The raw material for the manufacture of ceramic tiles is a mixture of several components:

• Clay and similar materials that give the total mass plasticity to form blanks;
• Quartz sand or similar raw materials - forms a kind of structural skeleton of the mixture, which simplifies the process of molding, drying and firing;
• Materials containing carbonates and aluminosilicates of calcium and sodium. With their help, the necessary viscosity is achieved, and the finished product receives a dense vitreous structure.

Production process

1. Extraction of raw materials- the first stage, originating in quarries, where components with a strictly defined chemical composition. The behavior of raw materials during pressing and firing, as well as the properties of finished products, depend on the composition. From the mining sites, the clay is sent to factories, where it is sorted into containers.

2. Preparing the mixture- clay materials that form the basis of ceramic tiles are mixed with the rest of the components in a certain proportion. Then they are pre-grinded to the desired size, crushed, mixed and moistened. To create a ceramic mass, several methods have been developed, each of which is used for different types of raw materials and types of future products:

• Semi-dry - clay passes through a crusher and dryer, then it is crushed and goes to molding;
• Plastic - after the crusher, the clay material is mixed with additives in the clay mixer, as a result, a plastic homogeneous mass is obtained, which is subsequently subjected to heat treatment;
• Wet - the primary components are crushed and mixed with a large volume of water (no more than 60%), the resulting homogeneous mass is sent to the tanks.

As a result, the mixture is prepared for shaping the body of the tile (or “biscuit”, so named because of the external resemblance to the dough product of the same name).

3. molding which is carried out by pressing or extrusion.

• Pressing means squeezing a powdery mass under great pressure. Small particles of the mixture move and are partially deformed, due to which the hardness and strength of the tile is significantly increased;
• For molding ceramic tiles by extrusion, a special installation is designed - an extruder. The mass is pressed through the hole that defines the shape of the tile profile. Unlike pressing, extrusion allows the production of tiles of any configuration, since in the "liquid phase" the mixture is squeezed out of the molds and cut off. Products obtained by this method may be thicker than pressed, be concave or convex. This is how corner clinker elements are made.

4. Drying- an integral part of the production process. Its purpose is to completely remove moisture from the product. The process is strictly controlled to prevent deformation of products during drying. For this, special installations are designed that treat the surface of ceramics with hot dry air. During drying, the tile "shrinks", that is, it slightly decreases in size. The amount of "shrinkage" cannot be accurately calculated, therefore finished goods may vary slightly from each other in size, even within the same batch.

5. Applying enamel or glaze- it's decorative protective covering, transparent, colorless or colored. Enamel owes its color to the addition of various salts and oxides. So, Blue colour give cobalt salts, green - chromium salts, red - iron salts. Glazed tiles consist of two layers: the base (lower) and, in fact, the glaze (upper). This layer provides additional protection to the base from external influences, as it has increased hardness, heat resistance and moisture resistance.

There are dozens of methods for applying glaze to tiles - in the form of granules, by spraying and rolling a pasty mixture. The process is carried out using drums, before, after or during firing. At the same time, different images can be applied. There are technologies in which each individual element of the tile has its own unique pattern, while maintaining the overall style of the series.

6. Burning- only after it the tile becomes usable. The kiln is a tunnel in which products move on conveyors. The firing temperature ranges from 900 to 1300 degrees, depending on the material and manufacturing technology. After processing, the tile cools and turns into a stone-like mass of high strength.

7. Sorting- during this process, damaged elements are rejected, tiles are separated and grouped different varieties. Modern production lines are equipped with special devices that check the tiles for defects by exerting a mechanical load on them.

It is important to note that different varieties ceramic tiles, the stages of its production can vary significantly.

Regardless of any crisis, ceramic tiles are always in demand. Even if in hard times people do not build houses and do not overhauls apartments, redecorating rarely does without laying tiles. Therefore, this facing material will always find its buyer.

