BATHROOM & KITCHEN
BATHROOM & KITCHEN TECHNOLOGY
RAK Ceramics is committed to developing eco-friendly sanitary ware products with a particular focus on water saving, and has launched the Eco-Fresh, Waterless Urinal Sanitation System. Eco-Fresh is an advanced urinal sanitation system which requires absolutely no water to flush.
RAK Ceramics’ Sanitary ware includes an elegant range in wash basins (mounted and pedestal), bathroom suites – wash basins, water closets and bidets (close coupled, back-to- wall and wall hung), water closets adapted for customers with special needs, bath tubs, shower trays, kitchen sinks.
Vitreous China sanitary ware products are manufactured using high quality Ball Clay, Kaolin Clay, Silica Sand, Feldspar etc.
The raw materials are tested as per the Standards procedure in laboratory before being taken for production. The non-plastic raw materials namely Silica Sand and Feldspar are crushed into manageable state to undergo a wet milling process in the ball mill. The mix is then transferred to a high speed blunger, where the clay will be added as per the recipe and the resulting ‘Body slip’ will undergo a 2 hours blunging process to achieve homogeneity of the mix. It is then passed through a vibrating sieve attached to a fine mesh with powerful magnets to remove impurities before being finally stored in the storage Arc. From the storage Arc the body slip is transferred to various casting departments after testing the rheological properties.
The Sanitaryware products are produced using three different types of casting processes namely high or medium pressure casting, battery casting and traditional casting. Majority of the products are produced by high or medium pressure casting using resin moulds, which results in very high quality products due to the atomization process involved.
The casted products are then arranged on trolleys to undergo a natural drying process of 24 to 48 hours depending on the size of the products. The products are then given a smooth finish before being sent for drying in Tunnel / Chamber dryers for another 10 – 12 hours in order to achieve moisture content below one percent. The dried pieces are then transferred to inspection booth before undergoing the Glazing process. During inspection, each and every piece will be checked for technical flaws before being transferred to Glaze Spraying Booths, where they are coated with an impervious, non-crazing vitreous glaze.
The glazed pieces are then arranged on kiln cars before the pieces are transferred to the shuttle or tunnel kilns for firing at a very high temperature of 1220 º C to obtain Vitreous China Sanitaryware with Water Absorption less than 0.5% of the dry weight.
The resulting fired product then undergoes different Quality checking / testing processes such as Visual Quality check, Leak test, Dimensional check, Crazing test, Burning test, Acid resistance test, Staining test, Water Absorption test etc. as per the procedure. In case of water closet the cisterns will be fitted in house with the approved flush mechanism before being shipped to our valued customers. Vitreous China is therefore highly Hygienic, Fireproof, Stain-proof, Rustles, non-fading and is also resistant to Acids & Alkalies.
Fireclay Sanitaryware products are manufactured using Ball clays, Kaolin Clay, Quartz and Pre-fired Clays. The clays are processed in the blunger and to this mix, Quartz and Pre-fired clay are added to undergo blunging process for an hour to achieve homogeneity. The final ‘Fireclay Slip’ is then passed through a mesh and powerful magnet to remove impurities before being stored in the storage Arc. The other manufacturing process remains same as of Vitreous China products.
In general, fireclay slip will be used to produce heavy-duty large size washbasins, kitchen sinks, service sinks, lab sinks etc., where the shape retention is critical.