How KAG Sanitaryware Products are manufactured?

KAG Sanitaryware products such as toilets, basins and urinals, are typically manufactured using a combination of industrial processes.

Raw Materials Preparation : The primary materials used in the production of sanitary ware items include clay, feldspar, quartz, and various additives. These materials are carefully selected and mixed to achieve the desired properties and colors.

Forming :

The first step in the manufacturing process is forming the basic shape of the sanitary ware item. There are two common methods used for forming

Slip Casting :

This method involves pouring a ceramic slurry, known as slip, into a plaster mold. The mold absorbs the moisture from the slip, leaving a layer of solid material on the mold's surface. The excess slip is poured out, and the remaining material is allowed to dry and harden, forming the basic shape of the sanitaryware item.

Pressure Casting :

In this method, the ceramic slip is poured into a closed mold, and pressure is applied to force the slip into the intricate details of the mold. This allows for more complex shapes and finer details to be achieved.

Drying :

After forming, the partially solidified sanitaryware item needs to be dried to remove excess moisture. This is typically done in a controlled environment to prevent cracking or warping. The drying process may involve natural drying, air drying, or the use of drying chambers.

Finishing :

Once the item is completely dry, it undergoes several finishing processes

Trimming :

Excess material or rough edges are trimmed off using cutting tools or machines to achieve the final shape and dimensions.

Smoothing :

The surfaces of the sanitaryware item are smoothed using abrasives or sandpapers to remove any imperfections and create a uniform finish.

Glazing :

Glazing is the process of applying a liquid glass coating to the surface of the sanitaryware item. This not only provides an attractive appearance but also adds a protective layer and makes the item easier to clean.

Firing :

After glazing, the sanitaryware item is fired in a kiln at high temperatures. The firing process vitrifies the clay and glaze, transforming them into a durable and non- porous material. The specific firing temperature and duration depend on the type of clay and glaze used.

Quality Control :

Once the firing is complete, the sanitaryware items are inspected for any defects, such as cracks, glaze imperfections, or dimensional inaccuracies. Defective items are discarded, while acceptable ones move on to the final stages.

Additional Processes :

Depending on the design and functionality of the sanitaryware item, additional processes may be involved, such as attaching flushing mechanisms, fittings, or accessories.