Our Production Capability

  • 5

    Pressers of Ph 6200 from Sacmi

  • 3

    Pressers of Ph 3800 from Sacmi

  • 4

    Chroma Machines from LB

  • 8

    Glazing Lines

  • 2

    Kilns of 218.4m from Sacmi

  • 2

    Kilns of 190.0m from Sacmi

  • 6

    Polishing Lines

  • 6

    Squaring Lines

  • 2

    Digital Printing Machines

765,000

Square Meters

Total Factory Area

Production Process

RAW MATERIAL

The porcelain tiles process starts by selecting the raw materials required for the body composition of various tiles, which are mainly clays, feldspars,alumina, zirconium, silica sands and kaolins.

Porcellan uses fine and natural raw materials imported from many countries around the world including Spain, Iran, Egypt, etc...

The mixture of raw materials is crushed and then moulded into the required shapes through special shaping processes, and finally fired in kilns at extremely high temperatures.

MILING & GRANULATION

The batched raw materials go into ball mills for grinding, mixing and transforming the ingredientsinto liquid-like refined granules technically known as "body slip". To complete this process effectively, Porcellan utilizes advanced ball mills from a leader in supplying all production equipments for the tiles industry, SACMI.

SPRAY DRYING

Most of the water contained in the resulting “body slip” is removed by spray drying to form a powder with low moisture content.

GLAZING

Glazing involves applying one or more coats of silica sand which gives a high-gloss finish and makesthe surface very hard, smooth and slip resistant.

Tile glazing is mostly used for residential units since it seals out water, is easy to clean, protects the tile from wear and tear and extends the life of the surface.

FIRING

Firing is a crucial stage within the whole production process. During this stage, the texture of the tile will be adjusted providing the body with strength, size stability, and resistance to chemical agents. At Porcellan, a state-of-the-art Sacmi kilns, with a total length of 218.4 meters, are used for firing. Recycled and natural gas is used to supply kilns with heat that is then transmitted to the tile body through radiation.

POLISHING

Porcellan has six polishing lines that provide glazed and technical polished products with a mirror-like soft and brilliant surface. In case of matt products, polishing is not required.

CROMA PRESS FEEDING

The CROMA press feeding unit is an advanced technology from LB company for the production of porcelain tiles with high aesthetic values. The four CROMA machines at Porcellan make it possible to produce a wide range of technical tiles with "veined" and varied color effects. In case of glazed products, after spray drying, is pressing and formation

PRESSING & FORMATION

The resulting powder is collected in huge silos before it goes to the SACMI pressers, PH-3800 or PH-6200, to be transformed to the desired body size and shape.

The pressing stage is controlled and regulated by proportional valves, which ensure maximum pressing precision and repeatability over time without any variation in the tiles.

The pressers have high compaction force, high productivity, easy adjustment and consistency in holding the pressing cycle schedule. In addition, the machines are eco-friendly because the consumption level is reduced to the minimum by eliminating energy use during stops.

All the SACMI branded pressers at Porcellan have an operating pressure of 3,800 tons or 6,200 tons. This allows the production of various tile sizes ranging from 30x30 cm to 1x1 m.

RECTIFICATION

Porcellan has eight squaring lines to deliver products with squared edges and size uniformity. Rectified porcelain tiles can be installed butt-tobutt with minimal grout lines.

SORTING

All tiles with surface defect and variation in shade will be eliminated. There are nine advanced sorting lines at Porcellan to automatically check each tile separately and ensure the quality of the products.

PACKING

Tiles are wrapped rigidly with a thick cartoon box around their perimeter to ensure it is safely delivered to the customers.