Sanitary Ceramics (Washbasin and Toilet) Production Line and Factory Setup

A sanitary ceramics production line for washbasins and toilets is an integrated industrial system designed to prepare slip, form pieces by high-pressure casting, dry, glaze with robotic systems and fire in a tunnel kiln under controlled conditions. The line produces high-quality sanitary ware with consistent dimensions and surface quality.

From an industrial perspective, sanitary ceramics manufacturing is important because it combines precise slip preparation, high-pressure casting (typically 19.5 bar), controlled microwave drying, robotic glazing with visual positioning and high-temperature firing (around 1230 °C) to achieve strength, dimensional accuracy and 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 (≈22 %), kaolin (≈30 %), quartz (≈23 %) and feldspar (≈25 %). Core machinery consists of ball mills (500–2000 kg), slip mixers (500–1000 L), high-pressure casting systems (4–6 cycles/h), microwave drying tunnels (±2 °C control), 6-axis RobotGlaze systems with visual positioning and tunnel kilns (up to 111 m long, 1230 °C).

The Industrial Department supports investors establishing a new sanitary ceramics 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 sanitary ceramics 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 sanitary ceramics production line is engineered as an integrated process system covering slip preparation, high-pressure casting, microwave drying, robotic glazing, tunnel-kiln firing, quality control and packaging. Design capacity is determined during the engineering phase and depends on the number of casting modules and kiln capacity.

Product types include washbasins, toilets and related sanitary ware. The overall process flow follows a defined sequence: slip preparation in ball mills and mixers, high-pressure casting into porous resin molds (19.5 bar, 4–6 cycles/h), microwave drying, robotic glazing (glaze thickness error ≤0.1 mm), firing at approximately 1230 °C in a tunnel kiln, inspection and packaging.

Main machinery groups include ball mills, slip mixers, high-pressure casting systems, microwave drying tunnels, 6-axis robotic glazing systems and tunnel kilns. Supporting infrastructure covers electrical power, gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers dimensional accuracy, surface quality, glaze thickness and packaging integrity. Finished sanitary ware is stored under protected conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial sanitary ceramics 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.

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

Products

An industrial sanitary ceramics production line can manufacture a variety of finished products depending on the selected molds and glaze. Typical product families include:

• Washbasins of various designs
• Toilets (one-piece and two-piece)
• Related sanitary ware
• Various glaze colors and surface finishes

Variant development (shape, glaze, packaging) is defined during product development and process engineering according to target markets.

Raw Materials for Sanitary Ceramics Factory

Raw material selection and quality control are critical for casting behavior, strength and glaze fit. The main materials used are described below.

Main Raw Materials

• Clay (≈22 %), kaolin (≈30 %), quartz (≈23 %), feldspar (≈25 %) – Form the ceramic body. Quality of incoming materials directly influences slip properties and final strength.
• Water, glaze, pigments, plaster or resin molds – Used for slip preparation, glazing and forming.

Secondary / Optional Materials

• Packaging materials

Storage and handling conditions must be controlled to preserve raw-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 sanitary ceramics 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 Sanitary Ceramics
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 sanitary ceramics process follows a defined sequence of unit operations.

1. Slip Preparation – Clay, kaolin, quartz and feldspar are mixed with water and ground in ball mills to a homogeneous slip of defined viscosity and density.
2. High-Pressure Casting – Slip is injected at approximately 19.5 bar into porous resin molds (4–6 cycles per hour).
3. Microwave Drying – Formed pieces are dried in a microwave tunnel with temperature control of ±2 °C.
4. Robotic Glazing – 6-axis robots with 3D visual positioning apply glaze with thickness error ≤0.1 mm.
5. Firing – Pieces are fired in a tunnel kiln at approximately 1230 °C.
6. Quality Control and Packaging – Finished ware is inspected 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 and Slip Mixer – Prepare homogeneous slip. Position: first stage. Importance: foundation of casting quality. Quality impact: particle size and viscosity control. Maintenance: media, liners and agitators. Sahi Rasa support covers design and spare parts.
• High-Pressure Casting System – Forms pieces at 19.5 bar. Core machine for dimensional accuracy. Position: after slip preparation. Quality impact: pressure and mold quality determine piece integrity. Maintenance: molds, pumps and seals. Sahi Rasa provides specialized casting support and overhaul.
• Microwave Drying Tunnel – Removes moisture under precise temperature control. Position: after casting. Quality impact: controlled drying prevents cracking. Maintenance: microwave generators and conveyors.
• 6-Axis RobotGlaze – Applies glaze with visual positioning. Position: after drying. Quality impact: uniform glaze thickness and coverage. Maintenance: robots, nozzles and vision systems. Sahi Rasa provides specialized robotic support and overhaul.
• Tunnel Kiln – Fires pieces at approximately 1230 °C (length up to 111 m). Core machine for final strength and glaze maturity. Position: after glazing. Quality impact: temperature profile determines product quality. Maintenance: refractories, burners and control systems. Sahi Rasa provides specialized kiln support and overhaul.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, slip preparation, casting hall, drying and glazing area, tunnel kiln, inspection 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 150–400 kW
• Gas: 500–1500 m³/h
• Water: 20–50 m³/day
• HVAC, dust extraction and drainage 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 sanitary ceramics factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for ball mills, casting systems, robots, kilns and related equipment.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn molds 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 adding casting modules, upgrading the kiln or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, robotic programming, temperature and pressure monitoring, 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 sanitary ceramics 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 sanitary ceramics 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

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 sanitary ceramics 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 sanitary ceramics (washbasin and toilet) 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 Sanitary Ceramics

FAQ

1. What is the typical cost of setting up a sanitary ceramics factory?
   Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
2. Which main machines are required?
   Ball mill, slip mixer, high-pressure casting system, microwave drying tunnel, 6-axis RobotGlaze and tunnel kiln.
3. What production capacity can be designed?
   Capacity is determined during the engineering phase according to market demand and investment criteria.
4. How much space is needed?
   Typical process area ranges from approximately 1000 to 3000 m², subject to final layout.
5. What are the main raw materials?
   Clay, kaolin, quartz, feldspar, water, glaze, pigments, molds and packaging materials.
6. Can raw materials be supplied?
   Yes, via the Supply Chain Department according to project scope.
7. Is machinery manufacturing or procurement supported?
   Design, manufacturing or coordinated procurement according to the agreed scope.
8. Can existing machines be repaired?
   Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
9. Is overhaul or refurbishment possible?
   Yes – comprehensive restoration and control upgrades.
10. Can capacity of an existing line be increased?
    Often yes, by adding casting modules or upgrading the kiln.
11. Are turnkey projects executed?
    Turnkey or partial turnkey scopes can be offered under defined contracts.
12. Are services available in Iraq and Kurdistan Region?
    Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
13. Are services available in Afghanistan?
    Yes, including Kabul, Herat and Mazar-e-Sharif.
14. Can raw materials be supplied from Iran for regional projects?
    Yes, coordination of material supply is part of possible supply-chain scope.
15. Is installation and commissioning included?
    They can be included according to the selected contractual package.