Porcelain Tile Production Line and Factory Setup

A porcelain tile production line is an integrated industrial system designed to prepare body materials by ball milling, convert slip into powder by spray drying, form tiles under high pressure, fire in a roller kiln at elevated temperatures (1200–1350 °C) and polish the surface. The line produces dense, low-absorption porcelain tiles suitable for demanding applications, including large formats such as 100×100 cm and 80×80 cm.

From an industrial perspective, porcelain tile manufacturing is important because it combines high-pressure forming, controlled high-temperature firing and surface polishing to achieve very low water absorption, high mechanical strength and excellent aesthetic quality. The process relies on a defined sequence of unit operations that must be correctly engineered and integrated.

Primary raw materials typically include clay, feldspar, silica and kaolin. Core machinery consists of ball mills, spray dryers, high-pressure hydraulic presses, roller kilns (1200–1350 °C) and polishing lines.

The Industrial Department supports investors establishing a new porcelain 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 porcelain 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 porcelain tile production line is engineered as an integrated process system covering raw-material preparation, spray drying, high-pressure pressing, roller-kiln firing, polishing and packaging. Design capacity is determined during the engineering phase according to market demand; modern lines support large formats such as 100×100 cm and 80×80 cm.

Product types include polished and unpolished porcelain tiles of various sizes and thicknesses. The overall process flow follows a defined sequence: ball milling, spray drying, high-pressure pressing, firing at 1200–1350 °C, polishing and packaging.

Main machinery groups include ball mills, spray dryers, high-pressure hydraulic presses, roller kilns and polishing machines. Supporting infrastructure covers electrical power, gas and process water.

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

Technical Specifications

The following technical data represent typical ranges for an industrial porcelain 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	Porcelain tiles (including large formats 100×100 and 80×80 cm)
Production Capacity	Depending on project capacity and selected equipment sizing (to be determined during engineering phase)
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, high-pressure hydraulic press, roller kiln (1200–1350 °C), polishing machine

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

Products

An industrial porcelain tile production line can manufacture polished and unpolished porcelain tiles of various sizes (including large formats) and surface finishes according to market requirements.

Raw Materials for Porcelain Tile Factory

Raw material selection and quality control are critical for density, water absorption and firing behavior. The main materials used are described below.

Main Raw Materials

Clay, feldspar, silica, kaolin – Form the dense porcelain body.
Water, glaze, pigments – Used for body 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 porcelain 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 Porcelain 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 porcelain 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.
High-Pressure Pressing – Powder is formed into tiles under high pressure.
Firing – Tiles are fired in a roller kiln at 1200–1350 °C.
Polishing – Surfaces are polished to the desired finish.
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 and Spray Dryer – Prepare body powder. Position: first stages. Importance: powder quality foundation. Quality impact: particle size and moisture. Maintenance: media, atomizers and chambers. Sahi Rasa support covers design and spare parts.
High-Pressure Hydraulic Press – Forms dense tiles. Core machine for low water absorption. Position: after spray drying. Quality impact: density and dimensional accuracy. Maintenance: dies, hydraulics and controls. Sahi Rasa provides specialized press support and overhaul.
Roller Kiln – Fires tiles at 1200–1350 °C. Core machine for densification and strength. Position: after pressing. Quality impact: temperature profile and atmosphere. Maintenance: rollers, burners and refractories. Sahi Rasa provides specialized kiln support and overhaul.
Polishing Machine – Finishes the surface. Position: after firing. Quality impact: gloss and flatness. Maintenance: abrasives and conveyors.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, milling and spray-drying hall, pressing area, 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 porcelain tile factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for presses, kilns, spray dryers and polishing 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) 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 porcelain 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 porcelain 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 porcelain 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 porcelain 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 Porcelain Tile

FAQ

What is the typical cost of setting up a porcelain 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, high-pressure hydraulic press, roller kiln and polishing machine.
What production capacity can be designed?
Capacity is determined during the engineering phase; modern lines support large formats.
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.