The process of how we manufacture our ceramic ware is truly unique. From preparing raw materials, to the molding process, to gazing, firing, and inspecting our wares to ensure the highest quality product, we have developed our own specialized process to deliver you the finest quality goods available today.
The first step for producing ceramic items is molding. Dolomite is the preferred material in our factory due to its formulation and ability to last a long time when hardened. With the dolomite clay and other materials, the molding begins.
There are three casting ways for mold forming: by hand, by roller and by high pressure. High pressure mold casting is the most advanced method. With this method, the possibility of deformed ceramic is less likely. However, high pressure casts have a much stricter requirement for the mold. In practice, these three ways are used in the production process, depending on the different shape and design of the ceramic items.
About 20-30 minutes later, the moisture evaporates to the appropriate level to release the mold. Since the mold is rough, the next step is to trim and smooth out the items.
4.Trimming and Drying Clay Body
After the mold is released, trimming is the next step. With special tools, our skilled specialists eliminate the unneeded parts from the cast. The mold will be smoother after the product is scrubbed with water and a sponge. After this step, the mold is allowed to dry before being fired. If the clay body is too wet, cracks and other imperfections are more likely to happen.
5.Ceramic Bisque Firing
The firing process is performed in a ceramic bisque firing tunnel with a temperature of approximately 1080 degrees. The firing usually lasts roughly 15 minutes, depending on the required durability of the products.
6.Ceramic Bisque Checking
This is the first quality check. If the ceramic bisque has cracks or appears to be broken, we view it as an inferior-quality product. For products with uneven surfaces, our technicians will attempt to buff the imperfection out to make it smooth. If the bisque has a severe problem and can't be repaired it is then discarded.
7. Hand Painting
Our unique products are hand painted by highly skilled artisans. Only those very special artists are engaged in this delicate task. Not all of the ceramic products have to go through this stage. Most products don't need hand-painting. Still, the ceramic products which have been hand-painted have an elegant, individual charm. This process also guarantees each product is slightly different and never mass-produced.
Ceramic glaze is an impervious layer or coating of a vitreous substance which has been fused to a ceramic body through firing. Transparent glaze is the glaze most frequently used in our products. Also we have opaque glaze, pigmented glaze, and some specialty glazes as well. Glaze can serve to color, decorate or waterproof an item. This step is vital for producing ceramic items that will meet “Food Service Quality” (FSQ) standards. FSQ products are products which are made in such a way that food and beverages can be safely stored, served, or held in them and remain safe for human consumption. Because we use only the highest quality glaze, all our products meet or exceed FSQ standards.
9. Glost Firing Process
Glost firing is the second firing of ceramic ware, in which the glaze is fused. Fired at a temperature of approximately 1080 degrees, the glaze changes the form with the ceramic body. After this process, the glazed products now have a shining luster. The temperature required for the glaze to properly fuse must be rigidly maintained. Too high a temperature may cause color distortion, while a low temperature may cause the glaze fuse incompletely. Time and temperature are of the upmost importance in this process.
10.Ceramic Enamel Glazing Checking
After the glost firing, the ceramic items move to their second QC. Our quality control specialists will inspect the glaze and the ceramic body itself. Products with cracks are immediately discarded. Only products with a smooth and complete glaze will move on to the next stage.
Decals are images or designs printed on a special paper so that they can be transferred onto bisque ware or a glazed surface and fired. Every season, we design many attractive decal patterns to lead the market trend. Our technicians will apply decals tightly to the glazed ceramic to make sure there is no air between the decal and the ceramic body. The product is then fired at a temperature of 830 degrees, which meets European Standards for FSQ ceramics (the global standard). With this temperature, the decal will be melted with the glaze and they come together as a single coat of glaze. Since the glaze and the decal are one, the coating will not melt should the ceramic items come in contact with acid or food. This is why our products are suitable for both storage and home decoration.
12.The Final Quality Checking
After the decoration firing, we now come to the last quality check. We need to make sure the decals are put in the right place per our customer's requirements. We also ensure there is no color distortion. At the same time, since this is the third QC, we not only need to check the decals, but we also inspect the final product for any other imperfections or blemishes. For instance, we check to see if there are any cracks in the glaze, which may have been overlooked in a previous inspection if the firing temperature was too high. If there are some defective products, then they will be removed and sent to the inferior-quality product area. Only our best quality ceramics will be moved to the next stop--packaging.
The first priority for the packaging department is safety. We ensure every package is safe for transportation. Normally, we have 4 packaging options. They are brown boxes, colored boxes, gift boxes and poly-foam. As an additional safety measure, we use bubble bags in all these packages. Since customized packing is available, we welcome our client's personal or customized packing designs. We truly want to help you achieve a reputation for quality ceramic products and help you stand firmly in the market.
We place great emphasis on our on-time delivery services. After the urgent production and safety packing, the final journey for the ceramic items will be loading and shipping. Our sales people will follow the shipping status and keep in contact with our clients until the ceramic goods arrive at the destination safe and sound.