps through the whole tile. In this method, the scratches on the tiles
become invisible because the tile is homogeneous and colored
throughout. Full body vitrified tiles are suggested for heavy traffic areas.
 Soluble salt vitrified tiles
 Insoluble vitrified tiles, liquid color screen printing is done on the tile
before the tile is fired. Soluble salts are used to penetrate into the vitrified
tile and give color, designs and create patterns on the tile.
 Glazed body vitrified tiles
 Glazed body vitrified tiles are tiles that are finished with a layer of liquid
glass. The glazed body adds extra shine to the tile and protects the tile
from any kind of stains.


5
6
 Raw materials

The raw material used from tile consists of clay minerals such as
feldspar that are used to lower the firing temperature and chemical additives
required for the shaping process. The mineral is often refined or beneficiated
near the mine before shipment to the ceramic plant.
China clay, soda feldspar, potash feldspar, ball clay etc.are used as raw
material.It contains china clay 4%,soda feldspar 25%, potash 28%, ball clay 7%
etc. The raw materials must be pulverized and classified according to particle
size. The primary crusher is used to reduce large lumps of material. Either a jaw
crusher or gyratory crusher is used, which operate using horizontal squeezing
motion between steel plate or rotating motion between steel cones,
respectively.
Secondary crushing reduces smaller lumps to particles. Hammer or
Muller mills are often used. Muller mills are often used. A muller mill uses steel
wheels in a shallow rotating pan, while a hammer mill uses a rapidly moving
steel hammer to crush the materials. Roller or cone type crushers can also be
used.
A third particle size reduction steps may be necessary. Tumbling types of
mills are used in combination with grinding media. One of the most common
types of such mills is the ball mill, which consists of large rotating cylinders
partially filled with spherical grinding media.
A glaze is a glass material designed to melt into the surface of the tile during
firing, and which then adheres to the tile surface during cooling. Glazes are
used to provide moisture resistance and decoration, as they can be color

7
MANUFACTURING PROCESS

 Once the raw materials are processed, a number of steps take place to obtain
the finished product. These steps include batching, mixing and grinding,
spray-drying, forming, drying, glazing, and firing. Many of these steps are
now accomplished using automated equipment.

 Batching

 For many ceramic products, including tile, the body composition is

determined by the amount and type of raw materials. The raw materials also
determine the color of the tile body, which can be red or white in color,
depending on the amount of iron-containing raw materials used. Therefore, it
is important to mix the right amounts together to achieve the desired
properties. Batch.

8
9
 PROCESS FLOWCHART FOR THE PRODUCTION OF CERAMIC SLURRY

 The powder is generally stored in dry vat s ready for use.

Spray drying provides a number of advantages, including the
provision of high uniform, more or less spherical hollow
granules that Can be easily transferred to the presses dies
which make format tiles a lot simpler.

10
 Mixing and grinding

 Once the ingredients are weighed, they are added together into a shell mixer,
ribbon mixer, or intensive mixer. A shell mixer consists of two cylinders
joined into a V, which rotates to tumble and mix the material. A ribbon
mixer uses helical vanes, and an intensive mixer uses rapidly revolving
plows. This step further grinds the ingredients, resulting in a finer particle
size that improves the subsequent forming process

 Sometimes it is necessary to add water to improve the mixing of a multiple-

ingredient batch as well as to achieve fine grinding. This process is called
wet milling and is often performed using a ball mill. The resulting water-
filled mixture is called a slurry or slip. The water is then removed from the
slurry by filter pressing (which removes 40-50 percent of the moisture),
followed by dry milling.

11
12
 Spray drying

 If wet milling is first used, the excess water is usually removed via spray
drying. This involves pumping the slurry to an atomizer consisting of a
rapidly rotating disk or nozzle. Droplets of the slip are dried as they are
heated by a rising hot air column, forming small, free-flowing granules that
result in a powder suitable for forming.

 Tile bodies can also be prepared by dry grinding followed by granulation.

Granulation uses a machine in which the mixture of previously dry-ground
material is mixed with water in order to form the particles into granules,
which again form a powder ready for forming.

13
14
 Forming

 Most tile is formed by dry pressing. In this method, the free-flowing powder
—containing organic binder or a low percentage of moisture—flows from a
hopper into the forming die. The material is compressed in a steel cavity by
steel plungers and is then ejected by the bottom plunger. Automated presses
are used with operating pressures as high as 2,500 tons.

 Several other methods are also used where the tile body is in a wetter, more
moldable form. Extrusion plus punching is used to produce an irregularly
shaped tile and thinner tile faster and more economically. This involves
compacting a plastic mass in a high-pressure cylinder and forcing the
material to flow out of the cylinder into short slugs. These slugs are then
punched into one or more tiles using hydraulic or pneumatic punching
presses.

