Ceramic Tile Production Line and Factory Setup

A ceramic tile production line is an integrated industrial system designed to grind raw materials in a ball mill, prepare slurry, spray-dry into powder, press tiles under high pressure, dry, glaze, fire in a roller kiln and finish by polishing and cutting. The line produces floor and wall tiles with consistent quality.

From an industrial perspective, ceramic tile manufacturing is important because it combines precise raw-material grinding (ball mill 500–2000 kg), controlled spray drying, high-pressure pressing (50–500 kg/cm²), glazing and high-temperature firing in a roller kiln (1000–1350 °C) to achieve dimensional accuracy, strength and surface quality. Typical capacity ranges from 2000 to 30 000 m²/day.

Primary raw materials typically include clay, feldspar, silica, kaolin and glaze materials. Core machinery consists of ball mills (500–2000 kg), spray dryers, hydraulic presses (50–500 kg/cm²), dryers, glazing lines, roller kilns (1000–1350 °C), polishing and cutting lines.

The Industrial Department supports investors establishing a new ceramic tile factory as well as existing plant owners requiring repair, overhaul, capacity expansion or automation of current lines. Projects can start from an empty site or from an operating facility that needs technical upgrading.

Whether the goal is a green-field turnkey ceramic tile plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The ceramic tile production line is engineered as an integrated process system covering raw-material preparation, ball milling, slurry preparation, spray drying, pressing, drying, glazing, roller kiln firing, polishing, cutting and packaging. Design capacity is determined during the engineering phase and can typically range from 2000 to 30 000 m²/day depending on final product mix and market requirements.

Product types include floor and wall tiles of various sizes and surface finishes. The overall process flow follows a defined sequence: raw-material preparation, ball milling, slurry preparation, spray drying to powder, hydraulic pressing, drying, glazing, firing in roller kiln at 1000–1350 °C, polishing, cutting and packaging.

Main machinery groups include ball mills, spray dryers, hydraulic presses, dryers, glazing lines, roller kilns, polishing and cutting lines. Supporting infrastructure covers electrical power, gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers dimensional accuracy, strength, surface quality and packaging integrity. Finished tiles are stored under protected conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial ceramic tile production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	Ceramic floor and wall tiles
Production Capacity	2000–30 000 m²/day (depending on project capacity and selected equipment sizing)
Required Area	2000–5000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 300–700 kW (depending on equipment selection and automation level)
Gas	500–1500 m³/h
Water Consumption	50–150 m³/day
Manpower	15–30 persons per shift (depending on automation level)
Main Machines	Ball mill (500–2000 kg), spray dryer, hydraulic press (50–500 kg/cm²), dryer, glazing line, roller kiln (1000–1350 °C), polishing and cutting line

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial ceramic tile production line can manufacture floor and wall tiles of various sizes, thicknesses and surface finishes according to market requirements.

Raw Materials for Ceramic Tile Factory

Raw material selection and quality control are critical for body strength, shrinkage and surface quality. The main materials used are described below.

Main Raw Materials

Clay, feldspar, silica, kaolin – Form the ceramic body.
Glaze materials – Provide surface finish and decoration.

Secondary / Optional Materials

Packaging materials

Storage and handling conditions must be controlled to preserve raw-material quality and prevent contamination.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by ceramic tile factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Ceramic Tile
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial ceramic tile process follows a defined sequence of unit operations.

Raw-Material Preparation and Ball Milling – Clay, feldspar, silica and kaolin are ground in a ball mill (500–2000 kg) to form a uniform slurry.
Spray Drying – Slurry is dried in a spray dryer to produce powder.
Pressing – Powder is pressed into tile shape under hydraulic pressure of 50–500 kg/cm².
Drying – Pressed tiles are dried to remove residual moisture.
Glazing – Tiles are coated with glaze on a glazing line.
Firing – Glazed tiles are fired in a roller kiln at 1000–1350 °C.
Polishing, Cutting and Packaging – Fired tiles are polished, cut to size and packaged.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Ball Mill – Grinds raw materials (500–2000 kg). Position: first stage. Importance: particle size control. Quality impact: grinding fineness affects body properties. Maintenance: liners, media and drives. Sahi Rasa support covers design and spare parts.
Spray Dryer – Converts slurry to powder. Position: after milling. Quality impact: powder moisture and particle size. Maintenance: atomizers, chambers and fans. Sahi Rasa provides specialized spray-dryer support and overhaul.
Hydraulic Press – Forms tiles under 50–500 kg/cm². Core machine for dimensional accuracy. Position: after spray drying. Quality impact: pressure and die design determine density and size. Maintenance: dies, hydraulics and controls. Sahi Rasa provides specialized press support and overhaul.
Roller Kiln – Fires tiles at 1000–1350 °C. Core machine for final strength and surface quality. Position: after glazing. Quality impact: temperature profile determines product quality. Maintenance: rollers, burners and insulation. Sahi Rasa provides specialized kiln support and overhaul.
Glazing Line, Polishing and Cutting Equipment – Apply glaze and finish tiles. Position: before and after firing. Quality impact: surface uniformity and dimensional accuracy. Maintenance: applicators, abrasives and cutting tools.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, milling and spray-drying hall, pressing and drying area, glazing, kiln section, polishing and packaging, finished-goods warehouse, quality-control laboratory, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect process flow, dust control and high-temperature zoning. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 300–700 kW
Gas: 500–1500 m³/h
Water: 50–150 m³/day
Compressed air and process utilities
HVAC and drainage according to local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing ceramic tile factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for ball mills, spray dryers, presses, kilns and polishing lines.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn liners, dies and rollers, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (press, kiln) or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and pressure monitoring, automatic dosing, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for ceramic tile projects.

Packaging

Protective packaging, secondary packaging, labeling, coding, cartoning and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for ceramic tile projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new ceramic tile factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a ceramic tile production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Ceramic Tile

FAQ

What is the typical cost of setting up a ceramic tile factory?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Ball mill, spray dryer, hydraulic press, dryer, glazing line, roller kiln, polishing and cutting line.
What production capacity can be designed?
Typical capacity ranges from 2000 to 30 000 m²/day, determined during the engineering phase.
How much space is needed?
Typical process area ranges from approximately 2000 to 5000 m², subject to final layout.
What are the main raw materials?
Clay, feldspar, silica, kaolin, glaze materials and packaging materials.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.