Operations

The ceramic body preparation integrates innovations designed to optimize and maximize the efficiency of the entire process, from the automatic management of raw material loading through recipe dosage all the way to powder loading in the storage silos. In this way, better performance is achieved in terms of energy savings, repeatability and process control, as well as product quality and consistency. Biofeedback Inc. is a company that will manufacture tiles, kitchen ware and sanitary ware from clay, sand, granite, feldspar and limestone. The exploration team carries out a study on raw material feasibility for manufacturing tiles, kitchen ware and sanitary ware. Earth moving team is responsible for land excavating, loading and hauling of raw material on the manufacturing facility. The processing team which is run by the founding share holder of Biofeedback Inc. is responsible for the entire manufacturing process, inspection of products during each manufacturing stage and finally adding value to finished products by polishing and spray painting of products. Up on storage of the manufactured products the sales team is responsible for all supply chains management to direct consumers and business customers. The entire business processes management will be run by the founding share holder of Biofeedback Inc.

Ceramic tiles are processed following a sequence of processes from raw material collection and storage, material will be batched , then the material will go through grinding, the ground material will be sieved, the sieved material will be spray dried from there it will be fed into a hydraulic pressing system to produce tiles. The finished tiles will be dried at atmospheric temperature while the glaze is being prepared to be applied on the surface of the tiles for aesthetic beauty. The product will be stored for a while and can then be further fired in the kiln to produce a final quality checked product. The products will be sorted, packed and stored in the warehouse ready to be delivered to the end users.

In Sanitary ware Manufacturing/Production process body preparation is the first step. In this process, slip produced by mixing Ball clay, Silica, China clay and feldspar. This composition is called Tri-axial body. Consist of Body former, Filler and flux. Body former is plastic material which is required to give strength at the green stage of the sanitary ware. The filler is non-plastic material which is going to give strength after the firing. Flux is a non-plastic material which added to the body to reduce the fusion temperature point of the body during firing.

All raw materials are mixed at the proper position and brought to required physical parameters. Usually following theological parameters are checked after slip preparations – Fluidity, Thixotropic of the slip at 1 minute and 5 minutes, lighter weight. These parameters will vary depending upon the composition, climate, casting (Bench casting, high-pressure casting, Low pressure casting for sanitary ware and others) required casting rate. Supply slip will be a mixture of virgin slip, runoff slip & scrap slip. This composition also will vary according to the availability of the scrap slip available and required casting rate. Once slip prepared according to the required parameter, it will be sent to slip storage silos. Whenever slip is required, then it will be supplied to the casting department for casting.

After that glaze and the moulds are prepared into which they are poured and then the removed pieces are dried before they sent to the control and spraying chamber. After the application of glaze .the glazed products are fired and later they are sorted and packed ready to be send to the end users.

The raw materials for manufacturing advanced ceramics come in powder form. The powders used by Biofeedback Inc. are of the highest quality, both in terms of purity and particle size, which are usually sub–micron. Prior to forming, the appropriate blend of raw materials are mixed together to form the stock material used in the forming processes. At Biofeedback Inc. this is usually one of 3 types: a spray dried powder, an aqueous slip or a dough feedstock. The forming process involves a consolidation stage and an optional machining stage.one of the method that Biofeedback Inc. uses is Slip casting, also known as drain casting, is a small to medium volume consolidation method for generally simple shapes such as tubes and crucibles but also for more complex shapes such as ladles.

Green machining is the machining of an un-fired ‘green’ or raw body. This needs to be done when the consolidation method used cannot produce the required shape. For example, the best way to make a part like a weld location pin is to green machine an isostaticaly pressed rod. Sintering is the process during which the consolidated green ceramic part is fired to give a dense, advanced technical ceramic. Just before or during this stage any organic additives need to be removed. This is best done in air atmosphere. Inspection is the final stage of the ceramic manufacturing process and generally involves a visual inspection of the part and dimensional inspection to a drawing.