Xin xiang Ceramic Mug Manufacturer, In the previous article, Xinxiang Ceramic Mug Manufacturer introduced, the three basic raw materials for ceramic mugs. The three basic raw materials after processing, became the clay material for making ceramic mugs. Mud preparation is the basic link of ceramic production, directly affecting the stability of subsequent molding, drying and firing. For the compression molding of mugs, the clay's: plasticity, moisture content, particle uniformity and other indicators are particularly critical. This has gone through what process, different links in the quality control for the later ceramic mug quality has what impact? Well, I would like to know more about customized ceramic mug knowledge buyers, one by one to answer.

1, the composition and function of ceramic clay

a. Kaolin, bentonite, ball clay
Their main role is: to provide plasticity, so that the clay is easy to mold and maintain the shape.
b. Quartz sand, calcined kaolin
Their main functions are: to reduce drying shrinkage, enhance the strength of the blank and prevent deformation.
c.Feldspar, nepheline orthoclase
Their main role is: to reduce the firing temperature (1200-1300 ℃), promote the formation of glass phase, enhance the degree of porcelain.
d. CMC (carboxymethyl cellulose), sodium humate
Their main role is: to regulate the liquidity of the mud, enhance the strength of wet blanks, to prevent cracking.

2. Key indicators of clay performance

Plasticity: the ability of clay to deform and not crack under external force, determined by the proportion of plastic raw materials and particle fineness.
Water content: 18%-22% water content for billet molding (30%-35% for slurry molding).
Particle gradation: coarse and fine particles are reasonably matched to reduce porosity (ideal particle size: <0.1mm accounts for 60%-70%).
Drying shrinkage: generally controlled at 5% -8%, too high easily lead to cracking.

3. Formulation of clay

Kaolin (45%), ball clay (25%), quartz (15%), feldspar (12%), CMC (1.5%), water (adjusted to the total weight of 22%)

4.Process of making mud

Firstly, pre-treat the raw materials, then mix the ingredients, then sieve and remove the iron, and finally dewater the mud.

4.1 Pre-treatment of raw materials

a. Coarse crushing:
Large raw materials (such as quartzite, kaolin) with jaw crusher crushed to particle size ≤ 5mm.
b. Removal of impurities:
Magnetic separator to remove iron chips (to avoid black spots after firing);
Water washing to remove sediment and organic matter (soaked and precipitated to remove impurities).
c.Aging:
Mixed raw materials are stacked in a shady and humid environment, covered with wet cloth aging for 3-7 days to promote uniform penetration of moisture.

4.2. Ingredients and mixing

a. Weighing and proportioning: weigh each raw material accurately according to the formula (error ± 1%), for example: kaolin 45kg + ball clay 25kg + quartz 15kg + feldspar 12kg + CMC 1.5kg + water (adjusted to 22% of the total weight)
b. Dry mixing: put the raw materials into the wheel mill, low speed (20-30rpm) mixing 20-30 minutes until the color is uniform.
c.Wet mixing: add water and transfer to mixing tank, mix at high speed for 1-2 hours to form a fluid slurry without lumps.

4.3. Sieving and iron removal

a. Sieving: pour the slurry into 80-120 mesh vibrating screen to remove coarse particles that are not crushed (sieve residue ≤ 0.5%).
b. Iron removal: the slurry flows through the electromagnetic iron remover (magnetic field strength ≥ 1.2T), circulating 2-3 times to no iron residue.

4.4 Dewatering and mud training

a. Dewatering:
Mud is pumped into filter press, pressurized to 0.8-1MPa, and pressed into mud cake with 25%-30% water content.
Or use vacuum extruder to dewater directly to the target water content (18%-22%).
b. Clay practicing:
Put the mud into the vacuum mud trainer and repeatedly squeeze 3-4 times to expel air bubbles (vacuum degree ≥ -0.095MPa).
After practicing the mud cut into 10-15cm diameter cylindrical pieces of mud, sealed and kept in reserve.

In summary, this is the whole process of making clay for ceramic mugs. In this process, the quality of raw materials, the control of each link, directly constitute the quality of ceramic mug. For example: some ceramic mugs have black spots, this is the clay “in addition to iron” link, quality control is not enough reason. Also, ceramic mug cracks, many quality problems, from the source. Xinxiang Ceramic Mug Manufacturer, has been strictly control the raw materials and production of each link, to provide high quality ceramic mug.