Small Business Benefits

Experts believe that it is more profitable to open such a business in a small format. In small-scale production, you can afford to have a variety of products, and already finished ones. In addition, the increased price of imported goods made buyers appreciate domestic goods better. At the same time, its quality is not much inferior to imported samples.

Market analysis

The production market is wide, so you should decide on your niche. The segment of inexpensive and high-quality products remains quite free. Therefore, it is recommended to study who is already working in this niche in your region, what assortment they offer, at what prices, what composition. Your advantage may be in the original design solutions for which you will have to invite specialists to develop samples. In addition, it is important to adhere to all established GOSTs. This is the only way to bring your business to a competitive level.

Registration of the enterprise

The business plan for production should begin with the definition of the form of registration of the enterprise. For a small business where few employees will work, it is enough to register individual entrepreneur. But if you plan to issue large volumes, it is better to register a legal entity.

When registering, you must specify the OKVED code 26.3 - Production of ceramic tiles and slabs. We also recommend that you immediately switch to a simplified taxation system. This will make it easier to start a business.

Range development

Another important question that a business plan should solve is what will be the range of your products. First you need to decide what type of tiles your company will specialize in. Tiles are distinguished by:

• type of raw materials: cotto, ceramic granite, clinker, terraglia, metlakh tiles;
• production technologies: with double or single firing, glazed, unglazed;
• molding method: hand molding, casting, pressing, extrusion, etc.;
• use decorative elements: mosaic, decorative inserts, etc.;
• texture: porous, antique, mosaic, stone, etc.;
• purpose: for the pool, fireplace, floor, kitchen, bathroom.

Another task is to determine in what style the production of ceramic tiles will be carried out. To solve this issue, you can invite an artist-designer to the staff who will develop exclusive options. But in this case, the cost plan will increase significantly. Alternatively, you can purchase templates and molds from leading Spanish or Italian developers.

You also need to decide what format of tiles you will produce. At the start of the enterprise, it is better to stop at standard sizes: 400x400, 330x330, 310x500, 200x300, 250x400, 200x400, 250x330, 200x300, 200x200 mm.

Related documentation

Whichever tile option you choose, the product must comply with the requirements of GOSTs. Each type of tile has its own standard:

• ceramic tiles - GOST 27180-2001;
• floor tiles - GOST 6887-90;
• facing tiles for internal walls– GOST 6141-91;
• facade ceramic tiles - GOST 13996-93.

For those types of tiles for which GOST is not provided, you can voluntarily issue a certificate of conformity. But in any case, include in the business plan the execution of a hygiene certificate in Rospotrebnadzor and a certificate of fire safety of the goods.

The production process of ceramic tiles must necessarily provide for constant quality control of manufactured products. To do this, it is necessary to organize the work of the technical control department and the laboratory.

Raw material

The production technology of ceramic tiles requires the use of several groups of components. These include:

• The main ones are clay components, due to which the mass acquires plasticity and the ability to be molded (kaolin, clay);
• Components to reduce shrinkage - quartz raw materials, due to which the skeleton of the tile is formed (quartz sands);
• Carbonate components, due to which the sintering temperature decreases, and after firing the product acquires a vitreous structure (feldspars, slags, nephelines);
• Additives - thinners, surfactants, mechanically activating components.

Naturally, the quality of the tiles depends on the quality of these components, so it is better to use raw materials of the highest grades. If every month to produce tiles with an area of ​​​​5 thousand square meters. m, the business plan must include at least 12 thousand dollars for the purchase of raw materials.

Equipment

Equipment for the production of ceramic tiles includes the purchase of:

• semi-industrial ovens (200 degrees);
• chambers for spraying glaze, drawings;
• forms for tiles;
• vibrating machine;
• concrete mixers.

In total, at least $10,000 must be included in the business plan for the purchase of equipment. All components can be bought separately, or you can order a ready-made production line and save a little on delivery. Include in the business plan the purchase of a set of stencils for drawing - approximately $ 600 for 200 pieces. If you take a sputtering chamber with an extended set of functions, it will cost $3,000.