15
 Drying

 Ceramic tile usually must be dried (at high relative humidity) after forming,
especially if a wet method is used. Drying, which can take several days,
removes the water at a slow enough rate to prevent shrinkage cracks.
Continuous or tunnel driers are used that are heated using gas or
oil, infrared lamps, or microwave energy. Infrared drying is better suited for
thin tile, whereas microwave drying works better for thicker tile. Another
method, impulse drying, uses pulses of hot air flowing in the transverse
direction instead of continuously in the material flow direction.

16
17
 Glazing

 To prepare the glaze, similar methods are used for the tile body. After a
batch formulation is calculated, the raw materials are weighed, mixed and
dry or wet milled. The milled glazes are then applied using one of the many
methods available. In centrifugal glazing or icing, the glaze is fed through a
rotating disc that flings or throws the glaze onto the tile. In the bell/waterfall
method, a stream of glaze falls onto the tile as it passes on a conveyor
underneath. Sometimes, the glaze is simply sprayed on. For multiple glaze
applications, screen printing on, under, or between tile that has been wet
glazed is used. In this process, the glaze is forced through a screen by a
rubber squeegee or other device. Dry glazing is also being used. This
involves the application of powders, crushed frits (glass materials), and
granulated glazes onto a wet-glazed tile surface. After firing, the glaze
particles melt into each other to produce a surface like granite.

18
19
 Firing

 After glazing, the tile must be heated intensely to strengthen it and give it the
desired porosity. Two types of ovens. After forming, the file is dried slowly
and at high humidity, to prevent cracking and shrinkage. Next, the glaze is
applied, and then the tile is fired in a furnace or kiln. Although some types of
tiles require a two-step firing process, wet-milled tiles are fired only once, at
the temperature of 2,000 degrees Fahrenheit or more. After firing, the tiles
are packaged and shipped. Kilns are used for firing tile. Wall tile or tile that
is prepared by dry grinding instead of wet milling usually requires a two-step
process. In this process, the tiles go through a low -temperature firing called
bisque firing before glazing. This step removes the volatile from the material
and most or all of the shrinkage. The body and glaze are then fired together
in a process called glost firing. Both firing processes take place in a tunnel or
continuous kiln can take two to three days, with firing temperature around
2,372 degrees Fahrenheit. For tile that only requires a single firing usually
tile that is prepared by wet milling roller kilns is generally used. This kiln
moves the wares on a roller conveyor and does not require kiln furniture
such as batts or saggers. Firing time in roller kiln can be low as 60 minutes,
with firing temperatures around 2,102 degrees Fahrenheit or more. 8 After
firing and testing, the tile is ready to be packaged and shipped.

20
 Parameter of vitrified tiles

 Water absorption – 0.02 to 0.03%

 Cooling MOR- 400 kg

 Planarity 30 to 50 mm

21
 By-products

 A variety of pollutants are generated during the various manufacturing steps;

these emissions must be controlled to meet air control standards. Among the
pollutants produced in tile, the manufacture is fluorine and lead compounds,
which are produced during firing and glazing. Lead compounds have been
significantly reduced with the recent development of no-lead or low-lead
glazes.

 Fluorine emissions can be controlled with scrubbers, devices that basically

spray the gases with water to remove harmful pollutants. They can also be
controlled with dry processes, such as fabric filters coated with lime. This
lime can then be recycled as a raw material for future tile.

 The tile industry is also developing processes to recycle wastewater and

sludge produced during milling, glazing, and spray-drying. Already some
plants recycle the excess powder generated during dry-pressing as well as
the overspray produced during glazing. Waste glaze and rejected tile are also
returned to the body preparation process for reuse.

22
 Quality control\

 Most tile manufacturers now use statistical process control for each step of
the manufacturing process. Many also work closely with their raw material
suppliers to ensure that specifications are met before the material is used.
Statistical process control consists of charts that are used to monitor various
processing parameters, such as particle size, milling time, drying
temperatures and time, and the like. These charts identify problems with
equipment, out of specific conditions, and help to improve yields before the
final product is finished. The final product must meet certain specifications
regarding physical and chemical properties. These properties are determined
by standard tests established by the American Society of Testing and
Materials (ASTM). Properties measured include mechanical strength,
abrasion resistance, chemical resistance, water absorption, dimensional
stability, frost resistance, and linear coefficient of thermal expansion. More
recently, the slip resistance, which can be determined by measuring the
coefficient of friction, has become a concern. However, no standard has yet
been established because other factors (such as proper floor design and
care) can make result meaningless

23
 The future

 ceramic-In order to maintain market growth, tile manufacturers will

concentrate on developing and programming new tile products, including
modular or cladding tile, larger-sized tile, slip and abrasion-resistant tile, and
tile with a polished, granite or marble finish. This is being accomplished
through the development of different body formulation, new glazes, and
glazes application, and by new and improved processing equipment and
techniques. Automation will continue to play an important role in an effort
to increase production, lower costs, and improve quality. In addition,
changes in production technology due to environmental and energy
resources issues will continue.

