MANUFACTURING PLANTS
THE HOME OF DESIGN AND INSPIRATION - ROCELL TILE MANUFACTURING PLANT
When Royal Ceramic Lanka opened its doors in 1992 to cater to the refined tastes of interior connoisseurs, the establishment had the distinction of being the first of its kind in Sri Lanka. Today, our sprawling manufacturing plants are located in the towns of Eheliyagoda & Horana, producing over 17,000 square metres porcelain, glazed porcelain, ceramic and wall tiles which reflect the epitome of design and production excellence. These plants house some of the most sophisticated machinery and modern technology, which allows for production of all categories of tiles available worldwide.
The process
RAW MATERIALS
The basic raw materials used to form the body of the tiles are Feldspar, Ball clay, Dolomite and Silica sand. Most of these materials are used in their raw state, as mined. These materials are generally homogenized to ensure consistency in composition.
It is important to mix the right amounts of raw materials to achieve the desired properties. Batch calculations are thus required, which must take into consideration both physical and chemical properties of the raw materials.
MILLING
After batching, all material goes through a grinding process. 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 performed in a ball mill until the required properties have been reached. It's result, a water filled mixure known as slip.
SPRAY DRYING
Body slip is put into a spray dryer. This involves pumping the slurry at about 16 bar to an atomizer consisting of nozzles. 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. This powder contains moisture of about 5.5% and stored in silos.
DRY COLORING TECHNOLOGY
Rocell, the largest tile manufacturer in Sri Lanka, modernized the pressing department which commenced the production of large-format glazed porcelain tiles. Together with new presses, one of which is a high-tonnage model, the company has also adopted the Recolor polychromatic dry colouring system from CMF Technology. This solution is capable of ensuring efficient transformation of the current base powder into a vast array of colours that will further enhance the new product range.
PRESSING
Tile is formed by dry pressing. In this method, the free flowing powder with low moisture content flows from a hopper into the forming dye. The material is compressed in a steel cavity by steel plungers and is then ejected by the bottom plunger. Automated presses are used with specific pressures as high as 280-500N/mm2.
GLAZING
Tiles have single or multiple coats of glaze applied to provide the required aesthetic in terms of appearance and to produce a hard wearing, easy to clean and maintain surface finish. The glaze also adds texture and enhances chemical resistance. There are many ways of applying the glazes which includes silkscreen patterns, spray glazes, waterfall glazes, brushes, and rotary screens, etc.
PRINTING
Digital Ink Infused Technology involves High Definition (HD) printing at a resolution of 600 dpi and has the capacity to deposit 70 Pico liters per square meter. The technology also allows for the infusion of printing inks into the ceramic which is further stabilized by a glaze. It utilizes ink jet technology to reproduce the entirety of the colour spectrum and the technology also facilitates high intensity and high quality ink fusion, whilst the inks employed can withstand much higher temperatures during the kiln firing process.
FIRING
This is the most important part of the process because it will determine mechanical strength, dimensional stability, chemical resistance, ease of maintenance and fire resistance. Roller kilns are used in this operation and fired at 1215C. The thermal cycle and kiln atmosphere are critical.
POLISHING
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PACKING
After the entire process, the finished tile is categorized by colour/shade, size and quality. The tiles are then packed & palletized with the assistance of modern machinery.
The process
TECHNOLOGY
TECHNOLOGY THAT ASSURES PURE PRECISION.
Rocell is unequivocally the largest porcelain and ceramic tile manufacturer in the country and relies on the very latest, cutting edge technology, to produce tiles that are advanced and superior in all areas. The companys immense manufacturing plant is fully equipped with new, state-of-art machinery and processes such as pressing machines, the Recolour Polychromatic Dry Colouring system, the Tintometric system, Digital Printing, Red Line Scanning Technology, Sorting & Palatization systems and Heat Recovery systems.
RESEARCH AND DEVELOPMENT
PERFECTION THROUGH RESEARCH AND DEVELOPMENT
Every tile manufactured at Rocell, begins with intense research and development which is the most crucial step of the production process. While we have already perfected our products in every way, we believe there are no limits to the insights and knowledge there is to be gathered. Through constant experimentation, studies of evolving global trends and with the collaboration of highly qualified, design experts, we ensure our products are novel, contain aesthetic value and function to precision.
QUALITY ASSURANCE
THE QUALITY IS IN THE DETAIL
A complex series of tests and certifications are conducted at every turn, from the production process to the final product in-store.
Standards on Dimensions and Surface
Rocell Tiles are tested for Rectangularity, Thickness, Exterior flatness and Warpage (EN ISO Standard 10545.2)
Standards on Physical Properties
Rocell Tiles are tested for Water absorption (ISO 10545.3), Module of rapture( ISO 10545.4), Resistance to abrasion (ISO 10545.6/10545.7), Crazing resistance (ISO 10545.11), Frost resistance(ISO 10545.12) &Thermal expansion (ISO 10545.8)
Standards on Chemical Properties
Rocell Tiles are tested for Chemical resistance (ISO 10545.13) and Stain resistance (ISO 10545.14).
Certification : Green Label
Green Label
Certification : ISO 9001-2015
ISO 9001-2015
Certification : ISO 14001-2015
ISO 14001-2015
Certification : ISO 14001-2004 Management System
ISO 14001-2004 Management System
Certification : CE Marking
CE Marking
Certification : SLS-ISO
SLS-ISO
Certification : SLS-ISO
SLS-ISO
QUALITY ASSURANCE