But this is a standard set that will allow you to make standard tiles. If you plan to prepare exclusive copies, you will have to buy special equipment.

Production technology

Regardless of which tile you specialize in, the production technology will be approximately the same. It goes through the following stages:

• Preparation of a mixture is a process that goes through the stages of grinding, mixing, homogenization, moisturizing.
• Molding - the most commonly used method of pressing, when the mass is compressed from two sides.
• Drying - removing excess moisture from the tile. It is important to ensure that the product does not crack.
• Glazing is the application of a glaze to a surface. This step is used only in the manufacture of glazed tiles.
• Firing - is carried out in special tunnel kilns, where, gradually heating up, the tile is kept at temperatures above 1250 ° C.

Some companies produce double-fired glazed tiles. In this case, the tile is first fired, then the glaze is applied, and only then fired again.

Staff

To organize small production tiles with a capacity of about 5 thousand. square meters per month, four workers are enough. Of these, two will serve the concrete mixer, one will work on the vibrating table and one more will dry and pack the finished product. You will also need a master who will be familiar with technological process and will monitor its strict implementation.

room

There are no special requirements for the premises. The main thing is that it be closed and have an area of ​​​​at least 100 square meters. m. Therefore, you can open production in the garage and in the hangar. The premises should be divided into the following zones:

• stock finished products;
• manufacturing facility;
• warehouse of raw materials.

The only thing that it is desirable to provide is that the production is located close to the place where the raw materials are purchased. Then you can significantly save on transportation and reduce the cost of finished products.

Markets

The marketing plan for finished products can include the development of such channels:

• individuals;
• repair companies;
• construction markets;
• building stores.

Alternatively, you can open your own point for the implementation of the tile. It is desirable to open it in sleeping areas near new buildings. Then residents who carry out repairs in new apartments will be able to buy tiles from you, and not go to the other end of the city for them.

But if you produce elite tiles, it is better to locate the store in the city center. Please note that before you start trading, you must obtain a certificate from the State Sanitary and Epidemiological Supervision.

The best option would be to sell products via the Internet. You can sell it using ads on free boards. But a greater return will be given by your own online store, where buyers can get acquainted with complete list goods and conditions of its purchase.

Production payback

Before opening production, it is necessary to calculate the cost, income and payback plan.

The expense item will look like this:

• equipment - 10 thousand dollars;
• raw materials - 12 thousand dollars;
• wages to employees - 3 thousand dollars;
• rent and utilities- 1 thousand dollars;
• other start-up investments - 1.5 thousand dollars.

In total, the launch of production will require at least 30 thousand dollars of initial capital, and then another 18 thousand dollars of investments every month.

A square meter of tiles costs an average of $7. If you produce and sell about 5 thousand square meters per month. meters, the monthly income will be approximately 35 thousand dollars. However, it should be borne in mind that not every month it will be possible to sell the entire volume of products.

Seasonality of production

Ceramic tiles are a seasonal product. The maximum demand for it is observed in the summer at the most active time. repair work. In spring and autumn, demand is slightly less, and in winter it is practically non-existent. However, it makes no sense to build up production volumes in winter for the future. In addition to seasonality, the tile has one more salient feature- the range is obsolete. What was fashionable last summer is no longer relevant on next year. Therefore, despite the high popularity of the product in the summer, the payback period of investments can stretch for a year. To reduce it, it is advisable to enter the market with goods by the beginning of the construction season - in March-April.

The production of ceramic tiles is a business that will have to be organized in a highly competitive environment. To slightly reduce its pressure, we recommend using these tips:

• all your employees must have up-to-date knowledge in the field of ceramic tile manufacturing;
• seek and listen to the advice of professionals in this field;
• always focus on the needs of customers;
• make sure that each client has an individual approach;
• if you hire a consultant or manager, make sure that they are well versed in the topic and have high professional skills;
• strive for the fastest order fulfillment without sacrificing quality.

