Ceramic Tile Production Line and Factory Setup

A ceramic tile production line is an integrated industrial system designed to prepare raw materials by ball milling, convert slip into powder by spray drying, form tiles by hydraulic pressing, dry, glaze, fire in a roller kiln and finish by polishing and cutting. The line produces wall and floor tiles with consistent dimensions and surface quality.

From an industrial perspective, ceramic tile manufacturing is important because it combines precise body preparation, controlled spray drying, high-pressure forming (50–500 kg/cm²), glazing and high-temperature firing (1000–1350 °C) in continuous roller kilns to achieve strength, dimensional accuracy and aesthetic quality. Modern lines can operate at speeds of 12 m/min with capacities exceeding 30 000 m²/day.

Primary raw materials typically include clay, feldspar, silica and kaolin. Core machinery consists of ball mills, spray dryers, hydraulic presses, dryers, glazing lines, roller kilns and polishing/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, slip production, 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 wall and floor tiles of various sizes, thicknesses and surface finishes. The overall process flow follows a defined sequence: ball milling of body materials, spray drying to powder, hydraulic pressing, drying, glazing, firing in roller kiln (1000–1350 °C), polishing and cutting, packaging.

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

Manpower requirements depend on the degree of automation. Quality control covers dimensional accuracy, surface quality, water absorption 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 wall and floor 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, spray dryer, hydraulic press (50–500 kg/cm²), dryer, glazing machine, roller kiln (1000–1350 °C), polishing and cutting line
Typical Line Speed	Up to 12 m/min on modern lines

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 wall and floor tiles of various sizes, thicknesses, colors and surface finishes according to market requirements.

Raw Materials for Ceramic Tile Factory

Raw material selection and quality control are critical for body properties, firing behavior and final quality. The main materials used are described below.

Main Raw Materials

Clay, feldspar, silica, kaolin – Form the ceramic body. Quality of incoming materials directly influences slip properties and final strength.
Water, glaze, pigments – Used for slip preparation and surface finishing.

Secondary / Optional Materials

Packaging materials

Storage and handling conditions must be controlled to preserve material consistency.

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 – Clay, feldspar, silica and kaolin are ground in ball mills to produce a homogeneous slip.
Spray Drying – Slip is converted into free-flowing powder in a spray dryer.
Pressing – Powder is formed into tiles under hydraulic pressure of 50–500 kg/cm².
Drying – Green tiles are dried to remove residual moisture.
Glazing – Glaze is applied on the glazing line.
Firing – Tiles are fired in a roller kiln at 1000–1350 °C.
Polishing and Cutting – Surfaces are polished and tiles are cut to final dimensions if required.
Packaging – Finished tiles are 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 into slip. Position: first stage. Importance: particle size control. Quality impact: body homogeneity. Maintenance: media, liners and drives. Sahi Rasa support covers design and spare parts.
Spray Dryer – Converts slip to powder. Core machine for powder quality. Position: after milling. Quality impact: moisture and particle size distribution. Maintenance: atomizers, chambers and cyclones. Sahi Rasa provides specialized dryer support and overhaul.
Hydraulic Press – Forms tiles under high pressure (50–500 kg/cm²). Core machine for dimensional accuracy. Position: after spray drying. Quality impact: density and thickness control. 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 glaze maturity. Position: after glazing. Quality impact: temperature profile and atmosphere. Maintenance: rollers, burners and refractories. Sahi Rasa provides specialized kiln support and overhaul.
Glazing Machine, Polishing and Cutting Line – Apply glaze and finish surfaces. Position: mid and end of line. Quality impact: surface appearance and dimensional accuracy. Maintenance: applicators, abrasives and conveyors.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, milling and spray-drying hall, pressing and drying area, glazing and 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 and dust control. 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
Dust extraction and HVAC according to hygiene and 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 finishing equipment.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn dies and refractories, 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), improving material handling 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 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 machine, roller kiln and polishing/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, water, glaze, pigments 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.