Xin xiang Ceramic Mug Manufacturer, Once the clay is prepared for the custom production process of ceramic mugs, the molding and shaping process will take place. The so-called molding forming is also the shape of the ceramic mug that we can see. Including: the shape of the ceramic mug, size, thickness, with or without a handle and mug lid. Xinxiang Ceramic Mug Manufacturer in the pressure blank forming (molding) of the link, from the technical details, equipment selection, operating procedures to quality control, for your detailed analysis of the core points of this process:

1, the depth of the analysis of the compression molding process

1.1 The principle of the process
Compression molding through mechanical pressure, the plasticity of the clay in the mold pressing molding. Pressing molding is divided into: single-sided press blank (only the upper mold pressure) and double-sided press blank (upper and lower mold pressure at the same time). Mug because of the simple structure (mug + handle), single-sided press blanks and double-sided press blanks, are in use. The old equipment is mostly used for single-sided pressing, with the update of the equipment, Xinxiang Ceramic Mug Manufacturer has also introduced 3 sets of new equipment for double-sided pressing. Double-sided press blanking can mold the handle and mug at one time, avoiding later bonding.
1.2. Core equipment and molds
a. Equipment selection:
Hydraulic press: stable pressure (common pressure range 50-200 tons), suitable for complex molds, adjustable holding time.
Mechanical press: higher efficiency (10-15 stampings per minute), but lower pressure control accuracy, suitable for simple molding.
Automated assembly line: integrating feeding→pressing blanks→demolding→conveyor belt collecting blanks, suitable for mass production with daily output of more than 10,000 pieces.
b.Mold design:
Material:
Metal mold (steel/aluminum alloy): wear-resistant, long life (up to 100,000 times or more), suitable for large quantities.
Resin reinforced plaster mold: low cost, but short life (about 5000 times), suitable for small batch trial production.
Structure:
Position of parting line: need to be designed in the hidden place on the side of the mug to avoid affecting the appearance.
Air venting slots: tiny air holes are set inside the mold to prevent air from stagnating and causing bubbles during pressing.
Slope of mold release: 1-3° slope should be designed on the inner wall of the mouth of the mug, which is easy to release the mold without sticking.
1.3 Clay Requirements
Composition: kaolin (40%-50%), ball clay (20%-30%), quartz (15%), feldspar (10%), plus a small amount of carboxymethyl cellulose (CMC) to enhance plasticity.
Moisture content: 18%-22% (too dry, easy to crack, too wet, sticky mold).
Pre-treatment: the clay should be processed by vacuum mud machine to eliminate air bubbles and enhance the density.

2、Pressing billet molding operation process

2.1 Clay preparation
The clay block is cut into standardized size (such as 100mm diameter × 60mm high cylinder), the weight error ± 2g or less.
2.2. Press molding
Steps:
a. Put the clay block into the lower mold manually or by mechanical arm;
b. The upper mold is lowered and pressurized (pressure 5-10MPa, holding pressure 2-5 seconds);
c. Remove the blank by suction cup or robot after demolding.
Key parameters:
Pressure: the thinner the wall of the mug, the higher the required pressure (e.g. 8-10MPa for 3mm thin wall);
Holding time: adjusted according to the moisture content of the clay (high moisture content can be shortened to 2 seconds).
2.3. Blank finishing
Wet finishing: immediately after removing the mold, wipe the seam lines with a sponge and smooth the edges of the mugs.
Dry finishing: when the billet is half dry (8%-12% water content), trim the foot with a metal knife and polish the handle joints.

3、Advantages and limitations of billet molding

Advantages
3.1. High efficiency: a single hydraulic press can produce 300-500 blanks per hour (up to 1000+ for automated lines).
3.2. High consistency: mold forming ensures dimensional error of ≤1mm, suitable for standardized brand orders.
3.3. Low breakage rate: high density of pressed blanks, stable drying and firing shrinkage (8%-12%), low risk of cracking.
3.4. Complex structure molded in one piece: no need to bond the mug + handle, improved strength.
Disadvantages and Solutions
3.5 High mold cost:
- Solution: Initially, the mold can be sent out for processing, but the purchase price of abrasives is high. Small orders, if you need to develop a separate mold, the price of a single product needs to share the cost of molds, so the price is high, on the contrary, the price is stable.
3.6 Restricted modeling:
- It is not possible to make deep cavities (e.g. fine and high mugs) or openwork patterns. Complex ceramic mugs require another process: grouting (see: Customized Ceramic Coffee Mugs - Grouting Process Explained).

4. Critical quality control points before kilning

4.1. Moisture content testing:
- Use infrared moisture meter to make sure the moisture content of billet is ≤2% before entering into kiln to prevent bursting.
4.2. billet strength test:
- Sampling blanks from a height of 10cm drop to the sponge mat, no cracking is qualified.
4.3. Dimension sampling:
- Focus on measuring the mug diameter, height, handle angle (the error should be in line with the customer's drawings).

Compression molding is one of the core technology of ceramic mug production, this technical link directly affects the quality of ceramic mugs. Ceramic factory only to ensure the quality of each link, in order to ultimately produce high-quality, stable ceramic mugs.