Decorative ceramic tiles, probably, will not lose their relevance very soon - and this despite great amount all kinds of finishing materials on the shelves building stores. And since there is a non-decreasing demand for products (and this, as you know, is almost half the success), then why not create an appropriate offer? And it would be wrong to assume that any manufacturing enterprise in the construction segment will require large investments. For example, a mini-plant for the production of ceramic tiles in Russia can pay off in less than a year. What details have to be thought out by a person who has paid attention to this market niche.

Our business valuation:

Starting investments - from 2500000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

Why is the production of ceramic tiles profitable?

Of course, in the case of large-scale production, a small workshop will bring much less profit. But the advantages here are also more than enough, the main of which is the affordable price of equipment. In addition, in this case, it is necessary to work with individuals, and it is much easier to find such customers than wholesalers.

A mini-workshop for the production of ceramic tiles can produce high-quality products at a cost that is quite acceptable to consumers. Judge for yourself - many of the major players in the market are only dealers of major European brands, and the increase in exchange rates has made the products they sell quite expensive. "Small" producers will not adhere to such high prices for finished products - raw materials are inexpensive.

Main competitive advantage, with the help of which a novice entrepreneur will be able to draw the attention of buyers to their products - the design of ceramic tiles. Large enterprises can hardly boast of a variety of product lines - quantity is more important here. But a small workshop can create truly unique products.

The main difficulties that the "young" enterprise will face are the development of recipes and original collections.

Product range

So that production, albeit small, brings maximum profit, it is necessary to expand the range as much as possible. Then each client will be able to choose what he needs.

All subsequent actions will depend on what type of product is planned to be launched - the selection of a recipe, the purchase of raw materials and equipment.

All ceramic tiles can be divided into several large groups.

And the products differ not only in the method of production, but also in their purpose:

• porcelain stoneware ( high-strength product, obtained by sintering a mixture of 2 clays, quartz, spar and pigments),
• double-fired tiles (a product that is fired twice during the manufacturing process),
• single-fired tile (a product that is fired 1 time during the manufacturing process),
• clinker (single-fired glazed or unglazed product with a compacted base, cured by extrusion),
• cotto (porous single-fired product made of red clay, obtained by extrusion).

According to the “fields of application”, tiles can be distinguished: for floors, for walls, mosaics, for interior cladding, for outdoor work. Practice shows that the manufacture of ceramic tiles for walls and floors brings great profit to an entrepreneur, since this is the most popular product among consumers.

When working on the assortment, it is important to correctly calculate your capabilities - some types of products will require additional expensive equipment.

The main stages of ceramic tile manufacturing technology

Technological scheme for the manufacture of ceramic tiles

It may seem that the technology for the production of ceramic tiles is difficult to implement, because this is a process within industrial enterprise. In fact, this is not so - even a person who is far from the manufacturing industry can figure it out.

In general, there are several methods for making tiles. But the easiest to implement is the pressing method. It does not require bulky devices, rental large areas, hiring highly qualified specialists, and therefore - for a mini-workshop this is the best option.

And no matter what products are made, technology system pressing method looks like this:

• dosing components,
• mixing of raw materials
• raw material pressing,
• drying,
• burning.

To develop a customer base, the manufacture of finished products must be debugged - no marriage!

What raw materials will be required?

The necessary raw materials for the production of ceramic tiles can be obtained in any region. You should not rush to choose a supplier, because each of them offers different conditions cooperation. Therefore, it would be better to pre-monitor this market.

The list of main components includes the following components:

• Clay and kaolin.
• Sand.
• Spars, slags, nephelines.
• Various additives (surfactants, thinners).

Even if you plan to make ceramic tiles with your own hands, it is important to supply only high-quality raw materials. Cheap components of a poor composition will negatively affect the quality of the finished product.

