Porcelain PaversOur process begins with the careful blending of quality clay, sand, feldspars, and kaolin with water to create a uniform mixture. This mixture is then transformed into an atomized powder, a finely particulate substance that is fundamental to our product’s quality. Once created, this atomized powder is stored in specialized silos, ensuring its purity and consistency are maintained.
The powder is then efficiently transported through an automated system of belt conveyors, which facilitates a seamless transition to the pressing stage. This meticulous process, from the initial blending of raw materials to the final transport to the press, underscores our unwavering commitment to quality and precision in every step of our production process.
The pressing stage of our process is where the atomized powder is transformed into the physical form of our porcelain pavers. Using high-precision machinery, the press exerts substantial force to compact the atomized powder into the desired paver shape.
Following the pressing stage, the formed porcelain paver retains a slight degree of moisture. To ensure the quality and durability of the final product, this residual moisture is removed in a pre-drying stage. Once the pre-drying is completed, the pavers are then forwarded to the glazing line, marking the next phase of the production process.
Following pre-drying, the pavers are transitioned to the glazing line. At this stage, they are transformed through the application of design onto their surface, made possible by a state-of-the-art machine. This high-precision technology brings to life a variety of designs, enhancing the aesthetic appeal and versatility of our porcelain pavers.
At the heart of our manufacturing facility is the kiln, powered by natural gas and vital to porcelain paver production. The pavers are heated to approximately 1,200°C (around 2,200°F) for about 1.5 hours, a temperature close to steel’s melting point.
Careful temperature management is crucial during this process to prevent internal stress in the paver. Our kilns, equivalent in length to a football field, are energy-efficient, supporting high production volumes while minimizing our environmental impact.
Post-quality control, the porcelain pavers are directed to a rectification machine. This crucial step in our production process ensures the uniformity and precision of our product, where all edges of the porcelain pavers are meticulously ground to achieve a consistent size across all pieces.
Rectification is vital for maintaining straight lines during a dry-lay installation. With the use of a permanent spacer, it allows for the creation of a consistently measured 1/8” joint. This process guarantees that each paver aligns perfectly with the next, resulting in an aesthetically pleasing and structurally sound installation
Our porcelain pavers are packaged with a commitment to both durability and environmental responsibility. Each paver is enclosed in resilient cardboard, which is made from recycled material. This packaging choice not only helps to protect the product during transportation and storage but also aligns with our commitment to sustainable practices.
Once on the pallet, the porcelain pavers are securely wrapped in plastic for added protection. This robust packaging enables the pavers to be stored outside in various locations across the country. Furthermore, they can be safely stored for a maximum duration of two years, providing flexibility for project timelines and logistics.
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