24
 What are the characteristics of vitrified tiles?

 Composition: Vitrified tiles are made by fusing silica and clay. The mixture
is then heated to high – fiery temperatures, which results in a non – porous
tile with a glass-like texture. Unlike Ceramic tiles, the vitrified tile doesn’t
need the additional glaze to be added on to it.

 Physical properties:  Vitrified tiles possess much better mechanical strength

and scratch-resistance compared to Marble or natural Granite.

 Thickness: Vitrified tiles are generally 10 to 12 mm thick, half the thickness

of natural stones like Marble or natural Granite.

25
 What are the advantages of vitrified tiles?

 Very durable: in comparison to Ceramic, Marble, and Granite.

 Consistency: Being machine-made products, Vitrified tiles are consistent in

sizes, shades, and thickness unlike the variable sizes and shades of natural
materials.

 Quality: Vitrified tiles are man-made, so their quality can be guaranteed –

tiles that do not meet standards are simply not packaged and sold. On the
other hand, the quality of Marble and Granite is a matter of chance.

 Laying and Setting time: Vitrified tiles are easier to install and need

practically no set time or polishing after laying. Therefore they can be used
within 48 hours after they are laid.


26
 What are the disadvantages of vitrified tiles?

 Installation: Tiles need to be installed by an expert tile layer to ensure thin,

even and neat joints between the tiles.

 Repair: The tile with the defect must be cut away along the grout lines and
surrounding material could be damaged in the process. Moreover, it is quite
unlikely that you will find the same tile after some years.

 Slippery: Vitrified tiles are slippery when wet.

 Grout Maintenance: Every year or two, the grout must be resealed or it will

begin to look dirty. Worse still, the sealant will create a hazy finish on the
tiles if allowed to dry.

 Not a green option: Vitrified tiles are not environment-friendly as the

process of making them causes a significant expenditure of energy and
carbon dioxide.

27
 Where are vitrified tiles best suited?

Because they are cost-effective, easy to clean, water-resistant and

very durable, vitrified tiles are suitable in a number of places as flooring,
wall covering, back-splash, benchtop, and showers. However vitrified tiles
look artificial. In comparison other man-made options like concrete which
has a more earthy feel and terrazzo which looks elegant are available, But if
economics is your driving concern, you should consider resilient flooring.
If you found this post useful, I would love it if you pin it or share it. I have
not blocked the site just because your ad blocker is switched on because l
hope my content will be useful to you. But I am able to run this site only
because of the ads. So I will be obliged if you turn off your ad blocker.

28
 Feature of vitrified tiles

• 1. These are nonporous hence don't absorb water as well stain. This
makes them suitable to be placed in the bathroom and kitchen.
• 2. Maintenance is easy, cleaning and wiping the tiles can be done by you.
• 3. When exposed to sun or rain they don't chip off or break proves that
they are strong enough to deal with temperature fluctuations.
• 4. They are costly than the ceramic tiles but even then doesn't pay heavy
to your pockets.
• 5. Different style and color variations of vitrified tiles may steal your
heart.
• 6. They stand good on quality. These tiles are durable also.

29
 Use of ceramic vitrified tiles

 Ceramic vitrified tiles are made of the porous body with a

coating of white or colored vitrified. These are used
extensively in Bathrooms, Kitchen in modern buildings and in
Hospitals and Analytical Laboratories, Toiletries, attached to
Railway platforms. This is because of t his product s have
properties like good resistance to wheat her and chemicals,
having high-strung h, hard, glossy surface with different
colors and pleasing appearance. In the near future t, he
chances for replacing these items by other materials look
very bleak. These tiles are rat her cheap, easy to clean
have more life and are available in pleasing colors.

30
 Vision

 The ability to think about or plan the future with imagination or wisdom or a
mental image of what the future will be DELTA TILES has few visions they
are as follows :

 1. We will offer unparalleled value to create customer delight and enhance

business productivity.

 2. We will also generate value for our capabilities beyond Indian borders and
enable millions of India's knowledge workers to deliver their services
globally.

 3. Build a globally respected and enduring business firm so that they get
closer to realizing their vision and become a leader in their industry.

31
 Conclusion

 DELTA TILES is a very big brand knows about the industry and I learned
that how the industries work and what they have to do for retaining their
person 1n the market.

 DELTA TILES LIMITED has trained me to face the Challenges whatever in

the future career. Name and 1 are very thankful to the DELTA ceramics
people to help me in completing my project in DELTA TIES LIMITED.

 DELTA ceramics provide me the good opportunities to make my skills

stronger in industrial production. While doing this project I have talked with
many people and came to.

32
 Bibliography

 Web sites: www.geogres.in 

 Email: [email protected]
 Mobile:9979904212

 Book referred

 Industrial instrumentation by V D Patel &

by Eckman Donald P.
 Industrial chemistry by B K Sharma.

Thank you so much

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