Mini workshop equipment

Line for the production of ceramic tiles

To start production, you need to buy equipment for the production of ceramic tiles. There are a lot of offers on the industrial equipment market - ranging from manual machines and ending with high-performance lines.

To organize a mini-workshop, you will need small-capacity devices, and, accordingly, their cost will be quite accessible only to an entrepreneur who is getting on his feet. The basic equipment of the line consists of the following machines:

• Concrete mixer. Price - from 30,000 rubles.
• Vibropress (forms - separately). Price - from 70,000 rubles.
• Kiln for drying and roasting. Price - from 1500000 rubles.

If according to the recipe it is planned to glaze finished products, then a special chamber will also be required, the cost of which is 80,000-100,000 rubles. The line can also be supplemented with an extruder (≈150,000 RUB) and a tile cutting machine (≈80,000 RUB) to introduce other production methods.

The final price of the equipment will depend on the degree of automation and capacity. And if for the production of products at home it is possible to equip a workshop for 2,000,000 rubles, then the cost of industrial lines sometimes exceeds 1,000,000 rubles.

Sales market and business payback

Sale of ceramic tiles can be carried out both wholesale and retail lots. Look for clients among:

• construction shops and markets,
• construction and renovation companies,
• individuals.

It has been proven in practice that the mini-production of floor ceramic tiles can fully pay for itself already a year after the launch. And the costs here can reach 2500000 rubles. (purchase of a line, rent of premises, purchase of raw materials). But such quick payback- this is an ideal case when the distribution channels are debugged from the first for the operation of the line. Most start-up entrepreneurs in the first year of operation of the workshop face the problem of seasonality, when the line is idle in the winter-autumn period. And to prevent this from happening, we throw all our efforts into advertising our products.

The production of ceramic tiles is carried out by many plants and factories around the world. This is considered a promising business and a good investment of capital. To date, there are industries in which the manufacture of ceramic tiles is largely focused on individual orders. An abundance of options ready-made solutions along with the possibility of making personal orders, it allows you to embody any design ideas in ceramics.

The production of ceramic tiles is quite possible to carry out independently. Ceramics were made long before there were special presses and other mechanisms. The manufacture of tiles is based on thousands of years of practice. Today, it is quite possible for anyone who wants to make tiles with the help of simple mechanisms that make it possible to make the initial mass, apply glaze and fire the tiles.

The process of making tiles is simple. Based on the variety of manufactured tiles and its purpose in production, a mixture of various types of clay is used with the addition of other natural impurities. To get a tile good quality it is important to use the right kind of clay. At first, all components are pressed with the help of appropriate equipment. The process is carried out under high pressure, after which the products are fired in a kiln at high temperature.

For the production of tiles, refractory or refractory clay is used. The first option is the most suitable due to a large number impurities. In the manufacture of tiles, it is extremely important not to violate the conditions provided for by the technology. Despite the fact that today the production of tiles is the basis of the activity of many enterprises, the growing demand allows not only to expand existing capacities, but also to open new lines.

For various tile options, it is planned to use a mixture of different types of clay and additional impurities. To obtain the glaze, a mixture is used, including kaolin clays, sand, glass chips and oxide pigments. Pigments are used to give the tiles the desired color. For the manufacture of the tile itself, a mixture of feldspar, clay and quartz sand is mainly used.

The production of tiles differs little from the manufacture of any other ceramic products. For a very long time, the technology for the production of ceramic tiles has basically remained unchanged. Despite the differences in the features of the manufacture of tiles different types, for the bulk of them, the scheme of production technology is also the same.

Tile production is a process consisting of several phases. To obtain high quality tiles, advanced technological equipment is used, the best views raw materials. For the production of tiles can be used fully automated industrial equipment. Manufacturing technology, which is based on high-tech equipment, allows you to make tiles large sizes with perfect shape and proportions.

Differences in production methods

All raw materials first thoroughly crushed, then stirred and moistened until a homogeneous mass is formed. The next step is molding, for which pressing or extrusion can be used. Pressed tiles are produced from raw materials crushed into powder. First, the powder is compacted, after which it is pressed under high pressure. This method makes it possible to more strictly adhere to the standard size of products and form a high-quality surface.

In the production of ceramic tiles, extrusion technology involves the passage of a pasty mixture of base materials through a special die of the desired shape. In the process of passing the prepared mixture through the mold, products of the required width and thickness are created. The use of this molding method is simple and less expensive compared to the pressing method. After this action, the ceramic tile is dried and fired.

How the mixture is prepared and products are molded

The manufacture of tiles begins with the preparation of raw materials. At the preparation stage, the components are mixed, from which a homogeneous initial mass is formed. To do this, clay is first crushed, after which the necessary impurities are added to it to obtain desired composition. Crushed clay must be wetted. The degree of wetting is determined by additives, the volume and proportions of which are determined by the required characteristics for finished products.

Next comes the molding of the tiles. As already described above, molding can be performed by two methods: extrusion or pressing. In the first case, the finished mass is passed through a special molding machine, in the second, a mass is poured into the prepared molds, which is then pressed under high pressure. The output is very dense and strong products.

Drying and glazing

At the next stage, the products are dried, with the help of which excess moisture is removed from the tiles. This stage is indispensable, because without removing excess moisture at the firing stage, intensive vaporization will occur. The resulting excess steam will cause a violation of the integrity of the tiled products, and the output will be too much defective product.

Glazing is required to give tiles a certain color or shade. The glazing is done the day before firing. Tiles are glazed by pouring and spraying. High-temperature processing of products in a furnace and the cooling process turn this type of coating into a kind of glass. This coating performs not only aesthetic, but also protective function. As a result, the tile will be protected from negative impact external factors and will acquire high hygienic properties.

How products are fired

High-temperature exposure in the furnace forms the required chemical reactions, leading to the necessary physical changes in tiled products. In production, the oven is arranged in the form of a conveyor, where the products move in a tunnel. There are furnaces in which the movement of products is based on the carousel principle.

In the technological equipment market, equipment for the production of ceramic tiles is presented in a large assortment. With the development and improvement of technology, it is constantly improving. Its range is large, you can buy do-it-yourself installations, large units for large factories or a separate machine for the production of tiles on site.

What are the benefits of new technologies

Tile production in recent times is undergoing an update. This is due to the fact that new modern types of equipment for coloring products have appeared. New technologies make it possible to form a decorative layer in such a way that it forms a single whole with the structure of products. Such a pattern does not fade over time and does not fade.

One of modern options Drawing a pattern on ceramic tiles involves the use of UV printers. This kind of printing is based on the use of special inks and glaze paints with good adhesion characteristics. Upon completion of the process of applying a graphic pattern in this way, polymerization is carried out using a UV lamp.

Special inkjet and laser printers can be used to apply a pattern to ceramic tiles. In the production process of small batches, inkjet printers for ceramics are used. With their help, mainly black and white drawings are applied. For large volumes of ceramic tiles, production can be equipped with laser printers. In this case, the picture is first transferred to the decal paper, after which it is fixed on the tile, which is then fired in a kiln.

Self-manufacturing

Recently, it has become more and more widespread independent production tiles. The motive for this is the desire not only to save money, but also to make an original, not found in anyone finishing material. Great popularity in independent production using cement tiles. She represents a very interesting material finishes that can be used for walls and floors. This coating is made manually, which was invented in the Middle Ages.

The production of cement tiles is an entertaining process. For its manufacture, a special metal mold in the form of a matrix with the contours of the tile pattern - like a stencil. Next, colored cement is prepared, for which a mixture is used, which includes fine sand, special cement, marble powder and natural-based dyes. The finished tiles form a matte surface, rough to the touch and non-slip. Products made in this way are not fired, but only dried. Thanks to this, the dimensions of the tiles do not change, while maintaining the original accuracy, which can be considered an advantage.